how I fixed my hard starting and replaced fuel pump CHEAP

[wmmihail]

There were a lot of good posts to help diagnose my hard starting problem on my 2000 Astro with 75K miles. If I sprayed it with carb cleaner or starter fluid it would start in an instant and I could drive all day perfectly. But as soon as I turned off the van it was a crap shoot whether it would start. Couldn't leave home without the carb cleaner. When I checked pressure at prime before starting it was between 58 and 61 psi. Running I was in the low to mid 50's.

A lot of people talked about how much a fuel pump cost. It ranged from about $250 for the aftermarket assembly only to $800 installed. I took a chance and bought a rebuild kit from a guy on E-bay. There are a few selling them. I paid $45 delivered to my door in 3 days. With it comes a new pump, 2 new strainers and 2 hoses. Everything else gets used from the old assembly.

I won't go into details on how to take the tank down. It's pretty obvious and pretty easy for the average backyard mechanic. Just a few tips.

Make sure it is as empty as can be. My wife ran vehicle down to the low fuel warning and I still pulled 5 gallons out after it was removed. That fuel sloshing around is heavy.

I ran the back wheels up on ramps and jacked the left front wheel up until it was barely touching the ground. I left the right wheel on the ground for safety. This gave me plenty of clearance to work from the left side of the van and the rear.

I blocked up the tank with 3 or 4 4x4's front and back while I worked on dropping the tank. I removed 4x4's as I went along. The strap bolts are pretty long. If you have an air gun you can make quick work of it. Be careful not to drop the tank too far before you remove the 3 fuel lines. They are quick connect. Once the tank is completely lowered just drop to ground and drag out the back.

I wasted some time trying to figure out how to pull the tank out while being obstructed by the fill vent pipe. The vent is inside the fill pipe and extends pretty far into the tank. I just removed the whole fill assemply all the way from the outsdie fuel door. 6 Torx screws on outside and one bolt by rubber hose connection must be un done. Then the fill pipe just pulled out by twisting it out through the side of the body.

Once the tank is out the assembly is pretty easy to figure out how to remove. The rebuild kit comes with clear instructions. Be warned, I screwed up and wasted a day while fixing my problem. The one glitch is with the pressure hose they give you. It is basically like an accordion straw tube. The instructions say you need a heat gun to soften the tube then push it onto the barbed fitting of the pump and on the top of the assembly. My first fitting on the pump went well. The problem was with the one on the top of the assembly. Either I over heated it or it was due to the fact it is a bit tight to fit it in but the hose basically folded over and deformed on me. At that point I was afraid to re-use it. I opted instead to seek out an appropriate rubber hose with clamps. You must use a submersible hose with SAE 30R10 rating. If anyone tells you otherwise don't do it. You take the chance of the hose degrading in the fuel bath. Gates has a hose that is suitable, part # 27097, and is rated to 100 psi. It is expensive. It comes packaged in a one foot piece for about $20. No one stocked it locally but my auto parts store got it delivered in one day. I used conventional hose clamps but you must use the smallest possible for this 3/8" hose as there is very little room for the clamp screw body in the head of the assembly. I used a 1/4" open end wrench to tighten the clamp. Hopefully you won't have a problem with the straw if you choose to go this way but if you do this is a fix that should work.

Put everything together. Re assemble the pump assembly to tank and re install the tank. The tank goes in much easier than it comes out.

Before I rose the tank into place I plugged in the pump electrical connector to check it ran OK.

The van started up in a flash. Drove fine. The one thing I will say, this new pump is much quieter than the original. Can't even hear it when running.

So for $45 for pump, $20 for hose and clamps, about 2 hours to get tank out, 1/2 hour bench time to rebuild pump and about 1 hour to re install I got a fine running van. You may be quicker and more sucessful. I worked all by my lonesome. Good luck if you choose to pursue this alternative.

[gspd750]

Good info. thanks for posting that. Time to check out ebay.

[gspd750]

Originally Posted by wmmihail

I took a chance and bought a rebuild kit from a guy on E-bay. There are a few selling them. I paid $45 delivered to my door in 3 days. With it comes a new pump, 2 new strainers and 2 hoses. Everything else gets used from the old assembly.

Unable to source the $45 pump on ebay for my 2000 astro. Do you have a link to 'the ebay store' of anyone selling these rebuilt pumps. thanks.

[gspd750]

I just called my local GMC parts line and was quoted $796.00 CDN for a new fuel pump assy for my 2000 Astro. I'm not kidding. GM is !

My pump is actually ok @ 110,000 kms but I would like to take a spare with me on the family road trip we take every summer. I have no problem taking my $ south of the border for this very signifigant savings.

It appears GM changed the design of this pump after '99 as the price goes waaay up after that. Cheapest I found was $205 USD here...
Would not mind the rebuild kit for $45...if I can find it.

http://cgi.ebay.ca/Chevrolet-Astro-G...QQcmdZViewItem

[MT-2500]

Originally Posted by gspd750

Unable to source the $45 pump on ebay for my 2000 astro. Do you have a link to 'the ebay store' of anyone selling these rebuilt pumps. thanks.

Do not fall for the cheap pump kits or just a replacement pump deal.
The fuel pumps should be replaced with the hole module assembly.
The module has all new hoses and fuel gauge and pressure sensor and sock and new wiring connector if needed.
And use a AC delco / Delphi for a replacement.
Shop around some dealers and parts places will cut you a good deal on the AC- Delco replacement pump. Sometime half of what some dealers list is.
MT

[gspd750]

Thanks MT for that advice. Your right, I only want to do that job once. Yeah, I'm sure I can find it cheaper here in Canada rather than buy direct from GM. Would you put an AIRTEX product in your van as in the following link? Sez it's OEM. It does not show the whole assy (no pic) which I assume it is, and the warrenty is good. Still cheaper than $796 CDN.

http://cgi.ebay.ca/Chevrolet-Astro-Gmc-Safari-Fuel-Pump-00-05-E3506M_W0QQitemZ330108996582QQihZ014QQcategoryZ335 55QQrdZ1QQssPageNameZWD1VQQcmdZViewItem

[MT-2500]

That part no E3506M airtex should be the complete module assembly.
Good price if shipping does not get you.
At Carquest auto parts my hole sale cost is 277.19 US. on it.

I have used airtex pumps and some people have good luck with them.
But some have not had good luck.
I would go for the GM OEM AC Delco pumps made by Delphi for GM
I would wonder why or how some airtex pumps would wind up on E bay.
They may say OEM or meets oem specs but the only real oem pumps for GM is AC DELCO /Delphi pumps.
Good luck
MT

[gspd750]

thanks again MT !