Fuel Filter & Fuel Pump Replacement Chevy Astro (GMC Safari) 96-05 Stealth Camper Van Build Part 2
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- เผยแพร่เมื่อ 12 ม.ค. 2025
- If you needing to replace the fuel pump and the fuel filter, then you came to the right place. The process should be very similar to all Chevy Astros and GMC Safaris alike. I am so excited to get this camper van in tip top shape to start building out the interior. If you are wanting more videos regarding the Astro Van, stay tuned!
Wish you all luck on the repair!
Here are the links to everything:
Fuel Pump: amzn.to/2GS95Ku
18 Gauge Clippers: amzn.to/3mcgOTK
Rive Nut Tool: amzn.to/3bRBGL7 (This one has better ratings and quality)
Snap Ring Pliers: amzn.to/33nC8Nl
Fuel Pressure Gauge: amzn.to/3kmgKPN
How to replace the fuel pump on the Chevy Astro Van
How to replace the fuel filter on the Chevy Astro Van
How to check the fuel pressure on the Chevy Astro Van
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AutoMotivate
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Removing the gas cap prior to changing the filter should relieve some fuel pressure so there should be less fuel leakage.
Real quick:
Starter fluid test is a good way to test for a fuel issue, but DO NOT spray starting fluid on that filter. Pop the filter out and spray directly into the air box. That filter will not last long at all if you douse it in starting spray.
You know, that makes a lot of sense. Ill keep that in mind next time I need to do that. Hopefully others will see this comment!
@@AutoMotivate yup, seen lots of filters crumble to pieces not long after being doused in the sauce. Definitely don't want to suck filter crumbs into the throttle body
Great comment RITT! For newbie van owners like me, being DIY but without mechanical experience, the exact steps are not always clear. Thanks so much! Yeah isn't this series the best? So Automotivate started another channel for Astro van owners. I forgot the name, Automotivate let me know. I will add here when I find it!
Your nerves are great. I would been freaking out changing the fuel pump. Very good video. selling my van today.
One of the best car videos I've seen. Thank you
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
If you grind out the access opening, you can use the piece you cut out to cover the opening, Cut 4 'tabs' of steel 2" long by the width of (one of) the (2) depressed parts of the floor. Using steel pop rivets, select a drill bit of the correct diameter and drill a hole in the floor and a corresponding hole in each of the four tabs then rivet the tabs to the floor, Cut two strips of steel the length of the right and let sides of the opening and two inches wide. Dill a hole in the floor and a matching hole in a strip and rivet it in place, then drill three more holes through the floor and strip, riveting as you go, Then repeat on the other side of the opening. You now have a supports for the section of floor you cut out. Place the piece you cut out over the opening and begin drilling holes through that piece into the tabs and strips sized to accommodate 1/4" pan head sheet metal screws - putting a screw in each hole as you go to maintain alignment. If you cut a rubber(?) gasket to match the size of the opening - maybe an inch or 5/8" wide and put in under the floor (double stick tape - two sided) before you install the tabs and strips, you will have a neat seal from beneath by the time the last sheet metal screw is installed. A bit of (paintable?) sealant applied from above and you have a near invisible repair as well as an access port to the fuel pump!
That is an amazing idea. Wish I did it that way. Hopefully this will give others ideas. My only concern is its strength.
That's what I did. Grinder is the way to go. Next time the pump goes you can swap it in no time.
Thanks for sharing your experiences with us.
Thank You just did this today 6/22/21.. Worked Excellent
My friend, you are such a blessing to me. Thank you so much.😀 You explained everything i always wondered about. By the way, i live in my van in Florida. 😀 Just subbed.😎God bless you always.
Cut a hole in the floor is wild. Not doing to my custom ass astro van lol.
Great video bud
Thanks for making 👍🏻
wow this underside is clean!
Just started watching this series and I’m looking forward to it. We just got a similar van it’s even missing a drivers side window too so I’m looking forward to seeing what you did with that. The last quarter of this video the audio wasn’t matching up with the video for me though. Hope you can fix that otherwise great video!
Good job, thanks for the video.
Excellent job 😊
this is gonna be an amazing series! When’s the next video!?
Thank you! I really enjoy working on the van. I have so many plans for it! Next video is planned for the beginning of next week 🙏
You need to clean up that hole with a file and go to the junkyard and get the same patch panel and cover that hole properly , I just did mine and it came out professionally done
Awesome video
The time you put in today is the time you'll save tomorrow, no problem cutting that hole I did the same thing to the bed of my 88 Toyota pickup. I have a shop so I used an air chisel for nice perfect cuts, could you tell me how did you determine those measurements?
Nice job
Sooo excited for this!
Yess 🙏 me too man!
Well splain,thank you gracias
Will these measurements works to a 95 astro?
