Replacing Fuel Lines: Astro Van 2002 Edition

Replacing the fuel line on a 2002 Astro van is a complex task that requires mechanical expertise and careful adherence to safety precautions. The procedure involves siphoning gasoline, disconnecting wiring harnesses and fuel lines, and manipulating components near the gas tank, which is highly flammable. Personal protective equipment, such as safety glasses and nitrile gloves, is recommended to safeguard against eye injury and exposure to carcinogens. Additionally, it is crucial to disconnect the battery and avoid open flames or sparks during the process. While some people opt for rubber, nylon, or stainless steel fuel lines, it is important to consult a professional or a repair manual for specific instructions and parts requirements for a 2002 Astro van.

The fuel line replacement procedure

Step 1: Safety Measures

• Wear safety gear, including safety goggles, gloves, and a face shield.
• Ensure adequate ventilation in the workspace.
• Disconnect the battery before starting any work.

Step 2: Siphon Gasoline

Try to siphon the gasoline from the tank through the gas filler tube. If that's not possible, proceed to drain the gas tank.

Step 3: Disconnect Components

• Remove the gas filler tube by unbolting it from the side of the van and detaching it from the gas tank.
• Disconnect all wiring harnesses and fuel lines connected to the gas tank.
• If needed, you can disconnect the EVAP purge line and sensor wires or unbolt the assembly from the side of the van to simplify the process.

Step 4: Lower the Gas Tank

• Support the gas tank with a jack, slightly off-center toward the back of the vehicle for balance.
• Loosen the tank straps on both the driver and passenger sides.
• Slowly lower the gas tank and remove it from under the vehicle.

Step 5: Remove and Replace the Fuel Pump

• Detach the fuel lines and wiring harnesses from the fuel pump.
• Remove the retaining ring and lift out the old fuel pump, being careful with the fuel pump float.
• Clean the retaining ring and replace the seal ring between the fuel pump and tank.
• Install the new fuel pump, ensuring it faces the same direction as the old one.
• Reattach the center line on the pump.

Step 6: Reinstall the Gas Tank

• Place the gas tank back under the vehicle and reattach the fuel lines and wiring harnesses.
• Reinstall the gas filler tube and secure all bolts and connections.

Step 7: Final Checks

• Check that all connections are secure and lines are properly routed.
• Refill the gas tank and start the engine to ensure proper functioning.

Note: These steps provide a general guide, and some variations may exist depending on the specific model and year of your Astro van. Always refer to a qualified mechanic or a service manual for detailed instructions specific to your vehicle.

Fuel line replacement kit options

When it comes to replacing the fuel line on your 2002 Astro Van, there are a variety of kits and parts available. Here are some options to consider:

Dorman Products:

Dorman offers a range of fuel line products that are compatible with the 2002 Astro Van. These include:

• Dorman 800-153 OE Solutions Series Fuel Line Kit: This kit includes a 3/8 inch x 18-inch fuel line with a 16mm fitting and a male O-ring connector. It is made of steel and is designed for a direct fit.
• Dorman SET-RB800153-2 Fuel Line Set: This set includes two fuel lines with different fitting sizes: 16mm for end one and 3/8 inch for end two. It also features male O-ring fuel line connectors and Viton gasket material.
• Dorman 800-075 Fuel Line: This is a universal fuel line made of nylon and offered in a 10-foot length. It has a 3/8-inch diameter and is pressure-rated for fuel injection.
• Dorman 800-074 Fuel Line: Another universal fuel line option, this one has a 5/16-inch diameter and is also made of nylon. It comes in a 10-foot length and is pressure-rated for fuel injection.
• Dorman 800-154 Fuel Line: This universal fuel line is made of steel and has a 5/16-inch x 12-inch double bead line design.
• Dorman Fuel Connectors and Unions: Dorman offers a range of fuel connectors and unions with different connector types, including barb, inverted flare, and quick disconnect. These are useful for connecting and securing fuel lines.

AC Delco:

AC Delco offers a fuel line product that is compatible with the 2002 Astro Van:

AC Delco 15728617 Fuel Line: This fuel line is sold individually and is located at the front. It comes with a 24-month or unlimited-mile limited warranty.

Cohline:

Cohline offers fuel hoses that can be used as replacements for the Astro Van:

• Cohline Fuel Hose 3.2 X 8.5 mm: This hose is made of smooth rubber with inside braiding and is designed as a universal fit. It comes with a 24-month or 24,000-mile limited warranty.
• Cohline Fuel Hose 12.0 X 17.0 mm: This hose has an outside cloth braid and is also designed as a universal fit. It includes the same 24-month or 24,000-mile limited warranty as the previous Cohline product.

When choosing a fuel line kit or parts, it is important to consider the specific needs of your vehicle and the compatibility of the products with your Astro Van. It is always recommended to consult a professional or a mechanic if you are unsure about the replacement process or the compatibility of the parts.

