2005 GMC Yukon Fuel Pump Access Hatch/Door Build and Pump Replacement
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- Опубликовано: 7 авг 2017
- I have constructed a video in regards to the well known issue of GM trucks not having a access hatch on top of the fuel pump thus making a fuel pump assembly swap very difficult. I simply did not have the funds to pay a shop to drop my fuel tank to replace it for me and neither would I want someone else working on my vehicles as I have had bad luck with shops.
My GM is a 2005 GMC Yukon XL 1500 5.3L
Disclaimer: I am in no way responsible if you hurt yourself or spontaneously combust.
Great Video! Just spray paint the bottom of the tank to say "Access thru top" "Do not drop tank"
Hmm good idea!
i know it is quite off topic but does anyone know of a good place to watch new tv shows online?
@Ryan Ernesto Yup, have been using Flixzone for months myself :)
@Ryan Ernesto Thank you, I signed up and it seems like they got a lot of movies there :D I appreciate it!!
@Emmanuel Francisco no problem xD
Thank you sir! You inspired me to do the same on my '09 Chevy Avalanche. Your fibreglass cover idea is awesome. Although I made the opening larger to have more room to work, all went super smoothly (not even had problem putting the ring back. I put the rubber seal on the tank and pressed everything down until it was flush). At first I was worried about zip cutting the floor as I had a fuel leak. But I made a hole above the pump large enough to flush the top of the tank with water. No more risk of "kaboum". The whole job spanned over 36 hours but took in total just over 6 hours. Now I have a hatch to access the fuel pump assembly should it need more service. Oh... and I generously smeared RustCheck undercoating all over the assembly to prevent it from rusting again - Should last another 10 years! Thx again my friend!
I dont know man.. You just turned a 4 hour project with a floor jack, jack stand, and cinder block for tank support into a serious situation... I mean it's 2 bolts, 6 hose/fuel line connections, and 2 electrical connections, take the left rear wheel off and maybe the spare...... You also made turning that lock-ring a nightmare thru that cut-out. Use a brass punch tool next time so you don't blow yerself up. Perhaps the long wheelbase is different but... I keep all big boxes for mats to lie on when under mine LOL.... It was interesting tho. I gave ya a like but only cause yer CRAZY... I'll probably get crushed next time I get under mine for blastin ya.. 😉
Did this on my 1999 Yukon Denali ....instead of cutter (sparks near gas tank ) used a pneumatic nibbler .....went to junk yard and cut access area that gm made for the early 2000 years of Buick LeSabre (under back seat ) out (over sized of course ) then drilled and pop riveted it in and it worked perfectly in the Yukon Denali . A little anti-seize works perfectly to make the hold-down ring easier to remove next time .
Great job and great video! Fantastic idea to access the fuel pump assy. I enjoyed the whole video and learned 👍🏻👍🏻
I keep asking myself
"Why didnt the GMC engineers think of creating a pump access door in all their vehicles?" 🤦🏻♂️
Thank you for uploading and sharing it.👍🏻👍🏻
Oh they most definately considered it and most likely even designed it only to have corporate deep six it to deter the customer from self-reliance repair and promote professional mechanic service necessity.
Standard Operating Procedure on any and all common logic, (ironically named as no longer is mechanical thought a commonality), ease of access purposely engineered out of design in everything cept heavy machinery.
Thats a great solution. I cut a patch panel a little bigger out of a wrecked truck and sealed and riveted it in.
The shop wanted 900 to replace the fuel pump on my 03 trailblazer. I did this and saved some money
Thank you for posting your video. I'm going to attempt this job very soon on my 01 Yukon. Hoping it will be a success. Excellent work!
I just got done doing the same thing but I didn't take the seat out and only cut three sides fold up the floor job done in 45 minutes
Wow
I did the same thing! Worked out great! 🤙🏼
Excellent. I was thinking about doing this, and searched to see it others had done it.
Excellent job you did! Thanks.
Beautiful work even if the time on this one is probably more than dropping the tank. Next time however, a breeze. Also will come in handy if you ever have to trouble shoot. My plan is to do the cutting pretty much the same as this, replace the pump, and put it back as best I can for now. Later I will find a junk yard that will will let me cut a slightly biger cutout which I will youse as a cover that I can screw down. We big city apartment dwellers do the best we can. You guys that go to the effort of making this videos are a great help! Thanks
I've watched several of these videos on this subject. Yours is the best. Thank you.
