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

Replacing the fuel pump in an Astro van is a complex process that requires a range of tools and precautions. The process involves disconnecting the negative battery cable, raising and supporting the van, draining the fuel tank, and removing various components such as the splash guard, fill hose, retaining straps, fuel lines, and wiring harness. It is also important to keep a dry chemical fire extinguisher nearby when performing any fuel-related work. The cost of replacing a fuel pump in an Astro van can vary depending on the year of the model and labour rates, but it typically ranges from $1,095 to $1,326.

Disconnect the negative battery cable

Disconnecting the negative battery cable is the first step in replacing the fuel pump in an Astro Van. This is a safety precaution to prevent any electrical issues or accidents while you work. Here is a detailed, step-by-step guide 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 often marked with a "-" symbol. It is typically located in the engine bay, close to the battery. Once located, proceed with the following steps:

• Put on safety gloves and goggles to protect your hands and eyes from any potential hazards.
• Prepare the necessary tools: a wrench or socket set to loosen the cable, and possibly a wire brush if there is corrosion on the terminal.
• Loosen the negative battery cable clamp: use the appropriate-sized wrench or socket to loosen the clamp that secures the cable to the battery terminal. Be careful not to touch any other parts of the engine with the wrench or socket to avoid accidental electrical connections.
• Detach the cable: once the clamp is loose, carefully lift and remove the cable from the battery terminal. Ensure that the cable does not touch any metal parts of the engine or vehicle to prevent short circuits.
• Secure the cable: place the detached cable in a safe location away from the battery and any metal components. You may wrap the end of the cable with electrical tape or cover it with a plastic bag to ensure it does not accidentally make contact with anything.
• Verify disconnection: use a multimeter to check that there is no voltage or current flow between the negative terminal and the cable. This ensures that the battery is completely disconnected.
• Work safely: with the negative cable disconnected, you can now proceed with the rest of the fuel pump replacement procedure. Remember to work carefully and refer to a detailed guide for the specific steps involved in replacing the fuel pump in an Astro Van.
• Reconnecting: once you have completed the fuel pump replacement, you will need to reconnect the negative battery cable. Simply follow the above steps in reverse, ensuring a secure connection between the cable and the battery terminal.

Remember, working with automotive electrical systems can be dangerous. Always take the necessary precautions and refer to a qualified mechanic or a detailed guide if you are unsure about any steps.

Safely raise the van with jack stands or ramps

To safely raise your Astro van with jack stands or ramps, you must first find a flat, level surface to park your vehicle. A garage or a flat driveway is the best place to do this. Avoid bumpy, uneven, or gravel surfaces, as these can cause the jack or jack stands to slip out from under your van. Ensure that each side of your van is level. Apply the parking brake and place chocks or tire wedges around each wheel if you're lifting the back end of your van. If you don't have tire wedges, you can use 2-inch by 4-inch boards in front of and behind the wheels.

If using ramps, centre your steering wheel so that the front wheels point straight ahead. Slide the first ramp directly in front of the front driver-side wheel until it touches the tyre, and do the same for the passenger-side wheel. Make sure each ramp is centred so that the wheels stay completely supported by the ramps as you drive up. With the engine running and the van in gear, slowly drive up the ramps until the van levels out, then stop. Put the van in park, apply the parking brake, turn off the ignition, and remove the key. Chock the rear wheels to prevent the van from rolling backward.

If using jack stands, locate the pinch points of your van, which are located on the sides of the vehicle behind the front tyres or in front of the rear tyres. Place the jack stands at these points or on the frame of the vehicle. Do not crawl under the van until the jack stands are secured. Check the weight of your van in the manual and ensure that your jack stands can support that weight.

If you need to lift the van higher than the jack stands allow, you can place a concrete paver or wooden blocks under the stands, but this may be unsafe as they could crack or break under the pressure. A safer option is to use jack stands designed for heavy-duty trucks or to repeat the process with a shorter wooden block under the jack.

Drain the fuel from the tank

To drain the fuel from the tank of your Astro van, you will need to use a hand siphon or pump. Siphoning is the act of removing liquid from a tank using a tube and your mouth to create suction. This method is not recommended for fuel because of the risk of ingesting toxic fuel. Therefore, using a pump is the best option.

To begin, locate the fuel tank and ensure the van is on a level surface. Place a suitable container to collect the fuel beneath the tank. Insert the pump into the tank and begin pumping to drain the fuel. This process may take some time, so be patient and careful not to spill any fuel.

Once the tank is drained, you can proceed to replace the fuel pump. It is important to note that working with fuel can be dangerous, so ensure you take the necessary precautions to avoid any accidents or fires. Always keep a dry chemical fire extinguisher nearby when performing any fuel-related work. Additionally, if your van is lowered, it is crucial to safely support it with jack stands or ramps.

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 locate the four press-in clips and multiple slip-on clips that secure it in place. Once you have found these clips, you can carefully release them using an appropriate tool. Be cautious when removing the splash guard, as there may be fuel remaining in the tank. It is recommended to drain the fuel tank before beginning this process, if possible. Ensure you have a dry chemical fire extinguisher on hand when performing any fuel-related work.

The removal of the splash guard will grant you access to the fuel tank and the fuel pump assembly. Before proceeding with any further steps, it is important to support the fuel tank securely to avoid any accidental damage or fuel leaks. You can use a transmission jack or an ATV/motorcycle jack for this purpose. Additionally, ensure that the van is safely raised and supported using jack stands or ramps.

Now, you can proceed with disconnecting the fill hose attached to the driver's side of the tank. There are two clamps on this hose that need to be loosened. For easier access, you may want to remove the retaining screws holding the fill hose inside the fuel door.

At this point, you can continue with the next steps in the fuel pump replacement process, such as loosening the retaining strap bolts and carefully lowering the fuel tank. Remember to work cautiously and refer to a reliable repair guide or seek assistance from a qualified mechanic if needed.

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 Astro van, first locate the two clamps on this hose and loosen them. Then, remove the retaining screws that hold the fill hose in place inside the fuel door to make it easier to disconnect the fill hose.

It is important to note that there may be a hidden 15 mm nut on top of the strap where it attaches to the chassis. You can use a needle nose vise grip, a 12" extension, a 15mm socket, and a 15mm wrench to loosen these. By breaking loose the driver's side retaining strap bolts, you can rotate the strap 180 degrees out of the way, making it easier to work on the fuel tank.

Frequently asked questions