To change the fuel filter on a 1997 Chevy Astro van what tools/sizes would I need? Need to know ASAP
Just so you viewers know, it's only two bolts to take the tank out. Seriously, it's SUPER easy on this truck. The tank is easily accessible underneath. Lots of room and easy access. Don't cut holes in the floor of your truck.
Imagine removing the tank when its full, not super easy. I already had to replace my fuel pump again and it took 10 minutes.
If your van is in great resto shape, I would agree. But, thats not the truth for most of the vans out there.
@@AutoMotivate Just did mine today. Took about 30 minutes including tank drop. Did it on jackstands in my garage.
@@NorthernChev I call BS on 30 minutes.
@@NorthernChev you're lying bro get outta here. My tank has 20 gallons in it so I'm not dropping shit anyway.
Do you have to use a pressure gauge?
Gracias por explicar los videos
Is the fuel tank and pump located in the same place in a 91 Astro?
You Didnt Use Calking Or Weather Stripping
Thank you!
No problem friend 🙏
you need to seal more, probably some sort of caulk or rubber gasket type material otherwise you'll get fumes in your van
deMerc Lopez I actually have plans to seal it; I didn’t didn’t want to do it yet because I had to de rust and paint the entire floor pan
I will disagree....
I have zero sealant around my Hatch that I made and get zero fumes in the van.
@@nwmod39 hehe just because you haven't died doesn't mean fumes aren't getting in... Just probably not in a high enough level plus my astro is not that well sealed anyway I can see around the doors
Dude so I just replaced mine and I had the door cut in for a few months and now it smells like gas after I put the new fuel pump in it's like the o-ring isnt sealing it off. I tried fireplace silicone and it didn't work the gas ate it
Wow no rust underneath. Mine is the exact opposite
Yeah it looked REAL clean under there compared to our rust belt vans.
To anyone who does this if you don’t have a ton of gas in your vehicle next time take a vack shack and suck it clean
Check your Parts Store ask if they will LEND you a tool - Auto Zone does, I suspect the competition will too - just call and ask! Tell 'em I sent you.
Why not drop the tank?
I subbed dude 😉
Yess 💪💪
Replaced ,My fuel pump same way ,on a 95' .Now ,I have intermintant starting and shutting off .Any ideas.
Which fuel pump did you get? Are you checking your fuel pressure?
@@AutoMotivate No, didn't check pressure. It started three times , lately .Not driving ,as it kept shutting down.Pump was from Rock Auto , a name brand ?
I cut a hatch for fuel pump In my 97gmc safari. Almost 300k miles and still rolling
If it's an ongoing issue that's one thing, but how many fuel pumps have you replaced?!
@@sscbkr48 2 I learned my lesson on the first one and made a hatch.
And what would one do if a hole was made in the gas tank
Probably get another gas tank..
@@AutoMotivate hey man! Love your videos and your attitude. I tried some steel epoxy stuff, worth a try before pulling trigger on that endeavor
@@benm4249 lol, I thought you were being sarcastic! There’s almost always an Astro Van at the junkyard you could pull a tank from.
That’s worth a shot. JB weld is also a decent idea. I appreciate the support!
My highest regard of guys like you...for me this is a total nightmare.
I am wondering why they cant engeneer vehicles where all those parts
could be easily accessible ?
My 2000 Astro w/141k loses power going up steep hills and gets this herky jerky action. I think these are signs the pump needs replacement.
I'll go with Delphi, AC Delco or Airtex.
Delphi seems to be the best route. You can get a fuel pressure tester fairly cheap and it’s easy to do!
I think I have the one I used linked in the description
Gonna do this . I’ll let you know if I survived
Don’t do something I wouldn’t do
Did it work?
So underrated!
4:09 It looks like you clamped down on a line.
There called snap ring pliers
Thank you 😂
Also the switch on your new grinder is called - a paddle switch
@@AutoMotivate I also have a 98 astro 178,000 miles still runs like new
I don't understand why you can't drop tank
You can if you want to. Empty the 20~ gallons and have at it. I have already had to replace my fuel pump again and it took me 5-10 minutes? The hole is sealed and strong.
IF y'all are dead set on cutting up your floors, I might suggest a nibbler instead of shears. Way easier and nicer cuts on corrugated metal... you can also get them for drill attachments now, and you can even take them to a junk yard. I don't have any reason to recommend this one other than it's a nice one: th-cam.com/video/ZqqUle5ljQ8/w-d-xo.html
Dang, wish I knew about that attachment when I did this video.. would have came out a lot better and probably could have kept the piece I cut as the cover.
Thanks man!
@@AutoMotivate it would have but it would also have been about an 1/8 of an inch smaller... that's why I said take it to a junkyard on a cordless drill, and cut an oversized plate from a donor van floor to cover it!