Finally someone did it right. Nice job. I'm actually going to make a assess door panel on my 96 tahoe. Dsmn fuel pump went out again. Plus I'm tired of dropping the fuel tank. But overall I live the clean job that you did. 👍
Amazing job . Thank you. Gmc don’t want those kind of easy jobs because they want you to bring the truck to the dealer , everything is a chain manufacturer, dealers etc . People that paying them have to pay more and more to make them rich . 😢
Nice job. Clean and thorough. Really like your responses to comments that are made by people that are basically uneducated at best.
I did the same thing to my 05 yukon and used a side panel from a washer or dryer and made my own cover for it with hinges and rivets. I do recommend having a fire extinguisher or hose near buy when cutting your access hole.
What a shame that GM doesn’t design a hatch from the get go.
Marketing strategy to increase amount of labor.
thank you for sharing the video. i did this cut yesterday on my 2005 yukon denali xl.
Excellent job nice and neat maybe little to much for a old vehicle but peace of mind is also important I enjoy your video thanks
God bless bro. Did it on my 2005 suburban. Your video was great. Thank You. :-)
Very thorough procedure, well done. Hoping to do a similar maneuver on my Jaguar XJ8 where the panel will be cut up behind the rear seat, just under the rear glass. Seems like a much better approach than trying to disconnect fuel lines underneath. I probably won't make a fiberglass panel but will reseal using the weather stripping and probably caulking. I like Ghosthunter's final tip of spraying the tank to say DO NOT DROP TANK!
I’m pretty sure that your Jaguar as already a trap door my Jaguar xtype don’t have a trap door
I think this is good stuff. I have thought about doing the bed of my truck, before it goes out. I thought I would go to the junk yard and cut a piece from a wrecked bed to make a steel door. My truck is 20 years old and still has the original pump. I always keep 1/4 tank full to cool the pump.
At first I thought it was a bit extreme , but if you keep your truck as long as I do (15 years ) it makes sense . I think I'm in need of pump replacement #2 at 258k miles .....shop charged me around 1000.00 for 1st replacement pump about 5 years ago ,this idea doesn't seem so extreme now.
Thank you for this great video! Yet i had a hard time figuring out how to remove the rear seats! That part sucked so bad! But i figured it out and made do! Cut the crap out of my fingers trying to remove wiring and the actual pump assembly! Anyways hope no one else makes my mistakes! And i'm going to pop rivet the cut out to a larger piece of metal and seal it all up in between with window weld and foam grey parts! All riveted into seal up! Mine was OEM factory! PA Road SAlt did make it almost not removable!
Great video great job thought the access hole should have been a bit bigger also the panel was a great build took a lot more pachent then I would have but it works for you that's all that matters great job.thank you
Not sure whats the big issue with dropping the tank. Just replaced my pimp in my Escalade. Took me a little over an hour by myself with no lift.
Tools needed are: screw driver, 15mm Socket, Rachet, hammer, floor jack.
GM pumps may be shit but at least they made the job pretty simple. Cutting a big ass hole in your floor giving the cab direct access ti exhaust , Fuel fumes extra road noise and moister. It would have been nice for GM to engineer a proper access but far from needed.
I couldn't believe all the extra work and money this guy went through. 🤣🤣🤣
You are the bomb... I have watched several videos on how to do this because I have a 2003 Escalade Ext. I'm a DOYER myself. You answered questions already in my head I didn't see in the other videos. Like how to keep from rusting and how to create something so it would be neat and properly covered. You are definitely the man. Thank you so much for sharing. You did a damn good job for somebody just f****** around with fuel.... lol 😂
Thank you very much I appreciate that! :)
RomaTul thought I had subbed the day I saw your video. That's okay because I subbed today.
I need help. I don't know what the black cord looking stuff was you used to line the access opening. Can you give me the name of it. I'm preparing to do the job and that's the only thing and the sheet metal screws I don't have.
