Chevy & GMC Vans

Everyone says, plan on replacing the fuel pump around 100,000 mi. I believe it, base on my last van. I did this once on a Ford Escort--also a tank mounted electric pump--and it was a PITA. Also, the fuel guage never worked after that--didn't care, it was a $200 car.

But when I do this with the Astro, I want to do it right. Are there any special tools I'll find useful for that one?

None that I can think of from me doing the pump on the 1994LT. PB blaster for the tank strap bolts and being sure the tank is empty or nearly empty.Bass drift to hit to release the retainer ring without any sparks.Floor jack to lower the tank and raise it back in place.

Relieve fuel pressure before disconnecting the fuel lines. Remove the engine cover, look for the Schreider valve on the fuel line. Press the center with a screw driver surrounded by a rag.

Disconnect the fuel lines before you drop the tank. Remove the shield between the tank and the drive shaft (if it isn't missing already, Grumpy), then looking between the drive shaft and the tank you should see the hard line/flex line connectors. Squeeze the tabs together on each connector, then pull.

Don't bother with the floor jack to raise or lower the tank. It's much easier to use some cam buckle straps. One mounted to the body near each of the tank retaining straps, undo the tank retaining straps then slowly let the cam buckles slip to lower the tank. Make sure you have the filler neck disconnect before you lower the tank.

Make sure that the tank is empty, use an AC Delco fuelpump only, change your fuel filter every 25k miles for fuelpump longevity.

For the most part, ACDelco = Delphi. For great prices on Dephi pumps check out http://www.getgmparts.com/.

If you're broke you can try an Ebay pump rebuild kit. Grumpy has one and is running fine, longevity has yet to be proven though.

OMG! The AC Delco catalog lists the fuel sender at just under $600 ($563.14, not counting shipping or tax if you buy local)! Basically a little less than two of the van's stinking payments when I was paying on it--and it aint even broke yet...

I'm thinking maybe it's a good idea to wait until the fuel pump starts humming real loud. They usually do that before they go don't they?

Once again we have a better suggestion.

Your 2003 uses the ACDelco MU1375 or MU1380 depending on if it has ROBUST FUEL SYS SENDER, both of which aren't available from http://www.getgmparts.com/.

Another cheap parts source is http://www.rockauto.com
Dephi FG0127 $257.79
ACDelco MU1375 $264.79
ACDelco MU1380 $272.79

I just saved you $300.

Socalli's right about the pump brand. the off brands can be a bit of a crap shoot. Mine crapped out short of 100K miles. replaced it, had to do it again inside of a year. Then again inside of a year. The third one has been running good for quite a while now. I think I've got the fuel pump replacement down pat now....

Okay. So, I'm still $300 with tax or shipping. But I can swallow that easier, so thanks.

Questions, though. If I do have the ROBUST FUEL SYS SENDER, does that still mean it get's a 100K replacement or did GM design that to make the system reliable enough not to need that? Also, if it doesn't can I put one in?

Yesterday did notice an ocassional intermittent hum when the van was idling for a prolonged period, so maybe I do need to do this...

Or you could buy a terrific pump from summitracing.com for about $150 and mount it outside the tank and tell us how you did it.

SoCalli V8 wrote:Make sure that the tank is empty, use an AC Delco fuelpump only, change your fuel filter every 25k miles for fuelpump longevity.

I've been changing my fuel filter every 30K and still have my original fuel pump with 194K miles.

I try to keep at least 1/3rd of a tankful at all times. The fuel is the heatsink that keeps the pump cool. Running the tank low causes the pump to heat up and self destruct.

Southern wrote:

SoCalli V8 wrote:Make sure that the tank is empty, use an AC Delco fuelpump only, change your fuel filter every 25k miles for fuelpump longevity.

I've been changing my fuel filter every 30K and still have my original fuel pump with 194K miles.

Now that's impressive!

geezer wrote:I try to keep at least 1/3rd of a tankful at all times. The fuel is the heatsink that keeps the pump cool. Running the tank low causes the pump to heat up and self destruct.

This is really important on the 1985-96 vans.

1997 and newer vans have fuel pump assemblies with a fuel cup that the pump sits in to keep it cool. When the pump is running, this cup is filled with fuel and it overflows back into the main part of the tank. It is designed such that the tank's level could be well below the pump's level and the pump would still be submerged in fuel. One could even run the tank dry and the cup would still have fuel in it.

When changing your pump get yourself a 4" peice of 2" PVC and cap it. Put this in the filler tube when you disconnect it and secure it with the hose clamp. That way you will avoid any spills when you tilt the tank to pull it out from the straps. I've done 3 pump replacements on 2 Astros. They aren't easy but it can be done by the shade tree mech.

Also, all 3 went without warning...no hum...nada. Just wouldn't start. If you listen when the key is turned you'll hear the pump pressurizing the system. If you don't hear it, it ain't working... Hope it works out well for you.