Cutting a hole in your Chevy Express GMC Savana Van for fuel pump access - with dimensions/location 

THANKS!!! What year is your van?

2000

He cut 15'" from the rounded area where the gas filler tube is, not from the wall itself.

Worked great. I used a Bosch vibrating saw with a metal cutting blade. Also slid a thick sheet of plastic over the top of the tank to help keep the blade and any sparks from the no go zone. Thanks Rob!

SFAIK, yes. Please report back if you do it, so others will know.

NO, use a grinder much easier than his saw.

On front of the tank and super easily accessable

It should be? Did you do it? How did that work out?

2002 and earlier models have a steel tank. In 2003 they started with the plastic tanks so it's possible the exact location of the fuel pumps may differ between them.

Upfitters modify stock or incomplete chassis, so I would think so. Crawl under the van with a tape measure and see what you can see

Because i'm a handy dude with the tools to do this literally in the van all the time, it took me about 20 minutes. But if you think your way is better, then you and I should have a race to see who can swap our fuel pumps out the fastest and easity *now*.... Lol It turns out that I had a ground wire issue, and this access hole actually saved me a ton of time on the side of the road doing diagnostics. I didn't have to waste time or money with a tow or a shop already.

@@robertccole13 what was your ground wire issue?

End rot/black wite disease in the fuel pump wire harness plug

Looking at a 98 Chevy Conversion Van. Wondering if this will work. 😁

@@robertccole13 was that issue with the new pump??? I've heard when you use the connectors that come With your pump eventually you're gonna have that issue. Is that correct? Thx

I'm not sure. Poke around under th van and see where the x member is. Do report back if they work for you, please

I was looking underneath and it looks like your measurement from the filler will work and the length measurement I’ll have to add the 20 inches and it’ll be spot on….I believe the regular wheelbase is 135 and the extended is 155, so it would make sense to add 20 inches more from the back of the seat

Ok so I ended up cutting the floor for the fuel pump……your measurement of 15 off the filler neck worked. I cut it 49 inches and 51 inches off the seat bracket

The filler neck is the metal tube that goes from where your gas cap is ..... to the fuel tank.

@@UTOBEDUDE ok I follow now I definitely need a new one on mine cause it leaks gas in the middle’

LOL, no If your mechanic could do this it would make it quicker to do it next time, and they would prolly still charge the estimated billable hour rate for it ;)

@@robertccole13 thats so gay. Lol i just needa bring like some burritos or somethin to sweeten the deal

@@robertccole13 Mine would try to charge more!

Hey, thanks for your excellent comment! I sure hope you feel better now that you've let the world know how you feel.

@@robertccole13 Anytime I can promote proper procedures and point out what a hack job looks like, is a win for people to see the difference.

Proper procedure needs to be defined in reference to the goal. Not everyone has the same goal that you do , clearly. You *do have a glaring lack of self-awareness and critical thinking skills. Have a great rest of your life.

@@robertccole13 You’re a hack so of course you won’t agree with me. The manual for a vehicle shows how to properly remove a gas tank. Nowhere in the manual does it say to cut the floor out to make an access.

@erik...Although noble you lack some realities. A conversion van does not allow you 5 inches or so from pavement for example. Lifting the vehicle with a 3 ton jack and lowering the tank even if you could get under the side of a van does not allow room to pull the 12 inch pump upward even more to get it out of the tank. Maybe rotate the tank? How about straddle a ditch near your house ...that would give it room if you just happened to stall the vehicle with a bad pump over a ditch near your house. How about drag and yank out...nope not enough room with standard jacks lifting. I have not done this method. If I did I would probably JB weld the panel I cut out back in place easy enough. Some visiting this solution NEED the vehicle running to move it or to drive it. I plan to try the rubber mallet to bang the bottom of the tank first. I have had to do this on 3 suburban's and one was lifted and was still a chore. Unfortunately time is rare and costs are so ridiculous. If done safely there is no reason not to do this. In fact the manufacturer should always place an access here. Not meaning to be mean or anything like that. Just suggesting it is not laziness. I am FAR FAR from being a lazy person. I am not sure what trash is but I wear a suit to work and can pay for any repairs but I do not. That is a waist of money if you can do it yourself. Lazy would be to just pay someone to do it with a lift. Last "Thank You" Robert Cole. I might try this as long as I can avoid cutting the lines I might do a three side cut and just bend it back for the removal and then bend it back and use those welding clip things and then JB weld the seams just to prevent fumes or roll over gas.