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

If you're looking to replace the fuel pump on a 1994 Astro Van, there are a few steps you'll need to take. Firstly, disconnect the negative battery cable and safely raise the van with jack stands or ramps. Next, drain the fuel from the tank and remove the splash guard from the driveshaft side of the fuel tank. You will then need to loosen the fill hose attached to the driver's side of the tank and remove the retaining screws that hold the fill hose in place. After this, you can remove the fuel lines and vent lines from the hard lines, and then remove the wiring harness. Finally, you can remove the fuel pump/sending unit assembly and replace it with a new one.

Disconnect the negative battery cable

Disconnecting the negative battery cable is the first step in replacing the fuel pump on a 94 Astro Van. This is a crucial safety precaution as it will prevent any electrical accidents or mishaps while you work on the vehicle. Here are some detailed instructions to guide you through the process:

Step 1: Park your Astro Van on a level surface and engage the parking brake. This will ensure the vehicle remains stationary throughout the process.

Step 2: Locate the negative battery cable. The battery is typically located in the engine compartment of the vehicle. The negative cable is usually black and has a "-" symbol near where it connects to the battery.

Step 3: Before proceeding, ensure that you are wearing protective gear, including safety goggles and gloves. This will reduce the risk of injury from any corrosive battery acid that may be present.

Step 4: Once you have located the negative battery cable, you will need to disconnect it from the battery. Start by loosening the nut or bolt that secures the cable to the battery terminal using an appropriate-sized wrench or socket. Do not remove it completely yet.

Step 5: Carefully move the negative cable away from the battery, ensuring that it does not touch any metal parts of the vehicle. You may need to slightly bend or reposition the cable to create some distance between it and the battery.

Step 6: Once you are confident that the cable is clear of any metal surfaces, you can now completely remove the nut or bolt securing the cable. Set it aside in a safe place, as you will need it again later when reconnecting the battery.

Step 7: Cover the negative battery terminal with a piece of electrical tape or a terminal protector. This will prevent accidental contact and short circuits while you work on the vehicle.

Step 8: With the negative battery cable now disconnected, you can proceed to the next steps of raising and supporting your Astro Van and draining the fuel tank, as outlined in the replacement procedure. Remember to reconnect the negative battery cable correctly once you have finished replacing the fuel pump.

Raise and support your van with jack stands or ramps

To replace the fuel pump on your 94 Astro Van, you'll need to raise and support your van using jack stands or ramps. Here's a detailed guide on how to do this safely:

First, park your van on level ground, preferably on a paved surface. If you must park on an incline, position your van close to the curb and turn the wheels inward to prevent accidental rolling. Next, secure the van in place by blocking the downside wheels with wheel wedges, wood blocks, or bricks. Make sure to engage the parking brake and put the vehicle in park. If your van has a manual transmission, put it in first gear as well.

Now, it's time to position the jack. Refer to your owner's manual to identify the proper placement of the jack under the car frame. If you only need to lift one corner of the van, place the jack under the corresponding corner. If you need to lift the entire front or rear of the van, position the jack at the center of the front or rear suspension or frame. Ensure that your jack has adequate weight capacity for your vehicle. It's recommended to use tools with a capacity of at least 50% of your van's weight.

Once the jack is in position, it's time to raise your van. If you're using a scissor jack, insert the rod and crank it until the jack connects with the car's lift point. If you're using a hydraulic jack, place the handle into the body of the jack and pump the handle smoothly to raise it until it contacts the car frame. Lift your van to the desired height.

Now, it's time to place the jack stands. Position the jack stands under the car frame at reinforced points or "pinch welds" near the jack. Make sure to use jack stands that are properly rated for the weight of your van. Do not attempt to substitute the jack stands with boxes, wood stacks, or bricks, as these may not be able to securely hold the weight of your vehicle.

When using pin-type jack stands, adjust the height using the locking pins, while screw-type jack stands use adjustable screws. Once the jack stands are in place and adjusted to the correct height, slowly lower your van until it rests securely on the stands. Give your van a gentle push to ensure that the jack stands are holding it securely.

If you need to raise the entire van, repeat the process for the other end of the vehicle, using an additional pair of jack stands. Remember always to use jack stands in pairs when supporting the front or rear of the van.

Now that your van is securely raised and supported, you can proceed with the next steps of replacing the fuel pump. Remember always to exercise caution when working under a raised vehicle, and ensure that the van is securely supported before proceeding with any repairs.

Drain the fuel from the tank

To drain the fuel from the tank of your 94 Astro Van, you will need to use a hand siphon or pump. Before you begin, make sure you have raised and safely supported your van, preferably with both the front and rear raised, using jack stands or ramps. It is also important to disconnect the negative battery cable.

Once you have completed these preliminary steps, you can begin to drain the fuel tank. If your tank contains more than a quarter full of fuel, carefully drain the fuel into an appropriate container. If you have less than a quarter of a tank, you may not need to drain the fuel at all.

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 van with jack stands or ramps. It is recommended that you raise both the front and the rear of the van.

Now, drain the fuel from the tank. This can be done with a hand siphon or pump. Once the tank is drained, you can begin to remove the splash guard. It is installed with four press-in clips and multiple slip-on clips. Be careful when removing the splash guard, as you do not want to damage any of the clips or the surrounding components.

Once the splash guard is removed, you can move on to the next step, which is to loosen the fill hose attached to the driver's side of the tank. There are two clamps on this hose that will need to be loosened. It is also recommended to remove the retaining screws that hold the fill hose in place inside the fuel door, as this will make it easier to disconnect the hose.

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, you will need to first identify the two clamps on the hose. Using the correct size wrench, loosen the clamps. Next, remove the retaining screws that hold the fill hose in place inside the fuel door. This will make it easier to disconnect the fill hose. Once the retaining screws are removed, you can proceed to disconnect the fill hose from the driver's side of the tank.

It is important to note that there is a hidden 15mm nut on top of the strap where it attaches to the chassis. You may need to use a needle-nose vise grip, an extension, and a socket or wrench to loosen this nut. Additionally, be sure to only loosen the driver's side retaining strap bolts and do not remove them yet. The bolts on the opposite side can be removed, and on most vans, they are set from the factory to allow the strap to rotate freely.

Frequently asked questions