Astro Van Fuel Pump through floor Tips # 1

[@eariamjh71]

I used this tutorial as a guide for changing the fuel pump in my 99 safari. Measurements were spot on and the whole job took less than three hours. Many thanks for uploading this vid.

[@BooooDog]

Great to hear it worked for you ! Hopefully it won't have to be done anytime soon though. LOL

[@albotiger7268]

You're the best man honestly! I'll be doing this in the next couple of days on 2000 GMC Safari. By far the BEST video showing the location to cut with measurements and how to install and wire it up! GOD BLESS YOU!

[@codygillespie8893]

eariamjh71 it took 3 hrs to do this way? No offense but if it takes that long I’m just going to drop the tank I dropped the tank in mine last year it too a 1hr start to finish and I broke both strap bolts off

[@jh8338]

Pretty good on the measurements...I went 4.5" high, then an 11x11 measurement to give myself just a little more room on the hoses, and I went just to the OUTSIDE of rib #2 and 4 (rib #2 does not run all the way through the 'door' area, rib #4 is where the right-side cut is) Couldn't have done it without your video, so THANK YOU. 2003 GMC Safari Van.

[@rickjames5140]

On my 2nd pump. And don't want to drop the tanks again. These measurements are spot on and saved me so much time. Thank you 👍

[@screengemm]

Thanks bro ...just nervously cut out the access with a sparking cut wheel ..ended up ok right on target

[@BooooDog]

Yeah it makes me a little nervous each time I do it. It is nice if you have to replce another fuel pump in the future. But yes, the cheecks do pucker a little until it's done, LOL

[@dangarrett9735]

Despite all the naysayers, I followed your instructions and layout to access my fuel pump today in my 2001 Chevy Astro van. Your layout was spot on and made an all day job last a few hours. I use a nibbler and a drill to cut out panel. The job went well. My grandson helped. Thanks for the great video!

[@Bryan-Hensley]

Dan Garrett I can change an Astro fuel pump in less than an hour dropping the tank. There's only 2 bolts and the fuel fill hose.

[@OkFixer]

The measurements for this are spot on! I have a 95 Astro work van. It had seats in it. And indeed, the square patch is for a seat hook in the floor. I measured just like the video and BINGO! I took my garden hose and flooded the top of the tank first, and then used my air cut off tool. It made a lot of sparks, but I felt more safe with getting everything wet first. If you can smell gas I wouldn't use the cut off wheel, I would use a pair of air shears like the body men have. Drill a hole first so you can start the shear. I bought my pump from rock auto online (mechanics secret,cheap/factory parts fast) It was an Airtex brand (pretty good) and came with the cable to plug into the factory harness. Fitting the cable was a breeze except the ground was a stripped screw..I drilled that out and used a nut and bolt for my ground. My connections were different, but I had plenty of room to maneuver. The Astro/Safari is the self employed persons secret weapon. Flower delivery, glass shop, painter, handy man....these vans are rock solid, cheap, easy to maintain and get reasonable fuel economy. I don't mind the hole, it should have had one from the factory like the Japanese do.

[@BooooDog]

Glad to hear !! Yeah I agree, they should make a removable door in the floor for these models. Would be a lot more covenant if they did.

[@andreinert]

Just did this today on my 2001 Astro LT vandweller camper conversion. I had a bit more work doing this since I have a bed over the area where the hole needed to be cut but, the whole van was in need of a thorough cleaning and some other work done so it just made me do the other upgrades while I was replacing the fuel pump. Your measurements are spot on and I had no real issues getting through the floor. Found out I had a critter living in the space for the fuel pump, there were a few acorn shells scattered around and some chewed wires. Thanks for the helpful video!!!! I also did what Daniel Allen did and drilled a hole then flooded the area with water and then used a cutoff wheel, not sure if it really makes a difference but, just eased my mind. Lol

[@scottymizzo415]

My man i just did my fuel pump and this DYI Hack just saved me about $700.00 buck also a full day time and incovenience thanks broham . my have was a 99 astro next time this will take ma about a few hours . good job

[@LenoreMaggs]

keep in mind that if you use a jig saw, your going to have to watch for clearance , might have to drop the tank a little to compensate for the blade length

[@BooooDog]

Very true, I was thhinking about using that but didn't want to punchure the tank. Thanks for the advise

[@globally123]

Your laugh right at the end. For any bloke who works on their own vehicle,priceless haha.

