Replacing Fuel Pump In Chevy Van: Step-By-Step Guide

If you're looking to replace the fuel pump in your Chevy van, you've come to the right place. This is a step-by-step guide on how to get the job done efficiently and safely. First, disconnect the negative battery cable. Next, safely raise and support your van with jack stands or ramps. It is recommended that you drain the fuel tank unless it is less than a quarter full. You can do this with a hand siphon or pump. Now, remove the splash guard from the driveshaft side of the fuel tank. Loosen the filler hose attached to the driver's side of the tank and remove the retaining screws holding the filler hose in place. You can now support the fuel tank and remove the tank straps and insulator strips. Finally, lower the fuel tank and disconnect the fuel feed and vapor hoses, as well as the electrical connector at the sender. With that, you can remove the old fuel pump and install the new one, following the steps in reverse.

Disconnect the negative battery cable

Disconnecting the negative battery cable is the first step in changing the fuel pump on a Chevy van. This is a crucial safety measure as it ensures that the vehicle's electrical system is inactive during the repair process. Here are some detailed instructions to guide you through this step:

Paragraph 1:

Locate the negative battery cable. The battery is typically located in the engine compartment of the Chevy van. The negative cable is usually black and has a minus (-) sign on it. Before proceeding, ensure that you have the necessary tools, such as safety gloves and a wrench or socket of the appropriate size. It is also recommended to have a basic understanding of automotive repair and electrical systems. If you are unsure, consult a professional mechanic or seek assistance from a knowledgeable individual.

Paragraph 2:

Once you have located the negative battery cable, it's time to disconnect it. Start by loosening the nut or bolt that secures the cable to the battery terminal. You can use a wrench or socket to loosen it, but be careful not to drop it into the engine compartment, as it may be challenging to retrieve. If the connection is tight, you may need to apply some force, but be gentle to avoid damaging the terminal or cable. Make sure you only loosen the connection and do not remove the cable completely at this stage.

Paragraph 3:

Now that the nut or bolt is loosened, you can carefully detach the cable from the battery terminal. Again, use a gentle motion to avoid any damage. Once the cable is disconnected, move it away from the battery to prevent accidental contact. Ensure that the cable cannot come into contact with any metal parts of the engine or vehicle body, as this may cause a short circuit. Place the cable in a safe location where it will not be disturbed during the fuel pump replacement process.

Paragraph 4:

It is important to note that the battery contains sulfuric acid, which can be dangerous if handled incorrectly. Always wear safety gloves and eye protection when working with a battery. If you notice any corrosion or leaks around the battery, clean it up carefully and dispose of the waste appropriately. Do not allow the corrosive fluid to come into contact with your skin or eyes, as it can cause irritation or injury. Always prioritize your safety when working on automotive repairs.

Paragraph 5:

At this point, you have successfully disconnected the negative battery cable. Before proceeding with the next steps of changing the fuel pump, verify that the cable is securely moved away from the battery and cannot make contact with any metal surfaces. You can now continue with the next steps, such as raising and supporting the van, draining the fuel tank, and removing the necessary components to access the fuel pump. Remember to work cautiously and refer to a repair manual or seek expert advice if needed.

Drain the fuel tank

To drain the fuel tank of your Chevy van, you'll first need to disconnect the negative battery cable. Next, you'll want to raise and safely support your van with jack stands or ramps. It's recommended to raise both the front and rear of the van.

Now you can begin to drain the fuel tank. To do this, you can use a hand siphon or pump. If your tank is under a quarter full, you may not need to drain it. Once the tank is drained, you can move on to removing the splash guard from the driveshaft side of the fuel tank. This is installed with four press-in clips and multiple slip-on clips.

Remove the splash guard

To remove the splash guard from a Chevy van, you'll need to locate it on the driveshaft side of the fuel tank. It is installed with four press-in clips and multiple slip-on clips, so you'll need to remove these carefully.

Firstly, disconnect the negative battery cable. Next, raise and safely support your van with jack stands or ramps. It's recommended to raise both the front and rear of the van to give you more space to work with.

Now, drain the fuel from the tank unless it is already at a quarter full or less. This can be done with a hand siphon or pump.

Once you have completed these steps, you can begin to remove the splash guard. Be sure to have a container ready to catch any remaining fuel that may spill out. Gently pry or pull the press-in clips away from the body of the van, releasing them one by one. At the same time, slide the slip-on clips out of their housings. Work your way around the splash guard until all clips have been removed, and then carefully lift the splash guard away from the driveshaft.

Place the splash guard to the side and be mindful of any fuel that may still be inside it. You can now access the fuel tank and proceed with the next steps of changing the fuel pump.

Loosen the filler hose

To loosen the filler hose of your Chevy van, you will need to follow these steps:

Firstly, disconnect the negative battery cable. Next, drain the fuel from the tank. This can be done using a hand siphon or pump. Once the tank is drained, remove the splash guard from the driveshaft side of the fuel tank. It is installed with four press-in clips and multiple slip-on clips.

Now, you can start to loosen the filler hose. The filler hose is attached on the driver's side of the tank and has two clamps. To make it easier to disconnect, remove the retaining screws that hold the filler hose in place inside the fuel door.

Once the filler hose is loose, you can proceed to the next steps of removing the fuel pump, which include breaking loose the retaining strap bolts and supporting the fuel tank.

Remove the retaining screws

To remove the retaining screws, you will first need to gain access to the fuel tank. Start by disconnecting the negative battery cable. Next, raise the van and support it with jack stands or ramps. It is recommended that you drain the fuel tank unless it is less than a quarter full. You can do this with a hand siphon or pump.

Now, remove the splash guard from the driveshaft side of the fuel tank. It is installed with four press-in clips and multiple slip-on clips. You will then need to loosen the filler hose attached to the driver's side of the tank. There are two clamps on this hose.

To make it easier to disconnect the filler hose, remove the retaining screws that hold the filler hose in place inside the fuel door.

Frequently asked questions