What with the hassle and expense of replacing the tank-mounted fuel pump, what issues are involved with splicing in an inline, universal fuel pump?

For example, for the 5.2, what pressure has to be maintained? If it's over 45-50 psi, that would limit the choices.

 

I would imagine that it is fairly straightforward to do. IMO, the biggest downside could be priming the pump since it is not sitting down in the tank near the fuel.

 

Hadn't thought of that. If the time comes and I go that route, I'll have to find out what pump type the unit -- whatever it is -- might be.

I supposed I could add an electric air pump to the tank on a simple timer, force fuel up into the fuel line. But by that point I might not be saving any money or time. And I have no idea about the effect on the vapor scavenging system.

 

Rock Auto has a replacment for about 135. Since it is the pump, filter, screen and sender, I don't see why you would want to change unless you were supercharging the motor

 

I don't really want to change -- I'm trying to avoid dropping the tank.

I've messed around with gas tanks once in my life. Full, they're heavy. Drained to a manageable weight, they're full of explosive vapors.

When push comes to shove, I'll throw in another option: cut a hole in the van floor. Back in the bad old days, vehicles were fitted with access plates for changing out the level float... but a plate adds a few pennies to the cost of a vehicle and pennies have been hard to come by in car production for 40 years or more.

 

If anyone ever has to drop their tank to replace the pump, cut an access panel in your floor and install a bolted down safe sealed plate using nutserts so that next time you don't have to drop the tank. I'm doing this on my next pump replacement.

 

Anyone have the location pinned down? And the right size for the cutout?

 

If your van is a 98 or newer then changing the in-tank fuel pump is quite simple and relatively easy. The 97 and older vans are much more difficult to change but it's still manageable. I have seen some of the hack jobs posted on YouTube where guys cut a hole in either their van floor or truck bed and I just have to laugh.



I mean, really -- are you that worried about dropping the tank that you are willing to risk all of the dangers associated with cutting a hole directly above the tank while the wiring, tubing and FUEL are still in place.

IMHO it's quite a bad idea.

 

It would be easier if you could buy new tank strap bolts too. When I replaced my tank straps, I had to hacksaw the old ones off. Eye bolts from Lowes customized with a hacksaw did the trick!

 

I don't believe anyone was suggesting cutting a hole over a gas tank while it was still mounted in the vehicle. I have had three pumps installed on my 94 since I've owned it. The next one I will drop the tank myself and cut and access door, of course everything I do is the right and safe way so, the next time I simply open my very securely sealed in case of an accident access door, and replace my pump, it's pretty much a no brainer if you plan on having your van long term as I do. After all they aint making them anymore.