Asked in Chevy Astro
Chevy Astro

How do I change a fuel pump on a 1996 Chevy Astro van?

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Wiki User
01/06/2007

The fuel pump is...................sorry to say.........in the fuel tank! First thing DISCONNECT THE NEGATIVE BATTERY CABLE FROM YOUR BATTERY!!!!!!!!!! Jack up the vehicle high enough where you will be able to get the fuel tank out from under the van. USE JACKSTANDS!!!!!!!!!!!!!!!!!!!!!! Try to get as much fuel as possible out of the tank, there is no plug to drain the fuel so syphon the fuel so you have maybe 1/4 tank. WORK IN A WELL VENTILATED SPACE........GAS FUMES ARE DANGEROUS, USE A BOX FAN, OPEN WINDOWS , DOORS You will need to remove the fuel filler neck and then get some help as you loosen the straps that hold the fuel tank up against the underbody. Once you have the straps undone, lower the tank slowly, the fuel inside will slosh causing the tank to be unbalanced so 4 hands are bettr than two. Or try using a jack with a flat board on it that will support the tank. Do not put the jack under the tank without the board. You will puncture the tank and have more mess and expense. Go buy GM fuel disconnect tool at AutoZone or Pep Boys and disconnect the fuel lines. There are electrical connections you will need to disconnect from the top of the fuel pump. They are like male and female and just press the tab so they can come apart. Once you have all the connections to the top of the fuel pump disconnected, bring the tank out from under the vehicle. Get a pair of snap ring pliers and remove the snap ringon top of the fuel pump, keep it, you will be putting it back on. If your tank has a TANG on it, you will need to take a punch and hammer and TAP the fuel ring to unseat it and the fuel pump should pop up. There should be a rubber seal ring that you will need to reuse if you didn't get one, clean it and lubricate it and transfer it over to the new fuel pump. You should get directions with your new fuel pump. Transfer whatever parts you need to from the old unit to the new one to make it look like the same unit you just took out. To reinstall it is just the opposite.........drop the fuel pump into the tank, press down on it, and get the fuel pump seated and oriented in the correct direction on the tank and put the snap ring back on top. Then take the tank back under and redo the electrical connections, the fuel lines will click back on the fuel lines , and prepare to hoist the tank up so you can get it close to the underbody so you can get the straps back under the tank. Try to mark the straps BEFORE you start to remove them to get an idea of just how far you should tighten them when you have a new tank in place. I CAN'T WARN YOU ENOUGH THIS IS A VERY HAZARDOUS JOB...........I HAVE DONE IT TWICE. YOU MAY WANT TO CONSIDER PUTTING AN AC DELCO PUMP AS A REPLACEMENT IF YOU PLAN TO KEEP THE VEHICLE. There has been a lot of problems with aftermarket pumps giving out prematurely. AND WHEN IT IS ALL SAID AND DONE...........KEEP YOUR GAS TANK AT LEAST 1/4 FULL AT ALL TIMES. THE FUEL IN THE TANK KEEPS THE FUEL PUMP COOL. WHEN YOU RUN LOWER THAN 1/4 TANK, THE PUMP CAN OVERHEAT AND CASUE PREMATURE FAILURE. GOOD LUCK AND FOR GOD'S SAKE...............DO NOT SMOKE WHEN YOU ARE DOING THIS JOB.