[@appliancedude63]

Bro you are spot on with your measurements. Great video. Thanks for making this. My only problem now is that the fuel pump has been changed before and the harness changed. Now I have to find an original harness. Thanks again though.

[@ozb2006]

the best explanation i have seen so far

[@galigalindo6839]

I just used ur method!! Ur awesome right in the spot. Dont know anything about mechanic. Thank u god bless u for taking the time. !!!!

[@BooooDog]

Thanks for watching, glad it helped

[@smoknjoe73]

Great vid man super helpful. Debating between this method and tank drop but this vid makes me think this is smarter.

[@macauten2786]

Ty, my good man. I thought if this, but I wanted to look it up, first. Great video!

[@BooooDog]

Thanks so much, hopefully it helped

[@marmars1081]

This 'door' is a life saver, as the fuel pumps on these vans seem to go out the moment you fill them up completely.

[@BooooDog]

Thanks Gary I appreciate it. I realized a few things that were left out, but making these videos are a work in progress. lol Thanks for subscribing to :-)

[@dwightgeorgecarlson]

In general, one of the most important things about these in tank fuel pumps is to NEVER let the fuel go below 1/4 full. My first pump went at 128,000 km because I didn't know this precaution. My second pump is at approx. 428,000 km i.e. 300,000 on the new pump versus the 128,000 for the original. And they were indentical pumps as far as where manufacturued etc.

[@gymover]

I did this to an 03 suburban, after watching the tutorial for it on u-tube, took 1.5 hours not counting the time finding the cutting blade for my angle grinder. To drop the tank takes 5 hrs, a no-brainer, only charged him 300 to do it nstead of 1000!

[@chrisfullerton5452]

I have a 1995 Astro van and there is noise that seems as though it is a pressure, air whining sound after I shut the van off. It kinda whines for several seconds. I use to have a Safari van and I needed to have the fuel pump replaced in it. I don't recall hearing any sound but it was a long time ago so I may not be remembering it. But I am thinking that that would be the only thing that may may sound after the van is shut off. Also, I am wondering why you needed to repair the wires? Do you think the fuel filter may need to be changed? I considered that a clogged fuel filter may make the pump work harder... Thanks Chris

[@veggiepowered]

I Just Got A 1999 Astro Van Somebody Hacked My Vans Floor Up Really Bad Trying To Find The Fuel Pump . Atlast I Have A New Fuel Pump Now

[@247liveazskies6]

good video, I like the follow through going over the clamps

[@mdrmoose]

great idea, works with or without carpet. im just curious as to how you fixed/resealed the hole?

[@slowpoke96Z28]

They never do. The possibility of cumulative carbon monoxide poisoning or rust does not bother them.

[@richardgarrett6981]

thanks Gary the worst part for me is location of the pump but this helps a lot

[@globally123]

Thanks. Are these the exact same measurements for the GMC Safari 2005 van? Thanks again.

[@willhernandez6309]

Did you ever do it? I have a 2005 and I think I need to. Curious if the measurements are correct.

[@reyveltrejo4301]

i was about to pull the gas tank down ....thank you very much for your video

[@BooooDog]

Thanks for the reply, glad it helped !

[@ChicagoBob123]

WHY didn't GM provide a door for doing this. Its upsetting that a replaceable part has to be almost impossible to replace. Drop the tank? On you back upside down when you could have an access panel. Thanks for the tip..

[@peterpiwoski]

My 97 Safari has an additional cover between the gas tank and the bed of the van which includes extra tedious cutting so you don't cut any wires or any hoses.

[@katok4754]

good video. thanks for taking the time to make it.

[@BooooDog]

Hope it helped, thanks for the reply Kato

[@stevenvasquez5266]

does that go for the measurements for all of years for the Astro van

[@BooooDog]

Not exactly sure, my friend has a 2005 and it was the same measurements for him.

