Here's a general outline. Specific steps might vary slightly depending on the exact configuration of your van. Always consult a repair manual specific to your year and model for detailed instructions and diagrams. A Haynes or Chilton manual is a worthwhile investment.
1. Preparation:
* Gather Tools: You'll need jack stands, a jack, socket wrench set (metric), wrenches, screwdrivers, fuel line disconnect tools, a fuel pump pliers (or suitable replacement tool), safety glasses, gloves, rags, and possibly a fuel pressure gauge (to verify pressure after installation).
* Safety: Disconnect the negative battery cable.
* Locate the Fuel Pump: It's usually located inside the fuel tank, requiring tank removal or drop-down access (depending on your specific model). Consult your repair manual to verify the exact location and access method.
2. Fuel Tank Access:
* Lowering the Tank (Most Common): This typically involves:
* Raising the van securely on jack stands.
* Removing the gas cap to relieve pressure.
* Disconnecting the fuel filler neck.
* Disconnecting the fuel lines (carefully!). Use the correct disconnect tools to avoid damaging the lines. Have rags ready to absorb any spilled fuel.
* Unplugging the electrical connector to the fuel pump.
* Removing any tank straps or retaining bolts securing the tank. Support the tank as you lower it.
* Alternative Access (Less Common): Some models might have access panels underneath the vehicle allowing you to reach the fuel pump without full tank removal. Check your repair manual.
3. Fuel Pump Replacement:
* Accessing the Pump: Once the tank is lowered or accessed, you'll see the fuel pump assembly. This is usually held in place by a retaining ring or clamp.
* Removing the Pump: Use the correct tools (often fuel pump pliers) to remove the retaining ring or clamp.
* Disconnecting the Pump: Disconnect the fuel lines and electrical connector. Keep track of where everything goes.
* Installing the New Pump: Carefully install the new fuel pump assembly, ensuring all components are properly seated and secured. Pay close attention to the orientation of the pump to avoid damaging it.
* Reconnecting the Pump: Reconnect the fuel lines and electrical connector securely. Double check all connections!
4. Reassembly:
* Raise and Secure the Fuel Tank (if applicable): Carefully raise the fuel tank back into its position and secure it with all retaining straps or bolts.
* Reconnect Fuel Lines and Electrical Connector: Double check these again!
* Reconnect Fuel Filler Neck: Make sure it's properly sealed.
* Lower the Vehicle: Carefully lower the vehicle from the jack stands.
5. Post-Installation:
* Reconnect the Battery: Reconnect the negative battery cable.
* Check for Leaks: Inspect all fuel lines and connections for leaks.
* Start the Engine: Start the engine and check for proper operation. Listen for unusual noises from the pump.
* Fuel Pressure Test (Recommended): Use a fuel pressure gauge to verify that the fuel pressure is within the manufacturer's specifications. Consult your repair manual.
Important Considerations:
* Fuel Line Clamps: Use new clamps when reassembling the fuel lines to ensure a proper seal.
* Fuel Tank Safety: Work in a well-ventilated area and take necessary precautions to avoid fire hazards. Never smoke near the fuel tank.
* Repair Manual: This is crucial. It will give you specific steps, torque specifications, and diagrams for your vehicle.
This is a complex procedure. If you're not comfortable performing this repair yourself, it's best to take your van to a qualified mechanic. Incorrect installation can lead to serious problems, including fire hazards.
