- New fuel pump
- Fuel line disconnect tool
- Flathead screwdriver
- Phillips head screwdriver
- 10mm socket
- 13mm socket
- Fuel injector cleaner
- Safety goggles
- Gloves
Step-by-Step Instructions:
1. Park your vehicle in a safe location, turn off the engine, and engage the parking brake. Allow the vehicle to cool down if it has been recently operated.
2. Locate the fuel pump. In a 1992 Plymouth Voyager, the fuel pump is located inside the fuel tank, which is situated under the vehicle.
3. Relieve the fuel pressure in the fuel system. This is done by disconnecting the fuel line from the fuel injector rail. Use a fuel line disconnect tool to depress the release tab on the fuel line connector and pull the fuel line off the injector rail.
4. Disconnect the electrical connector to the fuel pump. The fuel pump is located at the bottom of the fuel tank and has an electrical connector attached to it. Disconnect this connector by pressing the release tab and pulling it apart.
5. Remove the fuel tank skid plate. The fuel tank skid plate is a metal plate that protects the fuel tank from damage. It is held in place by several screws. Use a 10mm socket to remove the screws and take off the skid plate.
6. Drop the fuel tank. The fuel tank is held in place by two straps. Use a 13mm socket to loosen the bolts that hold the straps in place. Once the bolts are loose, lower the fuel tank until you can access the fuel pump.
7. Remove the fuel pump assembly. The fuel pump assembly is held in place by a lock ring. Use a flathead screwdriver to pry up the lock ring and remove it. Lift out the fuel pump assembly from the fuel tank.
8. Inspect the fuel pump and fuel tank for damage or debris. If there is any damage or debris, clean it out before installing the new fuel pump.
9. Install the new fuel pump assembly. Carefully lower the new fuel pump assembly into the fuel tank and secure it with the lock ring.
10. Reconnect the electrical connector to the fuel pump. Ensure that the connector is securely attached.
11. Reconnect the fuel line to the fuel injector rail. Press the fuel line onto the injector rail until you hear a click, indicating that the connection is secure.
12. Raise the fuel tank and reinstall the fuel tank skid plate. Secure the fuel tank skid plate with the bolts you removed earlier.
13. Start the engine and check for leaks. Look under the vehicle for any signs of fuel leaking from the fuel line connections or the fuel pump. If there are no leaks, the fuel pump replacement is complete.
Note: It's recommended to replace the fuel filter when replacing the fuel pump, as it can become clogged and affect fuel flow to the engine. Always refer to your vehicle's service manual for specific instructions and safety guidelines.