[@josesantos-my3hb]

My God wondering if at the dealer. They do the samething to bad a have a convertion van that has carpet on top of a playwood floor plus insulation it takes less time to lower the tank and that minus the sealing that hole up is about the same labor

[@slowpoke96Z28]

Can't say it didn't happen at a dealership, but they'd probably be fired if caught. Fuel leaks give off vapor that's dangerous, exhaust leaks give off toxic gases, a leak can actually spray up into the passenger compartment and collect, and a fire from the underside can get in the passenger compartment. No dealership wants that liability.

[@JosesGaraje]

Did you check before cutting if a piece of sheet metal would fit between the tank and the bottom of the body to add a degree of protection while cutting the square out of the floor?

[@BooooDog]

Yeah that area is sealed off on the top of the tank so there is no way to slide anything up in their prior to doing the work. At least on mine it was

[@andrewmiller6672]

Anybody know if the GMC 93 safari standard cargo is the same cut in the body?

[@trainsbangsandautomobiles824]

Those little clips that stay on the old pump, come off by pulling outwards on them and turning them "inside out", then they just pop right on the new pump in reverse order. I thought it would break them but thats what chevy told me to do

[@olheghtt]

Has anybody seen any videos on how to get these panels back on if you don't have welding equipment.

[@snowbambi69]

I'd use JB weld lol

[@ReuvenEtzion]

Would have loved to see how he repaired the floor.

[@BooooDog]

Hi Reuven, not sure if you seen my other video or not but it shows what you were talking about. Fast forward to about 3:40 and I think it might explain what you want. kzbin.info/www/bejne/a6q0onmenZpqp7M

[@michaelryan801]

So you cut a huge hole in the floorpan to avoid removing fuel tank ?

[@MrBillybathgate5]

your damn right -- -wrecking yards around here have cut outs everywhere ---- too much work if u cant get the car in the air

[@paulfromcleveland5871]

Its actually the smart way to do it. If you have any problems you can still access the pump without having to remove the tank again. I did this on my old F150. Made life so much easier.

[@nanmer7135]

Did you put an access panel in?

[@BooooDog]

Yes, I'll try to attach the link for how I did that here. kzbin.info/www/bejne/a6q0onmenZpqp7M

[@leoleonel6234]

after watching many vids including this one i decided to drop the tank and drain it ..disconnecting the fuel lines was not going to happen lines were too short to lower it enough to disconect with only one hand .. i cut the metal lines with a tubing cutter and added in rubber fuel line rated for 60 lbs and a clear filter .. i used an ac delco motor 50 bucks on ebay and used the original canister the intructions were useless but i figured it out .. in the end the van runs again and no hole in the floor to deal with .. ac delco or delphi are the best guality parts they say .. so went that route although i could have got a complete unit for as low as 30 bucks or a delco for 3 hun.. i bought just the pump.. lots ov videos show wrong ways to release the disconnects .. you need to push line in then using only your fingers depress the colored bit and pull the line off .. no vice grips no screw driver no fancy tool.. ..cutting a hole in the floor takes as long as dropping the tank at least not including sealing it up after correctly .. its a last ditch effort to do that for me ,, dropping the tank was not that bad .. imo

[@Bryan-Hensley]

The fuel pump Max pressure is near 100 psi. They run 62 to 74 psi. Those rubber lines are rated for certain temp. It gets pretty hot near the catalytic converter. You are asking for a fire.

[@eltorolocowey]

so what happends after you're done. can you NOT put anything over the area where you cut. cause I'm pretty sure anything heavy would go right thru the cut out area right and damage the fuel pump connectors????

[@BooooDog]

I cut a piece of aluminum and patched it up. It shows it at the end of this vid here: kzbin.info/www/bejne/a6q0onmenZpqp7M

[@Leatherkid01]

Those connectors are weather proof after u heat it up(it will shrink around the wires...no need for tape

[@jethrocathcart7452]

Are the seats facing u or are u looking at the rear doors

[@BooooDog]

Coming in the back doors facing the front, was the position I was in while filming this.

[@jethrocathcart7452]

Ok thanks. My 98" has a cover on it, cut it open now remove top cover...what the heck. Lol

[@vinchibookings8769]

Hey man.. Im having problems with my fuel gauge.. It reads incorrectly.. I can throw 10 bucks in the tank and my guage will say its full.. What causes that problem?

