Hello, long time lurker, occasional poster.

91 GMC Vandura G2500 5.7

I dropped the tank and replaced the fuel pump. Installed everything back and re-started the van, started up like a brand new van. Turned it off and now fuel pump does not pump gas. I used to hear the pump running for two seconds prior being started but is not doing it anymore. That's the job of the Hot Fuel Module. I smelled smoke under the seat and noticed the hot fuel module burnt (the voltage regulator was toasted, broken). I bought another hot fuel module, installed it, attempt to start the van but fuel pump still not working. Smelled smoke from the new hot fuel module again. This means the hot fuel module is handling excessive voltage for some reason. The fuel pump relay is clicking properly and like I mentioned the van started right up for the first time after installing the new fuel pump. Hardwired the pump and it works. Searched in 62,357,657,326 thread post all over the internet and found out sometimes fuse box contacts go bad. Removed the battery and noticed a hell of a mess the previous owner did. Found a black gooey stuff all over the contacts. I cleaned them up and re-installed the fuse box but still not go, hot fuel module still getting hot, unknown if the new one is now damaged ($45 damnation.). Will clean all the contacts and fuse box again to see if i can fix it. If I drop gasoline directly to the throttle the van will run until the gasoline is consumed. Anyone with this issue that can tell me where to look? No van no chevy no fun.




Location of hot fuel module, next to the computer, under driver seat (in my van).



Part number.



Hot fuel module connector.



New hot fuel module and old one.



Back of hot fuel module. Black stuff on board tells me is receiving a lot of voltage.



New hot fuel module and old one with voltage regulator toasted, cracked.



Black gooey mess behind fuse box, looking from engine bay. Under cleaning process at this time.

 

Did you ever figure out why the hot fuel module was burning up. Im having the same issue on my 92 g30 5.7 sportsvan

 

Yes. In my case it was the fuel pump. I bought a whole fuel pump assembly unit from Rockauto and for some reason the pump itself came out to be defective. It worked for the first 5 minutes and die after that. I kept the Spectra pump assembly unit and replaced the pump with a Bosch unit. Running like new again. Once again, this was my problem. I also cleaned ALL the wire connectors properly and made sure they were not damaged. If the module overheats that means there's a short somehwere, in my case it was the new defective pump. If you don't wanna drop the tank cut the floorboard CAREFULLY and create an easy access for the pump like I did. I was going nuts and about to send the van down a cliff but I'm now happy and the van is running strong.

 

Glad to hear you got yours figured out. I just installed a new pump and filter as well. been ruling that out cause its new. thanks for the reply so fast. Ill go check that again

 

So, UrbanCamper, I take it by your screen name your van isn't a work van. And as such, some of us here would like to see a pic or two. There are a few build threads going, that may interest you.

 

I didn't have the trouble with the fuel pump in my 87 g30 but did have electric troubles and found melted goo behind fuse box. The screws holding it together were loose so i tightened them and my troubles stopped and have not had any since. Maybe it gets hot from a short [before i bought it] ,like your trouble, melts the goo and causes screws to be loosen . Mine caused on and off opens . Might be something to check every now and then. I hate getting bad ''new'' parts as much as when i get the wrong part in the ''right'' box or getting a part someone returned as uneeded but they screwed up , like stripped threads , etc. I am glad you found your trouble and hope you get many trouble free miles . I am pushing 387,000 miles on mine and i think i have replaced every part on it atleast once some a bunch of time [lol].

 

Does anyone know if there is Hot Fuel Module in a 2002 Express 2500 and if so where it is located?

 

[QUOTE=draft2win;348379]Did you ever figure out why the hot fuel module was burning up. Im having the same issue on my 92 g30 5.7 sportsvan[/QUOTE

Saw the replies/ rplaced a 1992 chev 5.7 g20 van wire harness with a 1991Gmc1500 wire harness! The 1500 harness has no hot fuel modulator taped into the ecm lines like like the 92. Was this an upgrade taped into on the 92? Can someone share a schematic for the 91 & 92 contrast? Installing as is but would like to tap in a new modual but lost track of 2 wire routes at the tbi. Thanks!

 

I have a 1994 G20 and it dies in hot weather. Once it cools off the van starts right up. I can't find this control module. Anybody know where it's at? It's not under the seat.