Replacing Fuel Lines: Chevy Astro Van Guide

Changing the fuel lines on a Chevy Astro Van can be a complex task, and it is important to take the necessary precautions and have the right tools and materials before beginning the job. The process will likely involve raising the van, disconnecting the negative battery cable, draining the fuel tank, and removing the fuel pump and fuel lines. It is also important to take note of the type of fuel lines and fittings used, as well as their sizes, to ensure proper replacement. Additionally, it is recommended to have a second person to help with the task and to work in a well-ventilated area to minimise the risk of fire or inhalation of fumes.

Disconnect the negative battery cable

To disconnect the negative battery cable, you'll need to locate the negative terminal on your Chevy Astro van's battery. It's typically marked with a "-" symbol or a black cover. Once you've found it, use a wrench or socket to loosen the nut that secures the cable to the terminal. Be sure to disconnect the negative cable first to reduce the risk of electrical short circuits.

Before you begin, make sure you have the necessary tools, such as safety gloves and goggles, a wrench or socket that fits the battery terminal, and a safe place to store the disconnected cable. It's also a good idea to refer to your Chevy Astro van's repair manual for specific instructions and safety precautions.

Now, follow these steps:

• Put on your safety gear: gloves and goggles.
• Locate the negative battery terminal. It will be marked with a "-" symbol or a black cover.
• Use the appropriate wrench or socket to loosen the nut that secures the cable to the terminal. Turn it counterclockwise to loosen.
• Once the nut is loosened, carefully remove the cable from the terminal.
• Store the disconnected cable in a safe place away from any metal surfaces to prevent accidental electrical contact.
• Proceed with the next steps for changing the fuel lines, ensuring you follow safety precautions and refer to repair manuals as needed.

Remember, working with car batteries can be dangerous, so always take the necessary precautions and refer to expert resources for detailed instructions.

Raise and support the van with jack stands or ramps

To raise and support your Chevy Astro van with jack stands or ramps, you must first park your car on level ground, preferably on a paved surface. If you have to park on an incline, make sure to park close to the curb and turn the wheels inward. Next, you'll need to block the downside wheels with wheel wedges, wood blocks, or bricks to prevent the wheels from accidentally rolling. If you're lifting the front of the car, chock the back wheels, and vice versa. Put the car in park and engage the emergency brake. If the car is a manual transmission, put it in first gear and still engage the parking brake.

Now, you're ready to place the jack and raise the car. Check your owner's manual for the proper placement of the jack. Position the jack under the car frame. If you only need to lift one wheel, lift just that corner of the vehicle. If you need to lift the front or rear of the car, choose a jack point at the center of the front or rear suspension or frame.

When using jack stands, have them ready near the jack so they’ll be close by when you need them. You can use scissor jacks or hydraulic jacks, which include hydraulic floor jacks, bottle jacks, and ram jacks. If you have a scissor jack, insert the rod and then crank, raising the jack until it connects with the car’s lift point. If you have a hydraulic jack, place the handle into the body of the jack and pump the handle smoothly to raise the jack until it contacts the car frame. Lift the car to the desired height or ground clearance.

Place the jack stand under the car frame at a reinforced point or "pinch weld" near where the jack is placed. When using a jack stand to support one corner of a vehicle, place it under the jacking point, adjust the stand’s height, and use the pin or screw to lock it in place according to the manufacturer’s instructions. Once the jack stand is locked in place, slowly lower the car to rest on the stand. When supporting the front or rear of the vehicle, use a pair of jack stands by the same method, set at equal heights.

Drain the fuel from the tank

To drain the fuel from the tank of your Chevy Astro Van, follow these steps:

Park your vehicle on a level surface and turn off the engine. Allow the vehicle to cool down if it has been running recently. Ensure that you are wearing safety gear, such as gloves and eye protection, and that you have adequate ventilation in the work area to prevent the buildup of flammable fumes.

Locate the fuel tank. The fuel tank of the Chevy Astro Van is located on the driver's side of the vehicle, underneath the rear passenger seat. Once you have located the fuel tank, the next step is to relieve the pressure in the fuel system. This can be done by removing the fuel pump fuse or relay, or by disconnecting the negative battery terminal.

Place a suitable container under the fuel tank to collect the drained fuel. The container should be approved for storing flammable liquids and have a capacity greater than the amount of fuel in the tank. You can use a hand siphon or pump to remove the fuel from the tank. If you are using a hand siphon, follow the manufacturer's instructions to prime the siphon and begin draining the fuel. If you are using an electric pump, connect the pump to the battery according to the manufacturer's instructions and turn it on to begin draining the fuel.

Continue draining the fuel until the tank is empty. This may take several minutes, depending on the size of the tank and the rate of flow. Once the tank is empty, replace the fuel cap securely to prevent any remaining fuel vapors from escaping.

Dispose of the drained fuel safely and responsibly. Drained fuel should not be poured down drains or into the environment. Contact your local waste management authority or a hazardous waste disposal company for guidance on how to dispose of the drained fuel in a manner that complies with applicable laws and regulations.

Remove the splash guard from the driveshaft side of the fuel tank

To remove the splash guard from the driveshaft side of the fuel tank, you will need to first disconnect the negative battery cable. Next, raise and safely support your Chevy Astro van with jack stands or ramps. It is recommended that you raise both the front and the rear of the van.

The next step is to drain the fuel from the tank. This can be done with a hand siphon or pump. Once the fuel tank is empty, or near empty, you can begin to remove the splash guard. The splash guard is installed with four press-in clips and multiple slip-on clips, so you will need to remove these carefully.

Now you are ready to begin loosening the fill hose attached to the driver's side of the tank. There are two clamps on this hose, and removing the retaining screws that hold the fill hose in place inside the fuel door will make this process easier.

At this point, you can begin to break loose the retaining strap bolts on both sides of the tank. However, it is important to note that on most vans, the bolts on the driver's side do not need to be loosened, as they are set from the factory to allow the strap to rotate freely once the bolts on the opposite side are removed.

Once the bolts are loosened, it is time to support the fuel tank. This can be done with a transmission jack or an ATV/motorcycle jack. Now, the fuel lines and vent lines can be removed from the hard lines. For this step, you will need a 5/8 line wrench and a 3/4 line wrench for the fuel lines, and a pair of pliers for the vent lines.

With the lines removed, you can now slowly lower the fuel tank, being careful to ensure that nothing gets caught and causes the tank to fall.

Loosen the fill hose attached to the driver's side of the tank

To loosen the fill hose attached to the driver's side of the tank of your Chevy Astro Van, you will need to follow these steps:

First, make sure you have the necessary tools and materials. These include a set of wrenches, including a 5/8 line wrench and a 3/4 line wrench, pliers, a transmission jack or an ATV/motorcycle jack, a brass drift punch, and a new O-ring seal. It is also recommended that you have a helper to safely support your van with jack stands or ramps and to aid in other steps that require an extra set of hands.

Second, prepare your vehicle. Disconnect the negative battery cable. Drain the fuel from the tank, leaving a quarter or less, using a hand siphon or pump. 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.

Third, loosen the fill hose. There are two clamps on this hose, so use your wrenches to loosen them. You may also need to remove the retaining screws that hold the fill hose in place inside the fuel door to more easily disconnect the fill hose.

Finally, you can proceed to the next steps of removing the fuel lines and the vent lines. Be sure to support the fuel tank with a jack before doing so.

Remember to work safely and carefully, especially when working with flammable liquids like fuel. If you are unsure about any steps or procedures, consult a certified mechanic.

Frequently asked questions