[@BooooDog]

I believe it's a bad sending unit, at least it was on one of my other cars that had the same symptoms. Unfortunately the sending unit on a astro is all part of the fuel pump assembly. If you go to the trouble of replacing it, you might as well replace the pump while your doing it. No need replacing, then the old fuel pump goes out a few months later. Just my opinion though, thanks for the question.

[@joem1413]

That's a great video, except for one thing, how do you patch the hole in the floor ?

[@BooooDog]

If you look through my videos, there is another one that shows how to patch up the floor Tips# 2.

[@Bryan-Hensley]

@@BooooDog I swore I would never do this. I preached it doesn't take any longer dropping the tank. But here I sit. My Astro pump quit and it's sitting in my yard. It's been raining for days. I have jobs to do. The yard is too soft to jack it up plus it's not level. And it's got the ground effects step making it closer to the ground. Now here I sit giving it some serious thought of doing this. My only concern is some seem to have another piece of sheet metal in between. I guess I could drill a hole first and look. Thanks for sharing this

[@BooooDog]

@@Bryan-Hensley I don't think you'l regret it. I was hesitant at first as well. But after doing it I have always wondered why GM wouldn't put a little hatch door above the fuel pump in case it needed to be replaced. The way it is, you have to take half the vehicle apart just to get to the part your working on. But going forward... If you did it like I did then you'll always have that access. Undo a few screws and replace old fuel pump, should only take a half hour next time. Thanks for your comment

[@Bryan-Hensley]

@@BooooDog I've already finished. It took me about 40 minutes total thanks to these videos enabling me to pinpoint the fuel pump location.

[@LincolnSP150]

Do you know if a 2005 Astro Cargo van are at same location?

[@BooooDog]

Not 100% sure about that, but I know they have the same configurations as each other internally. The only things they changed between those years was the badging and grills.

[@onehawk8410]

thanks for the info it helped a lot. Just as few tips I learned......I used my oscillating cutting tool (sonicrafter) to cut the floor, it gave much more control than a sawzall or grinder and no sparks. Tape the sharp edges of the opening to prevent cuts on hands and arms. To be certain that you don't cut the fuel lines leave that side attached. If you get a pump with a different plug for the wires and they didn't include the conversion kit you can carefully remove the plug from the old pump and use it.

[@BooooDog]

+Onehawk Good idea to use the cutting tool. Mine was shooting sparks everywhere, made me just a hair nervous while doing it. lol

[@workingshlub8861]

how many blades did you go thru?

[@gegervary]

You did not show how to unplug the 2 bigger connectors. One has some sort of blue pin that prevents the conenctor from slipping out of the plug and I just can't figure out how to remove it without breaking it.

[@BooooDog]

Yeah it was a little tricky, sorry about not showing that. If I remember right I just grabbed those with some needle nose pliers and added a little pressure while pulling gently on them to remove.

[@davidescobedo4817]

GREAT VIDEO THANKS FOR INFO !

[@TILEROB]

What were your symptoms

[@BooooDog]

At first I noticed lack of power taking off, passing, etc. Later on the engine would just cut out when driving on the freeway, then suddenly resume as normal for a few minutes, then do it again.

[@darfoster7773]

So if your vehicle starts then it's not the fuel pump? My astrovan will start and run all day if I don't depress the gas pedal, but if I give it gas it stalls? Unfortunately, I can't afford a mechanic for awhile and it's a head scratcher!

[@BooooDog]

So sorry for the late reply, I would say it's more than likely your fuel pump. However, I did have a similar issue with the same vehicle where it would start and idle ok. When I pressed the gas to get going it would stall and eventually pick back up. In that occasion it turned out there was a broken vacuum line in the engine compartment and it was as simple as going to the hardware store and replacing with stock tubing. So my advise would be to visually check all your vacuum lines coming from the engine, make sure none are leaking or broken. If the problem still persists then go with the more time consuming solution of replacing the fuel pump. Again,sorry for the late reply, hope you get things working.

[@armelind]

The fuel tank was empty (according to the gauge on startup), and removing the tank would have taken about the same time as cutting the hole... that's my opinion. I guess a gutted van makes it easier to cut open but a fully carpeted and trimmed out van, I wouldn't do this.

