Repair 7

My 1990 Astro Van Ran Out of Gas and Wont Start

If your van runs out of gas, this can create more problems than just not being able to move at the moment. Once you ill the tank, you still may have problems restarting the engine. Any fuel system that runs too low on gas can experience problems with the fuel pump and fuel pressure. You might be able to restart the car if you can re-pressurize the system, but its possible that you will need a new pump altogether.

Instructions

Refilling and Re-pressurizing

1

Fill the fuel tank with unleaded gasoline from an approved gas can. Use the largest amount of fuel you can transport to the van.

2

Turn the ignition key to the start position for about two seconds, then tun it back to the off position for five more seconds. Repeat this five to 10 times to re-pressurize the fuel system.

3

Try starting the car again. If it wont start at this point, you will likely need to replace a burned-out fuel pump.

4

Siphon out the fuel with a never-used vacuum pump and store it in the gas can, if you need to change the pump, then disconnect the negative battery cable.

Fuel Pump

5

Raise the van on its rear end and support it with jack stands, blocking the front wheels with heavy blocks. Raise the floor jack or a transmission jack under the tank.

6

Disconnect the electrical connectors on the fuel tank and then unclip the lower shield on the tanks right side to reveal the fuel line fittings. Loosen and disconnect the fittings with a screwdriver, then disconnect the filler neck from the tank.

7

Unbolt and remove the straps for the tank and lower it down with the jack, disconnecting the fuel pump lead.

8

Tap and loosen the locking ring with a brass punch and hammer until the tangs and cut outs line up. Pull the pump assembly out of the tank.

9

Insert the new pump assembly into the tank, making sure it is lined up in the same position as the old one was, then turn/tap the lock ring into place.

10

Reconnect all the lines and electrical connectors to the fuel pump flange, raise the tank into position and bolt the tank into place.

11

Refill the tank and perform the pressurization steps as described in Section 1.