Safety First:
* Disconnect the negative battery terminal before starting any work on the fuel system.
* Ventilate the area well. Gasoline fumes are highly flammable.
* Wear safety glasses to protect your eyes.
* Have a fire extinguisher readily available.
* Use proper tools for the job.
General Steps (Consult your repair manual for specifics):
1. Locate the Fuel Pump: This is typically located under the vehicle, usually near the fuel tank. You'll likely need to access it from underneath the van.
2. Release Fuel Pressure: This is crucial to prevent fuel from spraying out. There are several methods, which may be detailed in your repair manual, but generally involve either using a fuel pressure release tool or disconnecting the fuel pump relay (if applicable). Your manual will specify the correct procedure.
3. Access the Fuel Pump: You might need to remove some surrounding components, such as the access panel in the undercarriage and possibly some heat shields or other parts to reach the fuel pump. Your repair manual will show you where these parts are located and how to remove them.
4. Disconnect Electrical Connections: Carefully disconnect the electrical wiring harness connected to the fuel pump. Take pictures or make notes to ensure correct reassembly.
5. Disconnect Fuel Lines: Carefully disconnect the fuel lines leading to and from the fuel pump. You'll likely need to use fuel line disconnect tools to avoid damage to the lines or spilling fuel. Be prepared for some fuel spillage, even after relieving the pressure; use rags to absorb any fuel.
6. Remove the Fuel Pump Assembly: The fuel pump is usually part of a larger assembly that includes the sending unit (fuel level gauge). This assembly is typically held in place by a retaining ring or clamp. Carefully remove this retaining device and lift out the assembly. This step may require specialized tools, again referencing your repair manual is critical.
7. Replace the Fuel Pump (if necessary): Install the new fuel pump assembly, ensuring the seal is properly seated.
8. Reassembly: Carefully reverse the removal steps, ensuring all connections are secure and all components are properly reinstalled.
9. Reconnect the Battery: Reconnect the negative battery terminal.
10. Check for Leaks: After reassembly, carefully check for any fuel leaks around the fuel lines and pump.
Important Considerations:
* Repair Manual: A repair manual specific to your 1989 Chevy Astro van is essential for this process. Generic instructions can only provide a general overview.
* Fuel Pump Replacement: If you're replacing the fuel pump, ensure you get the correct replacement part for your vehicle's model and engine.
* Professional Help: If you're not comfortable performing this repair yourself, it's always best to seek the help of a qualified mechanic. Working with fuel systems requires careful attention to detail and safety precautions.
This information is for guidance only. Always refer to your vehicle's repair manual for specific procedures and safety precautions. Improper handling of fuel systems can be dangerous.
