Before You Begin:
* Safety First: Disconnect the negative battery terminal to prevent accidental sparks.
* Gather Tools: You'll need a variety of tools, including sockets, wrenches (including a fuel line disconnect tool if you don't have a push-type connector), screwdrivers, jack stands, a fuel pump removal tool (often specialized), a fuel line clamp pliers, safety glasses, gloves, and rags. A fuel pressure gauge is also highly recommended.
* Consult a Repair Manual: A repair manual specific to your 1999 Dodge Ram 2500 van is crucial. It will provide detailed instructions, torque specifications, and diagrams specific to your vehicle's year and engine. Haynes and Chilton manuals are readily available.
* Prepare for Fuel: You'll need to relieve fuel pressure in the system. Consult your repair manual for the precise procedure, but it generally involves disconnecting a fuel line and cranking the engine until it stops. Be prepared for some fuel spillage.
* Ventilation: Work in a well-ventilated area. Gasoline fumes are highly flammable and dangerous.
General Steps (Consult Your Repair Manual for Specific Details):
1. Vehicle Preparation: Safely raise and support the van using jack stands. This will provide access to the fuel tank.
2. Fuel Tank Access: Locate the fuel tank access panel (usually underneath the van). You may need to remove some body panels or components to gain access.
3. Fuel Pressure Release: Critically Important: Completely relieve fuel pressure in the fuel system. Failure to do so can result in fuel spraying and potential injury.
4. Fuel Lines and Electrical Connections: Carefully disconnect the fuel lines from the pump. Use a fuel line disconnect tool to avoid damaging the lines. Note which line goes where! Disconnect the electrical connector to the fuel pump.
5. Fuel Pump Removal: This is where a specialized fuel pump removal tool often comes into play. The tool usually hooks onto the pump's retaining ring or collar and helps to pull the assembly out of the tank. If you don't have this tool, the process will be significantly harder.
6. Fuel Pump Replacement: Carefully compare the new pump to the old one to ensure they are identical. Install the new fuel pump, ensuring it seats correctly.
7. Reassembly: Reconnect the electrical connector and fuel lines securely. Carefully re-install the access panel and any removed body panels. Double-check all connections.
8. Fuel Pressure Check: Before starting the engine, check the fuel pressure with your gauge to verify the pump is working correctly and that there are no leaks.
9. Lower Vehicle: Lower the van from the jack stands.
10. Engine Start: Start the engine and check for leaks. Let it run for a while to ensure the pump functions correctly.
Disclaimer: This is a general overview. The specific procedures will vary depending on the engine and model of your van. Improper fuel system work can lead to serious injury or death. If you are uncomfortable performing this repair, take your vehicle to a qualified mechanic. A incorrectly installed fuel pump can create serious fire hazards. A professional mechanic has the right tools, experience, and safety precautions to complete this task safely.
