This is the most pract I cal way to replace the fuel pump, if you are a brave DIY type of guy. And owned some tools. Some comments here, are not diy friendly so they question your actions. Then you wonder why are they researching on RU-vid unless you planning on taking on the job. But this idea is great! You will always have access to the pump. All you need to do is make a cover for the opening. Good job mate and thank you for the Tutorial.
The tool to use for cutting the hole is one of those oscillating multi-tools. Use the 1/2 moon blade, it naturally cuts arrow straight, nearly zero chance of sparks, only cuts maybe a 1/2" deep and it cuts a nice, clean, paper thin line. I bought one specifically to do this same job on my '06 Avalanche and it worked like a charm and was one of the best mods I ever did to save a ton of headaches. And if you go to Harbor Freight the tool is as cheap as $20, or opt for the "premium" variable speed version for about $35. It's paid for itself a dozen times by now and so has this modification.
Do you know the name of that oscillating tool you speak of I’m going to harbor freight to find it when I cut the hole in the floor of my 04 Yukon Denali I used the circular saw it was way too many sparks but it got the job done I was nervous tho😂
Thanks for the Tip.Saved me a lot off trouble.Now i can work from the inside warm and dry because my Van is standing outside and it is raining a lot here in Holland during autumn.
Same as me... I'm watching this video as I am about to do the third one... just after I filled it... it went in the Walmart parking lot just as a snow storm was starting.
With 340,000 on my 2000 chevy van this is how I am going to do it. I had it replaced when the van was newer and it was $700. Just bought the pump online for $58.00.
IIRC there is a GM service bulletin that says to do exactly this for certain model Cadillac SUVs. Cut a hole in the floor. Probably a good choice on vehicles that have seen salt where the tank attachments may not come apart easily. But be sure to seal the hole well so carbon monoxide can't enter. If you can go to a junkyard and cut a larger piece out of the floor to cover it I would do that.
Hey, got those dimensions ya wanted; 35.5 Inches aft from the Driver's Seat Mount, 20.0 Inches inboard from Filler neck body shroud where it intersects the floor, mark (which falls right on a Bend of the corrugated floor) and drill a 1/4 Inch Hole saw pilot. Don't drill too deep, RIGHT?!! All measured on the inside of a 2000 2500 Express Standard Cargo Van. Tip: You can always make the Hole bigger later but, ya for sure can't make it smaller! I used a 5 inch diameter Hole saw, it's a little tight but, ya don't wanna make the hole really big like the in Video. Turn the Hole saw Backwards for a little while, STOP for lots of cooling time, Turn... STOP again, Turn... STOP again, Turn... STOP again, Turn... STOP again, try turning Forward if the Hole saw grabs too much resume Backward and use Oil! I used a 1 hp. Your Drill motor might not be powerful enough to turn a 5 inch hole saw forward. For finish work, I used a 6 inch Deck cover for a Boat to plug the Hole. The cover unscrews for EZ access images-na.ssl-images-amazon.com/images/I/71kRuhNnFWL._SL1476_.jpg Got on Amazon Yes, I needed to clean up a 1/2 inch all the way around cause, of the sharp Edges and damaged edge which made the Hole a little Bigger but, made a nice clean Job outta my work and also covers where I scratched the paint☺
There's Usually Enough Room To Squeeze An Angled Pair Of Needle Nose Pliers, Disconnect The Fuel Lines & Wire Tie The Harness Out Of The Way, Then You Can Cut The 2 Long Sides & The Short One @ The Top, Bend It Back, Like An Access Door, Bend Back & Seal With Silicone 💁🏽♂️
not to knock down your video which is great but taking down the fuel tank on these vans is super super easy. I've done it twice on my 1996. ive had this van many years and its a job that takes maybe maybe 3 hours taking it easy and stopping to eat. Now mind you, my van is a conversion van which has the rear ac next to the gas tank and its still easy. not nice to hack sheetmetal . cool vid though.
@@nyc1655 easy peasy, its easier to take that tank down than to curl up tug then glue everything or rivet a plate. Throw an acdelco pump and u will be fine. Throw in an airtex pump and u will be doing this job lots of times.
Hi there. Good idea. Just filled up and I believe it’s my pump. Can’t drop the tank as I do t want to deal with all that. I’m just curious if you’ve had any drawbacks from cutting out the hole? There has to be a better way to put it back with like hinges or something to prevent water from getting through or up. I have a cargo van so it’s not that big of a deal for me with carpet and all that but still I don’t wanna ruin the thing. Thanks man
Dave R don’t be concerned about having a hole in the floor as it does not affect the van in any way. The video is several years old and I never had any issues. Biggest concern is cutting the hole and staying away from gas lines. Somebody mentioned using a multi tool which will probably work better than sawzal.
Hey there Dave, did you try this out and wondering what technique you might have used if you did? Drawbacks etc? I'm strongly considering same on my cargo van since its dead of winter cold & no garage or even level ground to jack up & drop the tank. So, yeah any added info would be a help / greatly appreciated. (Hope your situation is resolved either way). -J
Hey guys. Yes I absolutely did this. However, I just cut three sides with a grinder and peeled it over so when closing it back I wouldn’t have to put any plates to keep it from falling through. I put a piece of sheet metal over the pump from underneath the van to protect the lines from any hits from the grinder. Just remember the rubber carpet needs to be removed or blocked because the underside is highly flammable from the grinder sparks!! Hope this helps. Thanks for the idea! I just modified it to make it a little easier!! Completely resolved the issue however upon further investigation, it looked like my fuse under the hood was loose! Felt like an idiot for not checking it first. No drawbacks. Once it is siliconed when covered back you won’t even know it’s there. This is the best way to change out the pump! Saved myself a good $700 from the mechanic!
There are cars that have fuel pump access holes from factory. But for most it is another thing they can save money on. Most pumps fail after warranty period so this will fall on the owner to pay dealer for repair.
@@tomkuz3689 yeah im pretty sure cause my 1985 e23 bmw has a hatch on top of the fuel pump assembly so you can access to it ...its a shame not all cars are like that
That little bit of hump is the fuel filler neck housing. That is the same in all of the vans. The fuel lines are $150 or so new now. The interchange is a ton of 1996-99 trucks and some through 02.
The only reason the fuel pump goes out cuz everybody likes to run it on empty you should just fill it up when it's at a quarter tank the fuel pump should last you at least 200,000 MI
the guy is just showing us how to cut a hole in the floor in the right place. The camera is moving so much that I cannot follow... As for replacing the pump through other methods, that is not the topic of this one. The only problem with this is that water will get in through the floor hole and rust.
