Here's a general outline. This is NOT a complete guide, and you should consult a repair manual specific to your year and model C20 van for detailed instructions and torque specifications. Improper installation can lead to serious consequences.
1. Preparation:
* Safety First: Disconnect the negative battery cable. This prevents accidental sparks.
* Gather Tools: You'll need a variety of tools, including wrenches (metric and possibly standard), sockets, a fuel line disconnect tool (essential!), possibly a fuel pump pliers, jack stands (if you're working under the van), rags, safety glasses, and gloves. A repair manual will specify exact tools.
* Locate the Fuel Pump: This is usually near the fuel tank, often under the vehicle. Your repair manual will show its precise location. For older mechanical pumps, it's often on the engine block.
* Reduce Fuel Pressure: If it's an electric pump, you might need to relieve fuel pressure before disconnecting lines. Consult your repair manual for the correct procedure – this often involves running the engine until it stalls.
2. Accessing the Fuel Pump:
* Electric Pump (Most likely on later models): This usually involves dropping the fuel tank, which is a significant undertaking. This requires siphoning or draining the fuel tank first. Consult your repair manual for the tank's straps, fuel lines, and electrical connections.
* Mechanical Pump (More common on older models): Access might be easier, as it's usually mounted on the engine block. However, you'll still need to disconnect fuel lines.
3. Removing the Old Fuel Pump:
* Disconnect Fuel Lines: Carefully disconnect the fuel supply and return lines using the fuel line disconnect tool. Be prepared for some fuel spillage – have rags ready.
* Disconnect Electrical Connections (Electric Pump): Unplug the electrical connector from the pump.
* Remove the Pump: This will vary greatly depending on the pump's mounting. You may need to remove bolts, clamps, or other fasteners. A repair manual is crucial here.
4. Installing the New Fuel Pump:
* Install the New Pump: This is the reverse of removal. Make sure to carefully align the pump and secure it properly.
* Reconnect Fuel Lines: Connect the fuel lines securely using the fuel line disconnect tool. Ensure tight connections to prevent leaks.
* Reconnect Electrical Connections (Electric Pump): Reconnect the electrical connector.
* Reinstall Fuel Tank (if applicable): Carefully raise and secure the fuel tank back into its original position.
5. Post-Installation:
* Reconnect the Battery: Reconnect the negative battery cable.
* Check for Leaks: Carefully inspect all fuel line connections for leaks.
* Prime the System (Electric Pump): Some systems require priming the fuel pump before starting the engine. Consult your repair manual for the procedure.
* Start the Engine: Start the engine and listen for any unusual noises or leaks.
Crucial Considerations:
* Repair Manual: A repair manual specific to your year and model Chevy C20 is absolutely essential. This will give you detailed instructions, diagrams, torque specifications, and part numbers.
* Fuel Safety: Gasoline is highly flammable. Work in a well-ventilated area, away from open flames, and use extreme caution.
* Professional Help: If you're not comfortable with this level of automotive repair, consider taking your van to a qualified mechanic. Incorrectly installing a fuel pump can lead to serious damage to your engine or even a fire.
This is a simplified overview. Do not attempt this repair without the proper knowledge, tools, and a repair manual. The steps may vary significantly depending on your vehicle's year and model. Consult your repair manual and prioritize safety.
