Tools:
* Safety Gear: Eye protection, gloves, and potentially a respirator (fuel fumes are dangerous).
* Socket set: Various sizes, including those for the fuel lines and possibly the pump retaining ring.
* Wrench set: May be needed for some fuel line connections.
* Fuel line disconnect tool: This specialized tool helps safely disconnect the fuel lines without damaging them. Improvising can lead to leaks.
* Jack and jack stands: To safely lift the vehicle.
* Wheel chocks: To secure the vehicle.
* Torque wrench: For properly tightening connections upon reassembly.
* Screwdrivers (Phillips and flathead): Depending on the year and model, you may need these to access the fuel pump access panel.
* Clean rags or shop towels: To soak up any spilled fuel.
* New fuel pump gasket(s) and filter (if needed): Always replace these when reinstalling the pump.
* Bucket or container: To catch any remaining fuel in the lines.
* Pressure gauge (optional but recommended): To relieve fuel system pressure. A fuel pressure release tool or even disconnecting the fuel pump relay will help.
Steps (General Outline - Consult a Repair Manual Specific to Your Voyager's Year):
1. Disconnect the battery: This is crucial for safety to prevent sparks.
2. Relieve fuel system pressure: Consult your repair manual for the proper procedure. This is often done by disconnecting the fuel pump relay and then running the engine until it stalls. A pressure gauge can confirm zero pressure.
3. Locate the fuel pump access panel: This is usually under the rear passenger seat or in the bed of a minivan depending on the model year and body style.
4. Access the fuel pump: You'll likely need to remove the rear seat or access panel.
5. Disconnect the fuel lines: Use the fuel line disconnect tool to avoid damage. Have your container ready to catch any fuel.
6. Disconnect the electrical connector: This connects the fuel pump to the vehicle's electrical system.
7. Remove the fuel pump retaining ring: This usually involves using a special tool or socket.
8. Remove the fuel pump: Carefully lift out the fuel pump assembly.
9. Install the new fuel pump: Reverse the removal steps, remembering to use new gaskets.
10. Reconnect everything: Ensure all fuel lines, the electrical connector, and the retaining ring are properly secured.
11. Reconnect the battery:
12. Check for leaks: Carefully inspect all connections for leaks.
13. Start the engine: Ensure the fuel pump is working correctly and that there are no leaks.
Crucial Note: This is a general outline. Always consult a repair manual specific to your Plymouth Voyager's year and model. The location of the fuel pump, access methods, and specific procedures can vary significantly. Incorrect procedures can lead to fuel leaks, fire, and injury. If you're not comfortable performing this repair, it's best to take it to a qualified mechanic.
