Replacing Fuel Pump In '94 Astro Van: Step-By-Step Guide

If you're looking to replace the fuel pump in your 1994 Astro van, there are a few different methods you can use. One way is to drop the fuel tank and replace the pump from underneath the van. This method is recommended by some Astro van owners, who note that it is not as difficult as some people make it out to be. It is also suggested that you run the tank as close to empty as possible before attempting this, as a full tank will weigh significantly more and be more difficult to handle.

Another method is to cut a hole in the floor of the van to access the fuel pump. This method is also used by Astro van owners, who recommend first drilling a small pilot hole to verify the location of the pump. They also recommend dropping the tank slightly before cutting the hole, to avoid accidentally cutting into the tank or fuel lines.

Disconnect the negative battery cable

Disconnecting the negative battery cable is an important first step when changing the fuel pump in a 94 Astro van. This is a safety precaution to prevent any electrical accidents. Here are some detailed instructions on how to do this:

First, locate the negative battery cable. It is usually black and connected to the negative terminal of the battery, which is also marked with a "-" symbol. Before disconnecting, make sure to wear safety gloves and goggles to protect yourself from any potential battery acid splashes.

Next, carefully loosen the nut or bolt that secures the cable to the battery terminal using an appropriate-sized wrench or socket. You may need to hold the battery terminal still with one wrench while loosening the nut with another. Once it is loose, carefully remove the cable from the terminal, ensuring that it does not touch any metal parts of the vehicle.

After the cable is disconnected, it is a good idea to clean the battery terminal with a wire brush to remove any corrosion. You can also use a solution of baking soda and water to neutralize any acid and prevent further corrosion. Make sure the terminal is completely dry before reconnecting the battery.

If you are not replacing the battery, it is recommended to disconnect the positive cable as well, especially if there is any corrosion on the positive terminal. This will ensure that there is no power drain on the battery while it is out of the vehicle. When reconnecting, be sure to connect the positive cable first and then the negative cable.

Finally, always remember to disconnect the negative cable first and reconnect it last when working on any electrical components in your vehicle. This will help ensure your safety and prevent any accidental short circuits.

Safely raise the van

To safely raise your 94 Astro van, you must first disconnect the negative (-) battery cable. Then, you can use either jack stands or ramps to raise the van. It is recommended to raise both the front and the rear of the van as high as possible.

Before you begin raising your vehicle, you must install wood blocks on the wheels of the opposite end of the vehicle being lifted. This is because if you raise the vehicle by the wheels that are keeping the vehicle from rolling, the vehicle will want to move on you because the tires that were holding it in place are now off of the ground. Pay attention to the drive wheels or the emergency brake wheels to help hold the vehicle in place.

Make sure you are on a flat, level surface that is hard, such as asphalt or concrete. Avoid grass, dirt, or anything else that is not a hard surface. You should also be away from traffic and random people.

When raising the van, do it slowly. As you go up, you will be creating inertia, and the last thing you want is to shift the vehicle. Always make sure that your vehicle is either in park or in first gear if you have a manual transmission, and keep the e-brake on.

Once the van is raised, you can position and adjust the jack stands under the main frame, bulkhead, or pinch welds of the vehicle. If you are working on a job that includes removing the tires, you can lay them down flat under the vehicle to give added protection against the vehicle falling.

NEVER GET UNDER A CAR WITHOUT JACK STANDS! A vehicle is very heavy, and trusting the floor jack alone is not wise.

Drain the fuel tank

To drain the fuel tank of your 94 Astro van, follow these steps:

Firstly, disconnect the negative battery cable. Next, raise and support your van with jack stands or ramps. It is recommended to raise both the front and the rear of the van. If your fuel tank is more than a quarter full, drain the fuel from the tank using 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. Then, loosen the fill hose attached to the driver's side of the tank. There are two clamps on this hose. To make it easier to disconnect the fill hose, remove the retaining screws that hold the fill hose in place inside the fuel door.