[@BooooDog]

Yeah I agree, I decided to do it this way cause it was accessible at the time. I also read that with dropping the tank breaks the brackets that secure the tank and you have to replace them when re-installing the tank. Not sure if that's true or not though, just thought I would already have the access if I had to do this again in the future. Thanks for the reply :-)

[@OKBAOK]

Of course it's 100% accessible specially if you have the code 0446 you just need to change the Fuel tank pressure sensor it's a snap to change. I'm planning to do this in my 2001 Astrovan got the measurements on the same year the other video he did on his Van.. I've been looking the tank under the Van just to remove the fuel tank pressure sensor. But by looking at it is better to do this, in case my fuel pump will break down. Thanks for sharing i also might go to junk yard and cut little big piece of metal flooring to match the curves and put screws on it after.. :)

[@gatorhaterdl]

It’s not even close to the same amount of time. Matinee if you have a lift and all that. But the access panel is much quicker than dropping the tank. Especially if your doing it alone.

[@luisguzman8180]

​@@BooooDog hey brother a question my gas tank has a quarter of gas it does not explode when cutting the hole

[@Leatherkid01]

those are weather proof heat shrinkable connectors

[@mrequi1]

It's actually easier I think, to drop the tank. It's 3 push pins, 2 hanger bolts, 2 hose clamps and 6 fuel door screws. Plus you don't mutilate your van. I just did one yesterday. And if I can do it, about anyone can.

[@jaimesantiago1475]

nicely done.like.Less to work.Thanks a lot

[@reynoldpetersen3280]

Very helpful.

[@MrMundaa]

IS 94 THE SAME

[@dangarrett9735]

Oh. By the way the hose on the fuel pump was broken. I suspect chemical attack. New pump had same hose. You would think that the manufacturer would use a better hose. I suspect I will be replacing the pump again. Your method will make it much simpler.

[@TaeTae-ux7lv]

Yk just sitting here trynna figure out if the camera is pointed to the back or to the front smh lmao

[@edb8257]

NOPE NOT ON 98 ASTRO. Cut thru floor (perfect measurements in this vid BUT) ANOTHER PLATE protecting the top of fuel pump on top of tank. Bummer! But thanks anyway...

[@bimmerman9839]

Ok thanks!

[@bimmerman9839]

Yes I had to cut through an additional metal plate which was butted to the tank so now I cut through the tank and all the fuel lines since they were also butted up directly behind additional plate with absolutely no space. Bummer......

[@bimmerman9839]

Now the tank has to come down anyways.

[@MrBillybathgate5]

hell yeah thanks man

[@bimmerman9839]

Shit the 97 is NOT in the same location!!! I guess thats two holes for me lol.

[@1wicked2008]

always use delphi fuel pump from napa only..like lowell did..never put a autozone junk fuel pump in or o'reillys or autoadvance ..they don't work !!!!,pay the extra money buy delphi

[@jethrocathcart7452]

I already have a auto zone pump wth

[@BigMikeD10001]

wow

[@juntosxsiemprereyreina8653]

CUTTING A HOLE on the FLOOR is STUPID . please work from below . take the tank down en replacle . 1 hr the most o a little more but no holes

[@gordolfino]

THE MOST STUPID WAY TO DO IT CUS WHEN YOU CUTTING THE FLOOR WITH A GRINDER WHAT ABOUT IF THERE IS A LEAK WITH THE SPARKS YOU JUST CREATED A FIRE

[@jaymzkardell1841]

Thanks... I tried your way and my fuel pump oring was bad and sparks blew the fuel tank up and it was in my garage on my house and burnt it half way down also caught my neighbors house on fire, they hate me so much they are move now so the husband doesn't kill me and the only good thing to come of it was I had all state on both. Thank you all state and take your van to a shop it's a lot safer for you and your neighbors.

[@leoleonel6234]

or just dont use a grinder ..

[@gatorhaterdl]

Yeah if you’re a dumb ass. I wonder how some people make it on a daily bases sometimes.

[@dennismanzano5640]

What a made-up story just to be on KZbin when is the dead burned down Thursday right cuz you're an idiot you could have watered it down from the bottom up before you start cutting but that's just me

[@FerGómez-s6t]

Cambiar al idioma español

[@gtaylor1564]

For the love of God green earth why would you cut a big ass hole on the floor crazy shit and very dumb and dangerous cutting that close to the gas tank wow