Fuel pump wiring?

Fuel pump wiring?

Postby Intenseman [OP] » June 5th 2010, 9:28pm

So the van died last weekend with the wife driving it. Went to where she was and started pulling things apart. Checked for spark and then took the cap off the fuel pressure test port. Pushed in the schrader valve with a screw driver and fuel trickled out. Cranked the motor with screw driver in schrader valve and still just a trickle. Couldn't hear the fuel pump pressure up either.

So I pulled the fuel tank (full tank of gas) and pulled out the pump. I tested the pump by connecting power from the battery to the leads and the fuel pump works. So I connected it back to the harness and turned the key. The fuel pump did it's 2 second pressure up. So the pump is good assuming that it is putting out enough pressure. I did notice that one of the leads on the pump was a little cooked.

I remembered years ago reading something on one of the old Astro/Safari forums about the wiring harness burning up. Is this what you guys were referring too?

Thanks in advance for your help.

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Re: Fuel pump wiring?

Postby Big_kid » June 6th 2010, 1:04am

That's how the pump quit in the 96 I used to drive. It cut out, came back, cut out, came back, then left me on the side of the road. This was over the course of 50 miles.

I don't remember the exact reasoning for replacing the harness, it has to do with wires building up resistance, IIRC. All I remember is I didn't replace mine 2 years ago, and if I had it to do over again, I would replace it this time.
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Re: Fuel pump wiring?

Postby Matrixx » June 6th 2010, 1:11am

Yes and that was me, and yes, that's what I was referring to.

I'm basing these suggestions on what you have stated above. Replace the fuel pump (with a Delco/Delphi), fuel pump wiring harness (inside the tank and any other wire you see damaged), and fuel filter.

Check the ground wire by the plug-in just before the fuel tank (underneath).:)

Might I also suggest here, to keep the fuel level above 1/4 tank at all times. This is probably the single most cause for fuel pump failures with these vans. The next cause would be not replacing the fuel filter on a regular bases (in that order).

Hope this helps.:)
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Re: Fuel pump wiring?

Postby thedark3rd » June 11th 2010, 7:29pm

Just from my own experience (1991 Chevy Astro, and 1998 Chevy astro - Still have the 98) I had the same kind of experience when I removed the pump on the '91, and even put everything back together, tested the pump outside the van on the battery (*real familiar right?*), it worked, out it back in, and failed. Walked to the AutoZone (thank god it was not far from where I lived. Picked up a new pump (don't remember how much but it wasn't costly then. Replaced the pump - and it ran for another year, before another problem came along.

The '98 I got in March of '08 and replaced the pump that August. $301 (wasn't happy about the cost, but didn't complain either - van ran fine after that. It might cost you, but unless you really like taking in the highway scenery - Replace the pump, and motor on...
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Re: Fuel pump wiring?

Postby rev_les » June 11th 2010, 11:48pm

It's recommended that the harness be changed with the fuel pump, regardless of what it looks like, and to elaborate a bit , CLEAN the ground point off. Don't forget to replace the fuel filter with the pump change as well!
Also, the later model pump modules have a submerged well that the pump motor sits in, the earlier ones do not have this, if you run it low on fuel...the motor's scorching.I'm not sure what year the change took place. I do know my '95 has the dry motor, and my '99 has the wet sump type. ( and apparently the 2001 has a different pump yet again, I'll figure out the difference when I change it out...probably later this weekend )
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