Now, you can support the fuel tank using a transmission jack or an ATV/motorcycle jack. This will make the process easier.

Finally, remove the fuel lines and the vent lines from the hard lines. The two fuel lines require the use of a 5/8 line wrench and a 3/4 line wrench. The two vents are simple pinch clamps that can be removed with a pair of pliers.

Remember to always replace the fuel filter when changing the fuel pump. It is also important to clean, inspect, and flush the tank while it is down.

Remove the splash guard

To remove the splash guard from your 1994 Astro Van, you'll first need to remove the engine cover. Here's a step-by-step guide to help you through the process:

Passenger Seat Removal

Although removing the passenger seat is not completely necessary, it will give you more workspace to work with. The passenger seat is held in place by four nuts, one in each corner. Use a 3/8” drive deep-walled socket to remove these nuts. After removing the nuts, pull the seat out. You'll then need to remove the seatbelt connector, which is not bolted down, so simply lift it straight off the bolt.

Glove Box Assembly Removal

The glove box assembly is held in place by two Torx screws, two bolts, and two clips. First, pop out the Torx screw covers to reveal the Torx screws. You may need to use a screwdriver for this step. The Torx screws are size 30. Next, pull the carpet slowly, as it is only fastened lightly with Velcro on both sides of the glove box assembly. Now, remove the two bottom bolts. They are 13mm bolts, and using a socket extension will give you more room to work with. With slowly increasing pressure, pull each side of the glove box assembly out. Be careful not to yank, as there may be a wiring harness that you could damage. If there is a wiring harness, carefully remove it.

Rear Air Duct Removal

If your Astro Van is equipped with a rear air duct, you will need to remove it. The rear air duct is connected at three points. Start by removing the hose on the top, driver's side. Then, pull the duct towards the driver's side to detach it from the passenger side duct. Finally, lift the duct up to detach it from the bottom duct.

Engine Cover Removal

The engine cover is attached by two bolts on the top and two brackets on the bottom. Begin by unbolting the top engine cover bolts. They are 15mm bolts located at the top of each side. You will likely need several socket extensions or one or two very long ones. The bolts will not detach completely, so stop turning when you hear clicking. Next, remove the bottom bracket bolts. These are 13mm bolts, and once removed, simply lift out the brackets. Now, you can pull out the engine cover. You may need to lift it slightly and wiggle it free. If it's not moving, check the top bolts again.

Loosen the fill hose

To loosen the fill hose of your 1994 Astro Van, follow these steps:

First, locate the fill hose on the driver's side of the fuel tank. You will notice that there are two clamps on this hose that need to be loosened. Before you begin, make sure you have the appropriate tools for the job, such as a line wrench and pliers.

Next, remove the retaining screws that hold the fill hose in place inside the fuel door. By doing so, you will find it much easier to disconnect the fill hose. Once the retaining screws are removed, proceed to break loose the driver's side retaining strap bolts, but do not remove them at this point. Most vans have bolts that are set from the factory to allow the strap to rotate freely once the bolts on the opposite side are removed. However, if the bolts have been over-tightened, you may need to loosen them with a suitable socket and wrench.

Now, move on to the driveshaft side retaining strap bolts. Again, break these loose but do not remove them yet. At this stage, you should also support the fuel tank with a transmission jack or an ATV/motorcycle jack to make the process easier.

With the fuel tank securely supported, you can now remove the fuel lines and vent lines 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. If the rubber lines for the vents are difficult to remove, try lowering the tank a few inches to provide some extra clearance.

Once all the lines and connections have been loosened or removed, you can now slowly lower the fuel tank, being careful to ensure that nothing gets caught and causes the tank to fall. With the tank safely lowered, you can proceed to remove the fuel pump and sending unit assembly. This can be done using a brass drift punch to rotate the lock ring counter-clockwise until it lines up with the notches in the top of the tank. Remember to be cautious during this step to avoid damaging any components, such as the strainer or the float arm.

Frequently asked questions