Here's a general outline. Specific steps might vary slightly depending on your exact engine and trim level. Always consult a repair manual specific to your 1996 Plymouth Voyager for detailed instructions and diagrams. A Haynes or Chilton manual is a good investment.
Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet and extensions
* Fuel pump pliers (or a suitable alternative for removing the fuel pump retaining ring)
* Screwdrivers (Phillips and flathead)
* Wire strippers/crimpers
* New fuel filter (replace it while you're at it)
* New fuel pump (ensure it's the correct one for your vehicle)
* Safety glasses
* Gloves
* Jack and jack stands (to safely secure the vehicle)
* Drain pan
* Shop rags or towels
* Torque wrench (highly recommended)
* Fuel line disconnect tool (helps prevent damage to the fuel lines)
General Steps:
1. Safety First: Disconnect the negative battery terminal.
2. Vehicle Preparation: Raise and securely support the vehicle using jack stands. Never work under a vehicle supported only by a jack.
3. Access the Fuel Pump: The fuel pump is usually located inside the fuel tank, accessed through a trap door under the vehicle's rear passenger area. You may need to remove some interior trim panels or carpet to reach the access panel. This panel usually has a cover that may require removing screws or bolts. Consult your repair manual for the exact location and access procedure.
4. Drain Fuel: Carefully siphon or pump out as much fuel as possible from the tank to reduce the amount of fuel you're working around. This is crucial for safety.
5. Disconnect Fuel Lines and Electrical Connections:
* Careful! Fuel will likely spray out when disconnecting fuel lines. Use a drain pan and have rags ready. Use a fuel line disconnect tool to prevent damage to the lines.
* Disconnect the fuel lines (be prepared for a little fuel spillage).
* Disconnect the electrical connector to the fuel pump.
6. Remove the Fuel Pump Assembly: This often involves removing a retaining ring around the fuel pump assembly. Fuel pump pliers are the best tool for this, but you may be able to improvise with other tools. Once the ring is removed, carefully lift the fuel pump assembly out of the tank.
7. Inspect the Old Fuel Pump and Sender Unit: Check the old fuel pump and fuel level sending unit for damage or wear.
8. Install the New Fuel Pump and Sender Unit: Install the new fuel pump assembly. Make sure the float arm on the sender unit is correctly positioned.
9. Reconnect Everything: Carefully reconnect the fuel lines and electrical connector, ensuring tight and secure connections.
10. Reinstall Access Panel: Reinstall the access panel.
11. Lower Vehicle: Carefully lower the vehicle from the jack stands.
12. Reconnect Battery: Reconnect the negative battery terminal.
13. Prime the Fuel System: You might need to prime the fuel system to get the fuel pump working properly (consult your repair manual for the procedure).
14. Start the Vehicle: Start the engine and check for leaks around the fuel lines and access panel. Let it run for a few minutes to ensure everything is functioning correctly.
Important Considerations:
* Fuel Pressure: If you're dealing with a fuel pump failure, you'll likely need to check fuel pressure. This requires a fuel pressure gauge and a specific procedure outlined in your repair manual.
* Fuel Tank Removal: In some cases, you may need to completely remove the fuel tank to access the fuel pump. This is a more involved process.
* Professional Help: If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. Improperly working on the fuel system can be dangerous.
This is a general overview. Always refer to a repair manual specific to your 1996 Plymouth Voyager for detailed, step-by-step instructions. The manual will provide the exact procedure, torque specifications, and safety precautions for your specific vehicle. Remember safety is paramount when working with fuel.