Nevermind. I went through the comments and found it. Thank you so much. You have made my life more easy. Being a single mom and a do it yourselfer, this helps me to get the job done independently. I was at Home Depot today showing your video while looking for my materials, just blowing people's minds....lol. It was fun. I kept telling everyone look at this awesome job this guy did.....
2006 Suburban 2500 pump is further towards Center and back of vehicle. Had to remove part of floor brace for pump to clear.
One more thing. Seems to me there would be a market for that hatch cover you made. I'd pay at least $75 for one ready made .
Dealing with this tonight. The access Hatch woukd sure be nice. This is the first pump on a GM product & likely the first &asthma on my yukon xl w 222k on it. Awfully tempting but curious if this is simply because they are prone to burn up pumps as it seems to be more work then nits worth unless it was really clean.
Eh for me I did it because it gives you quick access incase needed. Other reasons include bad fuel, you can clean from the top, if a pressure oring or something goes bad at the pump connections you can easily open it again. If I was to do it again I would mark the carpet area before removing the seat to possibly make a access door that works by simply folding the seat forward like every Japanese car has stock.
In regards to your "Bad Experience" with Shops one shop does not make all of the others bad. I usually charge 2 hrs to "exchange a Pump"
Ralf's Automotive Diagnostics & Repair unfortunately you are in the minority
Buena idea
Gracias por compartir.
Saludos amigo.
Great video 👍🏼
Good job very professional
I haven't tackled my XJ8 fuel pump yet because it seems to keep working. But I am wondering if there is direct access to it under the speaker on the rear ledge above the seats and under the window. Thanks for your comment.
Nice work!
Great job!. Thanks for sharing.
Great solution, however, for me its enough to engineer the cutout to be the hatch, just JB weld it back on. But I'm impressed. Finally got in there, on the Denali Sport Utility the configuration is off about 5 inches back. Turns out rats had chewed the wiring, but still a great shortcut. Such a hassle to drop the tank.
You do good work, but I would consider this overkill considering the location and need to re visit this repair.You could also retain the metal cutout and reuse that as your access plate. But nice job you did.
I have to agree. A tremendous amount of unnecessary work. I'm getting ready to replace my fuel pump. I think I may reweld the floor. Great video 👍
This is why I love YT. Any idea if there's anything different about an XL model that would change the location?
great job very clean, and a lot of patience
Thank you very much!
very nice job. wonder if some sort of shield could be slid over the tank to protect the wiring while cutting. that part scares me a bit. sparks and fuel, bad mix. otherwise best video i've seen yet
Well you could try sliding something over it from underneath but the chance of getting it over the cable and not binding up on something else is slim. The tank is pretty low and the tank is plastic so there would be no real way to start a fire. In addition sparks from grinding are normally not hot enough to ignite gasoline/vapors such as in this video ruclips.net/video/mTJUaJS5eRk/видео.html.
I used a diskgrinder and made a groove, but didnt cut all the way through. Finished cut w hacksaw blade, no sparks, clean
Maticulous effort. Good job!
Couple questions: 1) what size fuel tank and engine? 2) 1500 series or 2500?
There are fasteners called “rivnuts” that work like rivets with the retention of a screw.
3) Your vehicle odometer showed 207k mi, was this the first pump replacement?
Im not 100% on the tank size but I know I have put up to 28 gallons in the truck with a super empty tank. This is a 1500 with a 5.3L engine and the crappy 4L60E transmission we get with these lol. Yeah im at 220K miles now and I feel like this was the first pump change as far as I could tell the one I took out was OEM. The only other concern I obviously had was the dang fuel pump retainer ring.... I would recommend buying a new one like they tell you to do. I have a feeling the new ones purchased are slightly thinner. I spent about 2 or more hours trying to put the original ring back on.
Mannn...Wish I was as neat as you
Would like more information on the door measurements if possible, either the exacts or a link to the measurements. I have the same model. Thanks for a great video.
Well I sealed it up already but to be honest if I would have done this again the door would be a little larger to the left. As you can see when i pull the pump out the hose connections are a little close to the left side and it made installing it a little hard. But Like i mentioned if you use the X method with string it will get you pretty close and in addition using the spot welds gives you a better idea where everything is at from the video. I just counted spot welds over to compare my location to others I have found.
