Here's a general overview. Specific steps may vary slightly depending on the engine (3.0L or 3.3L) and whether you have access to a repair manual specific to your vehicle. Always consult a repair manual for detailed instructions and diagrams specific to your 1996 Plymouth Voyager/Dodge Caravan/Chrysler Town & Country.
Safety Precautions:
* Disconnect the negative battery terminal before starting any work.
* Work in a well-ventilated area. Fuel fumes are flammable and potentially harmful.
* Wear safety glasses to protect your eyes.
* Have a fire extinguisher readily available.
* Use proper jack stands if working under the vehicle. Never rely solely on a jack.
* Dispose of old fuel properly.
General Steps:
1. Locate the fuel pump. On most 1996 Voyagers, the fuel pump is located inside the fuel tank. You will need to access it from under the vehicle.
2. Lower the fuel tank (usually): This often requires disconnecting the fuel lines, electrical connectors, and possibly the fuel tank straps. This is where having a repair manual is crucial. You'll likely need to support the tank with a jack or jack stand to prevent it from dropping suddenly and potentially causing damage.
3. Disconnect the fuel lines: This is extremely important. You'll need to relieve pressure in the fuel system first. There are various ways to do this, and your repair manual will detail the safest procedure. NEVER work near open flames or sparks while working on fuel lines. Use fuel line clamps or plugs to prevent fuel spillage.
4. Disconnect the electrical connector: Unplug the fuel pump's electrical connector.
5. Remove the fuel pump assembly: This usually involves removing a retaining ring or cover plate on top of the fuel tank. The fuel pump assembly will be inside. The pump may be integrated with the fuel sending unit (the component that shows your fuel gauge level).
6. Install the new fuel pump assembly: This is the reverse of removal. Ensure the new pump's gasket is properly seated to prevent leaks.
7. Reconnect everything: Reconnect the fuel lines, electrical connector, and fuel tank straps. Double-check everything before lowering the fuel tank.
8. Raise the fuel tank: Carefully raise the fuel tank back into position.
9. Reconnect the battery: Reconnect the negative battery terminal.
10. Prime the fuel system: You might need to cycle the ignition key a few times to prime the system before starting the engine. Consult your repair manual for the correct procedure.
11. Check for leaks: After starting the engine, carefully check for any fuel leaks around the fuel tank and lines.
Important Considerations:
* Repair Manual: A repair manual specific to your 1996 Plymouth Voyager is essential. It will provide detailed diagrams, torque specifications, and safety precautions.
* Fuel Pump Assembly: Make sure you purchase the correct fuel pump assembly for your vehicle's engine and specifications.
* Tools: You will need a variety of tools, including wrenches, sockets, screwdrivers, fuel line disconnect tools, jack and jack stands, and possibly a fuel pressure gauge.
This is a simplified overview. Again, refer to a repair manual for your specific vehicle before attempting this repair. If you're not comfortable performing this repair, taking your vehicle to a qualified mechanic is highly recommended. This is a complex repair that could result in damage to your vehicle or personal injury if done incorrectly.