Astro van metal is made from razor blades
How in the hell do you have so little underside rust. My 02 is a sheet of rust, so much so that i cant remove the fuel filter for fear of snapping the line.
I got lucky. Had more top side floorpan rust than anywhere else.
I hear ya. So jealous of these rust free vans. I have a new filter but I'm scared to touch the lines. Need to wait until I have extra time to redo the lines in case it goes bad.
I actually have a 2000 Astro all wheel drive Van, that I just converted into my Astro Mini Camper Van, now I have to replace my fuel pump, got the fuel pump, but I don't have a grinder to cut a hole, so I'm gonna take it to my manager's dad's shop to do it, I've used grinders to cut metal and such, but not above the fuel tank, so I'll have them do it.
would have been nice to give the exact measurements after the hole was cut, DUH!!!!!
You need to seal that p.ate...water leak
PLEASE NO CUTs - my mecanic (MexicaN )change the gas pump taken the gas tank down1 hr done no cuts .saquen el tanque y renplacen 🤯
*should have used a grinder instead*
Did not feel safe using that above a gas tank
it takes all of 10 min to drop the tank why do this ? mine has a cover plate over the pump so you have to drop it anyway
I watched your video to enjoy seeing your beautiful eyes 😂😂😂
Dude wear gloves. They make venter cut spins for such cuts.
Are you talking about a flap disk for an angle grinder?
Why not just drop the tank
Hard to do when I had just filled it up so I cut the floor and now I have a door for next time!
@@chinadave2854 LOL! I understand! Mine had been getting noisier and noisier and decided to do last weekend when the tank was about an eighth full. I dropped my tank but I'll admit there were moments where I thought I should have cut the floor instead. It wasn't a hard job...just bulky. Even with only a little gas left in it. It was easy dropping the tank but getting it back in...was another story. It's done and it runs much better.
I really enjoy seeing you turn your van into a cherry keep up the great work and good job!
@@codyluka8355 did you do it by yourself? I am about to try it, just worried that I won't be able to get it back in alone... floor jack??
@@MartyMartMar Yes, I did the job by myself. A second pair of hands does make it a bit easier...that tank is heavier than you think. A floor jack is definitely needed along with some short pieces of 2x4s. Be careful when disconnecting the fuel lines...those plastic connectors may be brittle and you can't buy replacements. Good luck! You'll do fine.
Dude. Mechanic's gloves, $10.00
Literally playing operation with no gloves.
In the time it took to butcher your floor the tank could be dropped… 😂
When I had to replace the fuel pump the second time it only took 10 minutes. Some say butchered, most don’t
Without a lift that would be a nightmare that would take hours and hours instead of less than 2. and the next time you need to replace it it would be 15 minutes...
would have been less work to drop the tank and ya wouldn't have a big hole in the floor 🤣🤣🤣
Did you know that most cars on the road have holes in the floor to access the fuel pump? Fun fact.
@@AutoMotivate yes i have run a shop for about 20yrs and im not picking on ya but i done the job many times and i can drop the tank on it then less time then it takes to lay out the hole the big pain is how much fuel is in it and many folks have done the same as you just because you are young and don't have ASE certs on the wall ....so keep on doing you and when you are an old fart you to will get a chuckle at the young
I appreciate you Fuzy!
I definitely see your point. But, I would like to point out that the fuel pump did fail again and it only took 5-10 minutes to replace. So, it did work in my favor. I will definitely be spending extra money on a higher end fuel pump if it fails again.
@@AutoMotivate good luck on the sherch as most of the replacements are poor quality
@@AutoMotivate I had a different application(year, make, model vehicle) and I used a Denso fuel pump assembly.
"Tip top shape" proceeds to cut hole in the floor because you're lazy. Nice.
Cutting a hole in the floor, like most cars have, isn’t because I’m lazy.
Why not do something more efficient and make it easy access for the future? You know, like most other cars.
@@AutoMotivate, *facepalm*. But, hey man, whatever works. You do you.
It really makes sense, though. Why not create an access point if it isn’t sacrificing rigidity? I’ll be creating a seal around the hole when I tackle the floor pan rust.
@@AutoMotivate, it only half makes sense if you expect to be replacing the pump again. How many miles did this one last? You plan to be replacing it on the regular? If the answer to the last question is no, well, there you go.
@@aceseling I'm with you on this. Cutting a hole in the floor is for hillbillies. The pump lasts like 20 years. No problem there. However the rear brake line always rusts out above the gas tank. So you'll have to drop the tank anyway. Might as well drop the tank, replace the rear brake line while you're at it, paint it black/put it back, and use anti-seize on the bolts (just in case). AutoMotivate, check on your spare tire winch...nobody services them (lube once a year) and finding a decent replacement is getting hard to do. Good luck with the van, I love mine.