Darren Brooks iii
What an excellent job. Good work! Don't you have the little locking tab that you have to put a nickel against to release the ring? I never seen any ring with out this plastic locking tab that engages when locked. I like the fiberglass idea. Way over the top but very nice. Did you consider keeping the metal cutout and attaching it to your fiberglass frame making it incredibly strong and cover its original area. Happy with my reuse of the cutout rectangle metal sheet and using 2 pieces of plywood secured underneath to secure panel back on. Then some HVAC tape to cover. Wish I had done this years ago. Have over 275K on my sub. See you had over 200k as well. Nice!
Watched this several times. Thanks for the video! Would this be the same for a 2004 Tahoe? Would a multi tool with a metal cutting blade work instead of an angle grinder?
Awesome! Glad to help. It should be the same on the Tahoe. I do have the yukon XL and know the gas tank is larger on the XL like the suburban so maybe its a little different.
if you have a check engine light on don't make this cut. you need to ensure sparks don't reach the tank. I'm about to don't this with a leak on top of the tank so I need to be a lot more careful. stay safe everyone and don't get in a rush doing this. It could end very badly.
Nice!!!!
In the time it took you to reinstall the lock ring I did the whole job
nice how much rice did you burn so far in your 15 years of life?
You win the award for the hardest to watch, and listen to vid on RUclips. Who does this
Sound like this is your first time fabricating something? Whats hard about getting this done? Effort is tool as well.
You said you would have cut more left.. but with the "hump" edge there, you would have come more at an angle almost like a trapezoid to further left?
,
I meant for to the left as in the front of the vehicle because of the hose connections being longer.
Is it the same location for a sle instead of a xl
Great video. What was the cutting tool? Circular saw? Oscillating saw? Could you control the blade depth.
It was simply as pneumatic die grinder with a cutting disc installed. No adjustment. You need to cut and check. if you really need a blocking guard I guess you could hold a block of wood in your hand under the grinder.
@@ForwardEngineering Thanks!
Were you not worried about sparks?
Excellent video. Nobody else showed a good way to reseal the hatch. Speaking of which, where do you get that sheet metal edge seal shown at 23:18?
Thanks! I already had some and ordered it off amazon at some point. Don't remember the exact name for it though.
Greetings What kind of disc did you use on your air grinder?
Except if you drop the tank. U can properly clean the tank. It's really not that much harder then this
Also what's the best value (cost vs reliability) fuel pump for these? Mine has 222k & rust will be too bad to justify throwing in a low miles 5.3.
Personally I would get a new ac Delco and swap it out directly. In this specific case I wouldn't try to build your own. If your going custom I would us a walbro 255 but the assembly has other thing like fuel pressure regulator and what not.
What's the name model. And blade type of the grinder you used looks very smooth nice cutting
It was just a harbor freight air cut off wheel.
Can I use a metal blade angle grinder with no problems? That's all I got
Great video. People use the old gasket. Why is your oil pressure so high? 60 to 80.
I changed the oil pump to a high volume pump a while back because of my high mileage.
207,000 miles and over 60 lbs of oil pressure! That is excellent, what oil weight are you using?
I use rotella T6 5w40 and I changed to a high volume oil pump a while ago. Ended up selling the yukon now I have a 09 tahoe to deal with.
How hard it is to drop the tank,Idid mine using two floor jacks by myself with two 2x4 across no problem.
This is a preventative pre-caution. Next time this needs to be done ( Domestic cars are not very good with electrical designs so possibly soon) it will be very easy. They way it should be in the first place. Every single Japanese car I have owned or have worked on has a access hole up top with metal plate as it should be.
@@ForwardEngineering And you can change it wherever it go out on you no need for a tow or jacks and such.
I watch a video and a lot of people videos that do this and I'm about to do this but I'm just wondering why nobody buys an access panel I think I'm going to do that
Honestly you can just use the peace you cut out. Its Just a matter of making it weatherproof so it wont rust.
Oh great!! Now we need a word for the opposite of "n" rigging .... but seriously good job
The word is African Engineering!
I filled up my tank to full soon after my fuel pump went out. is there a eazy way to take out the gas.
