GMC VANDURA FUEL PUMP REPLACEMENT (CAB AND CHASSIS/WITH BOX) (((*on GMC Vandura cab and chassis box vans remember that most boxes are aftermarket so my assembly may very from yours slightly to dramatically always consult other sources before attempting any DIY projects*)))
(((*Please use caution and take safety precautions whenever performing any DIY mechanic work.*)))
I'm a do it yourselfer, I've always done my own oil changes and basic maintenance, but never something this big. I'm 24 and my family business has a GMC 3500 V8, which two years ago had a 1991 350 LT1 Caprice engine changed out from a previously blown out motor (makes no difference to the tank). Anyways one day the engine began having problems in hesitation after it got warmed up (10-15 min in town driving), It would occasionally not accelerate. When you would let off the accelerator no problem but push again and it hesitated. It was pretty much identified as fuel pump so, on a budget I was assigned to learn to fix the problem and be paid a minimal amount for my work.
The pump cost around $40.00 and I bought some new hose for the main fuel entry line ($13.25 a foot, ouch), and the strainer sock for the pump around $5.00 I studied a site picture tour for ideas http://www.automedia.com/GM/Gas/Tank/Replacement/a/res20011001ft/1 This was the closest site I could find with pictures similar to what I needed. Then I went to work. Try and run the tank very low on gas if applicable, if not try and siphon the tank dry (I didnï¿½t have much luck siphoning.)
1# I first removed the fuel pump fuse (under the drivers seat near brake/gas pedals) to ensure no sparks, and removed the negative terminal post on the battery to be safe. Following that up with locating the tank underneath the truck towards the back centered between the tires (itï¿½s a big one)
2# I disconnected the main entry line (sending line), and the relay line that connects at the filler hose (where you put in the gas at a gas station). This later seemed unnecessary because the main pieces are near the gas tank (one a neck on the tank another a relay line next to it that went above the tank.
3# I placed two jack stands underneath the tank to support it while I loosened and eventually removed the nuts from the strapping bolts. After the bolts were removed I removed the bracing straps (you might want to replace these, a brittle brace is dangerous). I then had another person help me remove the jacks and slowly lower the tank down. Located on top of the tank should be the top assembly for the fuel pump and floater with three fuel lines, an electrical line and a lock ring on the top. From there I marked each line 1, 2, and 3 before removing them from the tank. I disconnected the electrical line as well. (**be careful depending on who put in that electrical work they may not have left much slack**, which was my case, if so follow 3B attachment)
4# I removed the tank from underneath the truck by carefully lifting and sliding it out from under the chassis. Once out I had to remove the clamping ring on top of the fuel pump,(located on top of the gas tank)(be sure to clean this area before removing pump)I found a hammer and flathead screwdriver gently tapped against the tines of the locking ring in a counter clockwise motion worked. I gently removed the fuel pump and floater arm careful not to bend it (if applicable).
5# I studied the pump and looked at my replacement pump and assembly to understand how it all went together (you gotta figure that out, because there are many types, mine did not need the electrical assembly, but I replaced everything else)
6# I removed the old pump, put the new pump together and attached it to the pump assembly.
7# I placed the pump/floater assembly back in the tank, (check if the tank is dirty, couldnï¿½t hurt to clean it out if it is) replaced the seal ring(new one, should come with the pump) and put the locking ring back in place (clockwise turn to tighten back down)
8# I pulled the tank back under the truck and connected all marked hoses and re-ran the electrical connector back through the passage holes and connected it. I replaced all the hoses I wanted replaced, and made sure I had all my fasteners and bolts.
9# I took the hooks for the straps (which are just "J" bolts) and removed them from their holes on the frame, and re-attached the small assembly on the braces, but donï¿½t thread them up more than a third of the way (this is much easier in putting on the braces. It has less tension on it.)
10# I slowly lift up (with another persons help) and place the tank back up and reconnect the main sending line. Then with another persons help fit the tank back into place (this was difficult for me) and put the j bolts back in place in the holes in the frame(as I mentioned before about 1/3 way threaded was enough slack for me).
11#I then had to SLOWLY tighten the braces back up while I placed force against the tank to tighten it as best I could back against the frame. I reconnected the relay line which had its detachment/reconnect area next to/above the tank
12# I made sure everything was connected well and secure. I replaced the battery terminal post, then and fuse to the fuel pump.
13# (key in ignition) After two or three times of pumping and turning on the ignition my truck started up with a healthy roar (Vanduraï¿½s donï¿½t purr). Make sure to keep an eye out for leaks and run it around the block a couple of times to make sure itï¿½s warmed up and you should be good to go, check for leaks for the next few days, and thatï¿½s it hope I could help people out there because before this I couldnï¿½t find I a single page that could help me with even remotely close to this and I didnï¿½t have access to a Chilton/Haynes manual either.
14# If you have comments to add feel free or if I could be corrected by all means Iï¿½m a novice so any extra knowledge is appreciated.Answerforgot I used a crescent wrench for the straps and a crescent wrench and pair of plyers to remove the fuel lines from the tope of the tank leading to the fuel tank.
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