Before You Begin:
1. Safety First: Disconnect the negative battery terminal. This prevents accidental sparking. Work in a well-ventilated area away from open flames.
2. Gather Tools and Materials: You'll need:
* New fuel pump assembly (ensure it's the correct one for your vehicle's engine)
* Socket wrench set (metric)
* Torque wrench (important for proper tightening)
* Screwdrivers (Phillips and flathead)
* Fuel line disconnect tools (may be specialized; pliers might work, but careful not to damage the lines)
* Shop rags
* Safety glasses
* Gloves
* Jack and jack stands (crucial for safe working conditions)
* Fuel pump pliers (sometimes needed to remove the retaining ring)
* Possibly a fuel pressure gauge (to ensure the system is properly depressurized after replacing the pump)
3. Consult a Repair Manual: A repair manual specific to your 1999 GMC Safari van is essential. It will provide detailed instructions, torque specifications, and diagrams unique to your vehicle. This is the single most important step to avoid mistakes. Online manuals are available, but a physical copy is often preferable.
General Steps (These are generalized and may vary slightly depending on your specific model):
1. Vehicle Preparation: Safely raise the van using a jack and secure it with jack stands. Never work under a vehicle supported only by a jack.
2. Access the Fuel Pump: This usually involves removing the rear seats and possibly some interior panels to access the fuel pump access panel in the floor of the cargo area. Your repair manual will guide you precisely.
3. Disconnect Fuel Lines and Electrical Connectors: Carefully disconnect the fuel lines. Have rags ready to absorb any spilled fuel. Use caution as pressure may remain in the lines. Disconnect the electrical connectors to the fuel pump.
4. Remove the Fuel Pump Assembly: This often involves removing a retaining ring or cover. This step is where fuel pump pliers might be necessary. The pump assembly will likely be located in the fuel tank. You may need to lower the fuel tank slightly for easier access (consult your repair manual).
5. Install the New Fuel Pump Assembly: Carefully install the new fuel pump assembly, ensuring it is seated correctly. Replace the retaining ring or cover.
6. Reconnect Fuel Lines and Electrical Connectors: Reconnect the fuel lines and electrical connectors, ensuring they are secure.
7. Lower the Fuel Tank (If Necessary): Carefully raise the fuel tank back to its original position.
8. Reassemble: Reassemble any interior panels and seats that you removed.
9. Lower the Vehicle: Carefully lower the vehicle using the jack.
10. Check for Leaks: Inspect all connections for leaks.
11. Reconnect Battery Terminal: Reconnect the negative battery terminal.
12. Prime the Fuel System (If Necessary): Some vehicles require priming the fuel system after a fuel pump replacement. Your repair manual will explain this procedure. This often involves turning the ignition key to the "on" position for a few seconds several times without cranking the engine.
13. Start the Engine: Start the engine and check for any problems.
Important Considerations:
* Fuel Tank Pressure: The fuel tank may have pressure. Be extremely cautious when disconnecting lines.
* Fuel Spillage: Minimize fuel spillage to reduce the risk of fire.
* Electrical Connections: Be careful not to damage any electrical connections.
* Torque Specifications: Use a torque wrench to tighten bolts to the manufacturer's specifications.
This is a general overview. Always refer to your vehicle's repair manual for specific instructions and safety precautions. If you're not comfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic. Improper installation can lead to serious problems, including fire.
