"guyonearth" has a valid point....guyonearth said:It's a lot easier to just cut a hole in the floor and make a panel for it. (Assuming you don't have seats in the way)
I don't post a lot on this forum; however, i have used it for a lot of research on my 95 astro, including this post on how to change the fuel pump. So without further delay, here is my story:
Once upon a time (haha).... it was a long week for me (working late nights) and i was on my last call on a snowy friday night about to head home while on the phone, to the not so impressed wife due to my late nights, when the van stalled. I turned the key a couple of times and i knew exactly what was wrong... fuel pump. A great way to end my week.
So there i sat in my cold van while i waited 1.5hrs for the wife to come get me - i had a lot of time to trouble shoot. I could hear the fuel running but it sounded weak so i second guessed my first diagnosis. I had spark. The engine turned over good without any mechanical failure sound... It wasnt until the next day when i came to get the van that i had a fuel pressure tester with me and determined that the pump was weak for sure (20psi) at the motor. So i stuffed the van into a car trailer and headed home.
Getting prepared to crawl under the van to drop my tank (3/4 full of fuel) i read this post and the comment about cutting a hole in the floor got me thinking... Since it was freezing cold and very windy i figured it would be way better to work on the tank from above and inside my van. So i tossed a heater inside the van and started to prep for my "mission". Once my rear seat was out and the carpet was peeled up i did some measuring and decided where to cut the hole. I used a sawsall (recip saw) to cut the hole on 3 sides then folded up the "hatch". Then.... i turned OFF the heater (very important step) haha and started to pull the pump.
My local parts store gave me a Carter fuel pump that had a shorter body and outlet port than the one i pulled out, which concerned me but this is what i was given so i "assumed" it was good. My van has the pulsator which means i don't have the small section of hose between the pump and the steel line on the pump assembly. I pushed the pump outlet as far as i could into the pulsator and replaced the whole assembly back into the tank. The van fired up and the pressure at idle was 55psi - good.
It gets better.... 2 days later i started the van in the AM and it took a couple of cranks before it fired...hmmm...makes me think the pump isn't holding pressure because the pump was shorter and maybe started to slip out of the pulsator. The next day i'm jammin on the throttle while merging onto the highway and it started to bog down. I called my parts store and talked to the "right" person to help me and he advised me the AC DELCO fuel pump was longer in body and outlet tube, just like the one that i took out. As soon as i got off the phone wih him the van stalled again....crap! i had a feeling what it was so i jumped into the back and started to move the seat, my tools, and carpet. I opened that wonderful hatch in the floor and pulled the pump assembly up just a bit to fit my hand in and push down on the pulsator - done. Started the van and i was on my way.
Back at the parts store i had the AC Delco pump in hand and i figured it was faster to swap it in the parking lot rather than go home and return at a later date. It took me 15 minutes to swap the pumps and i was on my way again, but this time with a solid solution. Could you imagine if i had to drop the tank, a second time, on the side of the road, just to make it home only to drop it a 3rd time to swap out the pumps....Honestly i am thrilled i have an access hatch because it was the most comfortable in-tank fuel pump change i have ever done.
So the moral of the story is..... get the right fuel pump and do it right the first time.
Thanks for reading my story, hopefully it wasn't too long, and thanks for all of the great info i have found on this website.