Safety precautions

Safety should be a top priority when replacing the fuel line on your 2002 Astro Van. Here are some crucial precautions to keep in mind:

• Gasoline is highly flammable and volatile. Its vapors can easily ignite with a spark or heat source. Before starting any work, disconnect the battery to minimize the risk of sparks. Avoid using an open-faced trouble light for additional lighting; instead, opt for flashlights.
• When working underneath your vehicle, wear safety gear to protect yourself from falling debris and rust. Safety glasses are a good idea, but a face shield will provide even better protection.
• Gasoline can contain carcinogens, so it's important to wear nitrile gloves and ensure good ventilation during the repair. Performing this task in a driveway instead of a garage is recommended.
• Start by siphoning the gasoline out of the tank. If possible, try to do this through the gas filler tube (where you usually insert the gas nozzle). If that's not feasible, you may need to remove the gas filler tube and siphon from the tank directly.
• When removing the gas filler tube, be cautious of any rust buildup. It's a good idea to clean, sand, and paint the tube with rust inhibitor before reinstalling it.
• When working with fuel lines and the fuel pump, be extremely cautious. Even a small leak can pose a significant fire hazard. Always use the appropriate tools and never cut corners when dealing with flammable liquids.
• If you need to grind or cut any components, be extremely careful to avoid creating sparks near leaking fuel lines.
• When reconnecting fuel lines, use proper clamps and fittings to ensure a secure and leak-free connection.
• If you're working alone, use a jack to support the gas tank while you loosen and remove the tank straps. Have a helper nearby if possible to assist with the tank removal and reinstallation.
• When reinstalling the gas tank, be cautious not to kink the fuel lines. Ensure that the lines are securely attached and routed away from the muffler.
• Before starting the engine, double-check all your connections and look for any signs of fuel leaks. A small leak can have severe consequences if left unattended.
• Always dispose of gasoline and related waste responsibly, following local regulations and guidelines.

Removing the gas tank

To remove the gas tank from your 2002 Astro Van, you will need to first siphon the gasoline out of the tank. Try to do this through the gas filler tube (where you insert a gas nozzle to refuel). If you can't fit a hose into the tank through the filler tube, you will need to remove the tank to siphon the gas.

The next step is to remove the gas filler tube. There are two small bolts (7mm) attaching the filler tube to the side of the van, and a bracket underneath the van that holds it in place (13mm bolt). Loosen the clamps on the hose connecting the filler tube to the gas tank, then remove the filler tube from the tank and the van.

Now that the tank is drained, you can start removing all the wiring harnesses and fuel lines connected to it. There are two fuel lines between the gas tank and the drive shaft (coming from the fuel pump) that you may not be able to reach. If you can't, don't worry about it for now—you will have another chance to remove them after lowering the tank.

Detach the wiring from the side of the fuel tank. This is the wiring going into the fuel pump. It is hooked onto the side of the tank to keep it from dangling when you drive. Now, support the gas tank with a jack, slightly off-center toward the back of the vehicle for balance. Begin to loosen the tank straps, then slowly release the tension on the jack to lower the tank.

If you weren't able to reach the two fuel lines before, you will now have another chance to remove them before lowering the tank completely. Additionally, remove the two wiring harnesses attached to the fuel pump. Now, drop the tank to the ground and pull it out from under the vehicle.

Replacing the fuel pump

To replace the fuel pump on a 2002 Astro van, follow these steps:

Firstly, disconnect the negative battery cable. Next, raise and support your van with jack stands or ramps, ensuring both the front and rear are raised. 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.

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. Loosen the fill hose attached to the driver's side of the tank. There are two clamps on this hose. It is easier to disconnect the fill hose if you remove the retaining screws that hold the fill hose in place inside the fuel door.

Break loose, but do not remove, the driver's side retaining strap bolts. On most vans, the bolts 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. There is a hidden 15mm nut on top of the strap where it attaches to the chassis. You can use a 12" extension and a 15mm socket and wrench to loosen these.

Now, break loose the driveshaft side retaining strap bolts but do not remove them yet. Support the fuel tank with a transmission or ATV/motorcycle jack. The fuel lines and vent lines should now be removed from the hard lines. The two fuel lines require a 5/8 line wrench and a 3/4 line wrench. The two vents are simple pinch clamps that can be removed with pliers.

Remove the wiring harness. The wires run across the top of the tank, over to the driver's side, and then follow the "frame" rail forwards, attaching to the body near the transmission. Unplug the harness and remove it from its retaining clips. Once it is free from the clips, feed it through the hole in the "frame" and set it aside.

Remove only the driveshaft side strap retaining bolts and then turn the straps 180 degrees out of the way. Now, slowly lower the fuel tank, being careful to ensure nothing gets caught.

It is now time to remove the fuel pump/sending unit assembly. Use a brass drift punch and a hammer to rotate the lock ring counterclockwise until it lines up with the notches in the top of the tank. Remove the assembly from the tank carefully so that the strainer does not fall off into the tank and the float arm does not get damaged.

To remove the fuel pump from the sending unit, remove the wiring harness and then push the pump up towards the top of the unit. When you have clearance, tilt the fuel pump outwards and then pull down on it to remove it. Replace the O-ring seal on the top of the tank with a new one.

Installation of the new fuel pump is the reverse of the removal process.

Frequently asked questions