1996 Plymouth Voyager Fuel Pump replacement

  • 6 CYL
  • 2WD
  • 197,532 MILES
I have the gas tank dropped and it is not coming out from under the van. I need to know what I need to do to finish getting it out and also what to do to get the pump out?
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have the same problem?
Wednesday, January 28th, 2009 AT 10:28 PM

1 Reply

Disconnect the negative battery cable.
Remove the fuel filler cap.
Properly relieve the fuel system pressure, as outlined earlier in this section.
Insert a fuel syphon hose into the fuel filler neck and push it into the fuel tank.
Drain the fuel tank dry into a proper holding tank or a properly labeled gasoline safety container.
Raise and safely support the vehicle.
Disconnect both the fuel filler and vent rubber hoses at the fuel tank.
Disconnect the supply lines from the fuel pump module located on top of the fuel tank.
Slide the fuel pump module electrical connector lock to the unlock position, then push down on the retainer and pull the connector off of the module.
Place a transmission jack, or equivalent support fixture, under the fuel tank.
With the tank supported by a transmission jack, or equivalent, remove the bolts and fuel tank mounting straps.
Lower the fuel tank slightly. Carefully remove the filler hose from the tank.
Lower the fuel tank. Disconnect the pressure relief/rollover valve hose at the front of the tank. Remove clamp, then remove the fuel filler tube vent hose. Remove the tank from the vehicle.

Position the fuel tank onto the transmission jack. Connect the pressure relief/rollover valve hose. Connect the fuel filler tube vent hose and replace the clamp.
Raise the tank into position and carefully work filler tube into the fuel tank. A light coating of clean engine oil on the tube end may be used to aid assembly.
Feed the filler vent line through the frame rail, being very careful not to cross the lines.
Tighten the fuel tank strap bolts to 40 ft. Lbs. (54 Nm). Check to make sure that the tank straps are not twisted or bent. Remove the transmission jack.
Attach the fuel pump/module electrical connector and place the retainer in the locked position.
Lubricate the fuel line with clean 30W engine oil, then install the quick connect fitting.
Carefully lower the vehicle.
Fill the fuel tank, install the filler cap, then connect the negative battery cable.
Pressurize the fuel system using the Chrysler DRB, or equivalent scan tool, to perform the ASD fuel system test. Check the fuel system for leaks.

Remove the fuel filler cap and properly relieve the fuel system pressure.
Disconnect the negative battery cable.
Remove the fuel tank assembly from the vehicle.
Clean the top of the tank to remove any loose dirt
Using special tool No. 6856 or equivalent, remove the fuel pump locknut by turning it counterclockwise.

CAUTION: The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed.

Remove the fuel pump and O-ring from the tank. Discard the O-ring.

Thoroughly clean all parts. Wipe the seal area of the tank clean. Place a new O-ring in position on the pump module.
While holding the fuel pump module in place install the locking ring and tighten to 43 ft. Lbs. (58 Nm) using special tool No. 6856 or equivalent spanner-type tool.
Install the fuel tank assembly.
Reconnect the negative battery cable.
Fill the fuel tank with fuel. Install the fuel filler cap. Turn the ignition switch to the ON position to pressurize the system. Check the fuel system for leaks.

Fuel system pressure testing requires the use of a DRB or equivalent scan tool.

The fuel pump operates at about 49 psi (338 kPa).

Release the fuel system pressure, as outlined earlier in this section.
On all 4-cylinder models, remove the cap from the fuel pressure test port on the fuel rail and connect a suitable fuel pressure gauge.
On the 6-cylinder models, disconnect the fuel supply hose at the engine. Refer to the quick-connect fitting disengagement procedure earlier in this section. Install fuel pressure test adapter 6539, or equivalent, between the fuel rail and fuel line. Connect a suitable fuel pressure gauge to the test port on the adapter.
When using the ASD fuel system test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the OFF position.

Turn the ignition key to the ON position. Using the DRB or equivalent scan tool, access the ASD Fuel System Test. The ASD Fuel System Test will activate the fuel pump and pressurize the system. Note the gauge reading and compare with the following:
If the gauge reading equals approximately 49 psi (338 kPa), no further testing is required. If the pressure is not correct, record the reading.
If the fuel pressure is below specifications, check for a restricted fuel pump inlet strainer. If restricted, replace the inlet strainer. If not restricted, check for an incorrectly operating fuel filter, pressure regulator or fuel pump, and replace as necessary.
If the fuel pressure is above specifications (54 psi or higher), check for a kinked or restricted fuel supply line. If the line is not kinked or restricted, check for a restriction in the chassis fuel supply line or for a kinked or plugged fuel supply line. If none of the lines are restricted, replace the fuel pressure regulator.

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Thursday, January 29th, 2009 AT 1:01 AM

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