I would assume you could still do it even if the tank is full because even a full tank shouldn't be higher than the ring at the top. But now there's no direct weight and drain the fuel except for maybe taking off the fuel rail connection and then running it into a container I guess
There is also a fuel pressure testing valve on the fuel rail you can probably screw onto and then take some fuel out but it would take you quite a while I would assume because the pump only primes for a few seconds when you turn the ignition on and it won't stay on the whole time
@@ForwardEngineering Thank you so much took me 2 months to do it your way he he he
I don't understand your logic of going thru the trouble of this. How many fuel Pumps are you planning on changing? How are you going to clean the Tank if needed? If in fact you have multiple failures, I would invest some time checking wiring and their output. Use the OE Pumps. I had way too many of the Aftermarkets come back an bite me. Last set of O-Reilly pumps was pushing almost 80 PSI that is about 15-20 more than spec. meaning the pumps are laboring way harder than what they should.
What is the material you used to line the raw edges of the hole and where did you get it?
Of all the thru-the-floor videos out there, this is the one that I'd show off to a brother-in-law.
It's just used to line the edge of sheet metal. I don't know the exact name but here is a link. I'm not sure what's in the link is the correct size fyi.
Logctee Car Door Edge Guards, 16ft Black Chrome Universal U Shape Rubber Sealed Door Edge Protection Fit for Most Car www.amazon.com/dp/B096584FKJ/ref=cm_sw_r_apan_glt_fabc_Y7TNEXDYWQ3RMG6PAA2N
@@ForwardEngineering, thanks for the response. I wasn't sure which direction to head off in to search for it. If nothing else, it'll be good for my '03 Suburban and '08 Silverado.
this job is already a pain in the ass, This guy made it a pain in the ass with extra steps. dropping the fuel tank was easy. replacing the pump was even easier. took me roughly 1.75 hours to complete. Goahead and use a die grinder that creates SPARKS on top of the FUEL CELL. Stupidity at its finest.
Grinder sparks cannot light petrol vapor. They are not hot enough inform yourself. It seems like you prefer the definition of insanity then when working on vehicles.
Inform myself? I am well informed not to put fire or even sparks close to anything flammable. your half assed method just shows your intelligence level and laziness. Ive done this exact job and anyone with the intelligence of a potato could do it, you were just plain lazy.
You would think engineers would think about doing this to all vehicles
Lincoln did on the Jaguar / LS under back seat
will this work the same on a 1999 GMC Yukon?
Im not 100% sure but as long as the fuel tank is in the same location I dont see why not.
clever..overkill..but very clever
Roma, do you think cutting the floor compromises the integrity of the structure of the vehicle? I would assume since no cuts were made to the frame itself it should be fine. What's your opinion?
No it does not because the large structure framing is left untouched. We are just removing a small portion of the sheet metal. If you watch the peace I take out isnt even compromising any spot weld locations.
Where did you get the rubber lining for the Sharpe edges??
Also wondering this.. did you ever find it?
@@eazhar nope I ended up dropping the tank. It was easier then I thought. I heard that your interior will always smell like fuel if you do it this way so I passed
Not to be a smart ass, but if I seen that part of any truck or suv with a round or square hole in that area I’d know what was done. Don’t get me wrong, that was a nice job you did. My thing is that you mentioned and somewhat happened to you cutting is goin to deep or not knowing what too deep is in this. Cut the tank with sparks flying around and 🤔, you’ll be in the news.
The temperature from grinder sparks is not high enough to ignite fuel vapors. In addition if you used a massive whole saw (I have yet to see one as big as is needed here that would not rip your arm off when it grabs ) you would for sure put a hole in the tank and or wires from either the pilot bit or the fact that your not cutting on a flat surface.
RomaTul
I’ve got a good friend whose mother in-law was severely burned from her husband. Story is not related to grinding a whole but he tried welding a rod to a empty propane tank. Not knowing what the consequences would be. Maybe you heard about it a bunch few years ago. True story
RomaTul. If I had to replace mine that’s the way I’d do it too. Dropping the tank is in my yard without some proper tools would be very difficult
@@theozman38 Yeah welding is a completely different ball park as the temperatures are much higher and different spectrum's are emitted.
