Fuel Pump Access Door

[astro fan]

My 97 Astro now has 180,000km on the clock with original fuel pump. Judging from this forum this component seems to be a high frequency replacement.

I have been considering the addition of a fuel pump access door in the floor so I can easily replace it myself if stranded away from home but here's where I need your advice.

1) Will a door approx. 9" X 9" be large enough?
2) Will I have enough room to disconnect electricals & fuel line?
3) How are the fuel lines attached to the pump?

Thanks in advance

[CD Smalley]

It's a good idea.

I think the size would be big enough.

The lines use small clamps to connect to the pump assembly.

Think long and hard about how you will seal this door up completely once done though...

[astro fan]

Thanks CD for your advice.

This access door is only in case the pump fails when I'm away from home. You see I don't want get nailed an additional 200 to 400$ to empy tank, drop-it down and put it back together not to mention the risk associated with the welded nuts for the straps.

We read many entries on this forum about fuel pump replacement but it doesn't mean they all crap-up sooner or later does it?

I've followed OEM recommended filter replacement interval and I kind of hope the fuel pump will last the life of the van! Am I dreaming?

Astro Fan

[CD Smalley]

astro fan you live in a nice little dream world....

Everything I have read has them failing at some point....

[Kings-x59]

I've been thinking about doing the same to my ole '89, a nice access panel tucked away under the carpet.
I think a small bead of RTV or just plain silicone sealant would do the trick to seal it up.

[astro fan]

Well it seemed like a good idea until I came across a baffle between the floor and the tank. I might have to visit a junk yard to figure out how that shield is attached to the floor.

From what I can see, this part only covers the pump & hose area. It's a good thing that GM put those in in their vans since a lot of peoples add plywood floors and drill a bunch of holes to secure it in place. You would not want to drill a hole in the hose or in the pump flange!

Stay posted as I might have more details later this week.

[astro fan]

Good news folks a fuel pump access door can be added to your Astro.
It took me a little over 2 hours to locate and cut the opening but think of the $$$ savings if the pump was to fail away from home. No more tank removal required!!

All you'll need to replace the pump assembly is a screwdriver to remove Access door and snap ring pliers to free the pump!

Here's a couple of pointers. As a safety precaution I parked the van outside away from buildings just in case. Locate the center of the tank using the bench seat anchers as references. Cut the carpet instead of tearing down interior cause it's hidden under a rubber mat anyways. Mark steel floor approx. 8"x8" centered on the tank center. Using a Dremel with a cutting disk cut the floor out and remove all sharp edges.

At this point the pump is not visible yet because there is another piece of steel protecting it. Here you have to be very very carefull with the Dremel as the fuel lines and the electrical wires may be touching the underside of that part. So do not cut through with the disk. Try going half to 3/4 of the thichness and rip the steel with a screwdriver and pliers. Locate fuel lines and wires and use another piece of steel as required to protect them while you resume cutting. Sand or file all sharp edges.

Take the floor piece to a tin shop and have them shape a new one identical to the cut piece but larger by an inch all around. I used galvanized steel so save myself priming and painting.

Apply a thin coat of grease to the underside of the door and apply a generous bead of silicone to the floor to form a gasket. Press new door in the silicone until it squeezes out all around. Remove excess silicone and let door alone with some weight on until silicone is cured. Secure door with SHORT metal screws not to puncture tank. Use a drill stop on the bit when drilling holes for the screws.

Good luck.

Astro Fan

[CD Smalley]

Pics please!!!

[Old-730]

Astro fan
Would you have a template plan made out? I'm stuck with a broken down 96 Astro in the cold of Canada' s best weather trying to get this fixed without freezing. my email is [email protected]
Thanks
The Old Guy