Near death experience: Fuel pump on my Chevy van went out years ago. I decided to ride a bicycle to work for the rest of the week until I could work on the van during the weekend. I was married to this relatively hot and very handy little redhead at the time. I came around the corner and immediately smelled gasoline. I looked in my driveway and a trail of gas was coming out from underneath my van and into the gutter, forming a puddle. Even scarier was the shower of sparks shooting out the door of the van, Accompanied by a grinding noise. I immediately grab the extension cord and unplugged it. My wife was inside the van cutting an access hole just like this one and didn't realize that she had cut through the fuel line! Another couple of seconds and she would have nuked herself clear to Jupiter. Consider taking the panel that you have cut out and bolting on four mending plates about 3/4" x 4", locating them in the low areas of the corrugation. Much easier than going to the junkyard and cutting out another panel oversize.

Man, I watched 3 videos of people hacking up their floors to make an access. You're the FIRST and only person smart enough to undercut the access and make a spot to overcut a new panel. Subscribed, Rob. THIS is the way it should be done. I'm amazed GM did not add an access, as notorious as the pumps and wires are for failing.

Just for people reading comments. I did an access panel on a 99 Astro van. After using cutting tools and bouncing around to much, I just used a 5in1 painters tool, the scraper edge,and a hammer.. opened up like a can of tuna.. easy$.

Rob! You’re the man. I just did this on my 2001 2500. I crawled under and through at least 4 times to make sure everything was right on, and it definitely is. I’d go 8” instead of 7.5” but if my pump goes out I won’t have to cut the floor out again 🤣

I’ve seen a few of these videos and none express overlapping on the edges from a junkyard piece very clever very smart I was pondering on how to bracket that thing on but now I see how a couple of self tapping screws and you’re done great job

Perfect! Your measurements were right on target for our 1997 Chevy 1500 Express with the 5.7. Thanks!

Thank you for the dimensions; knew there would be someone on YT!

yep just like the blazer i just did -cut it out and saved about a days worth of work

Genius and thank you! just a fyi this worked on my 2002 Savana 2500. dead center. Chaaaaaaching!

I know this video is 2 years old but on my 2012 Chevy express 2500 I had to cut back much farther than the 15”. From the wall to center of the fuel pump is 28”. Maybe i misunderstood your comment in the video. From the fuel port wall to center of full pump it’s 21”. I only cut 3 sides and pulled it back so that I can push it back down and tack weld corners and then seal it with watertight epoxy.

@damkayaker

Жыл бұрын

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

Your dimensions were spot on thanks

@robertccole13

Жыл бұрын

THANKS!!! What year is your van?

@heeman2078

Жыл бұрын

2000

Thanks man for the measurements 👌

Thanks Rob. This will be my entry point.

@robbydockery1272

2 жыл бұрын

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!

Thank you. Best Video on this topic.

Helped me out so much. Thanks

Can confirm these dimensions work for a 2002 chevy express 1500 v6 !

I just dropped the fuel tank it wasn't so bad if U have a helper it's really easy Tru grade pump 75 whole assembly bucks at AutoZone very nice fit in my 1995 k 1500 5.7 litre.

Good stuff bro! Thank you

Hey Rob, are the dimensions the same on a 2014 2500 express. Ty for any info

@robertccole13

Жыл бұрын

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

It is not just about replacing the pump,,,,,guess where the fuel filter is?

@robertccole13

2 жыл бұрын

On front of the tank and super easily accessable

I LOVE YOU ROB

Hi, it is possible to cut the opening with sheet metal shears? Is the truck metal bed tough to cut? Thanks

@sdfv4zx

Ай бұрын

NO, use a grinder much easier than his saw.

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

Good video

Thanx bro good info

Thanks a bunch

Too funny... i got 8800 views on just the dropping of the tank to replace the pump... Cool approach but it took me the time you took to cut out the hole to drop the tank....

@robertccole13

2 жыл бұрын

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.

@michaeljfigueroa

2 жыл бұрын

@@robertccole13 what was your ground wire issue?

@robertccole13

2 жыл бұрын

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

@rvdreamer8855

2 жыл бұрын

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

@rsanchez7111

2 жыл бұрын

@@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

Hi, are these dimensions ok for my 2004 savana gmc 2500? Thanks

@robertccole13

Жыл бұрын

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

@damkayaker

Жыл бұрын

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.

I do this all the time why pull the tank dum in less u have the money to get it done ✅

Can u do this in the conversation van to

@robertccole13

10 ай бұрын

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

I don’t know what a filler neck is and it’s kind of hard for me to follow because the inside of my 2003 express doesn’t look like his so I can’t really follow lol

@UTOBEDUDE

5 күн бұрын

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

@hollywoodthedj1673

5 күн бұрын

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

Do these measurements work for an extended van too?

@robertccole13

Жыл бұрын

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

@victor-ri7ey

Жыл бұрын

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

@victor-ri7ey

Жыл бұрын

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

Would it be cheaper if i told my mechanic to do this lol

@robertccole13

2 жыл бұрын

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 ;)

@Forsakenmusic

2 жыл бұрын

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

@robbydockery1272

2 жыл бұрын

@@robertccole13 Mine would try to charge more!

This is trash. Lazy. All you have to do, to do it properly is: put a jack under the tank, loosen the straps holding it in, lower it down a little bit, disconnect the lines and harness, remove the straps, then lower the tank down. You may have to jack up one side of the vehicle. Slide the tank out, remove the old pump, put in the new pump, and re-install the tank in reverse of the removal. I've had three Chevy vans and had to do this on all three. 2-3 Hours is all it takes.

@robertccole13

4 ай бұрын

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

@erikthered7422

4 ай бұрын

@@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.

@robertccole13

4 ай бұрын

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.

@erikthered7422

4 ай бұрын

@@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.

@markstang1965able

3 ай бұрын

@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.