Just duct tape it and put the damn carpet down!!!! Too much
John McLean you definitely want to add rust preventative to the fresh cut metal . Other than that ya I agree either ductape it up or silicone .
Is yours an xl?
Yes
I've seen LA mechanics take care of this in one hour..........
John McLean and your point is?
You took a simple tank drop into a hugggeeee job lolol. W t f
So much work why not just take the two bolts off of the gas tank straps & drop the tank? It's only a 2hr job
In the case of future work or modifications this will allow easy access. You wont always have a empty tank when your fuel pump dies.
Its just not two bolts, its multiple vacuum lines, gas filler neck, and 17 gallons of gas at 6.3lbs per gallon. Add on that 98% of all replacement parts are made in china and are crap that are likely to fail sooner rather than later, this makes perfect sense. I will be doing it this weekend (After I had just replaced the fuel pump 3 weeks with a Bosch that has decided to fail)
Sean Berry , good points. I had thought the same. It only took me 1.5 hours to do a replacement on my Tahoe, but the lifetime warranty pump I put in seems to only have lasted 3 years. Chasing the issue now, which may turn out to be an electrical issue getting signal from the ignition switch. Always stick a 12 power wire on before pulling a pump. Many times the pump isn't the issue, but fuses, or connections.
That’s a two man job, plus two jacks my man. I’m on my 4th fuel pump right now.
Nice Job, If you use wax free polyurethane for laying up, it is way easier. It only dries to a slight tackiness, which is key for multiple layer applications. You dont need to sand in-between layers. If it is a waxed resin, it will have a shine when dried, and a hard shell that has to be sanded for next layer to properly adhere. I use wax free all the time, then last coat you just add surfacing wax and it dries to a hard shell. Fiberglasssite.com is the best imho. cheap prices and good quality. don't listen to stupid haters who are lazy and don't know shit. I am gonna do this in my 02 burb as I will need a new pump soon, to go with my all new stainless brakelines and new fuel lines/filter all done by me, the only way to fix your stuff. DIY . great trick for smart people. Making things serviceable in the future is soooooo key!
Hope there is no fuel in that tank, with all them sparks just sayin
No vapors would be around the tank when cutting. In addition there is a huge misconception that "sparks" can ignite fuel which is wrong. First you cant actually ignite gasoline not even with a torch its only the fuel VAPORS that can ignite. In addition the sparks from a diy grinder are not hot enough to ignite the vapors either way.
Why
Because engineers have to fix what other engineers failed to do.
Just an FYI to anyone & everyone that happens across this video. Do not cut the access hole with a cutoff wheel. They make sparks & sparks + gasoline = a very bad day. Use the cutoff wheel to cut a jigsaw blade nice & short for cutting the access panel.
Cutoff wheel sparks are not hot enough to ignite gasoline vapors. A jigsaw will cause havoc to the plastic tank
Good job..... Your definitely NOT A MECHANIC!!
John McLean for what ? Because he made an access panel to the fuel pump ? Thousands of people have done this . There is a write up about doing this . Dropping these fuel tanks are not the funnest job. Work smarter not harder .
The fibreglass idea is fucking horrid...don’t do it
zzz zzz. great video. but you need to speak faster.
So much overkill. Buy quality pump and drop the tank. You will have to change it at most twice in the lifetime of vehicle
A upgraded design is what this is. Evey Japanese car has a access hole for fuel pump but Americans didn't care. I do.
way to tecnicle . its just a hole.
Thank you for your comment. How technical are you about your toilet?
LMAO!!!!!
Hey, is anyone else looking at that hella nasty carpet under the rear seat 🤢, did he ever clean up any spill from inside, or just let it marinate into the fabric..🤮
I'm extremely obsessed with detailing my vehicles this was a couple days after I got it from the auction so don't generalize bruh...
problem is . the folks watching know more than the teacher. way to much talking.
I'll be sure to watch your videos on teaching 😉
Changing the pump isn’t hard. Did it in the driveway with basic hand tools and a jack. Quit being lazy
Lol yeah this is a comment from the ignorant. This is preventative and required fabrication skills. A bolt on guy is and always will be that doing only bolt on's. This is a upgrade to what every Japanese manufacturer does but ignorant American companies don't think is important.