How to install the fuel pump - 1997 Plymouth Voyager

Fuel Pump Module Removal & Installation To Remove:
WARNING
Highly flammable mixtures are always present in any fuel related component. Smoking or carrying lighted tobacco or an open flame of any type may ignite the flammable mixtures.
WARNING
Even when the engine is not running, fuel in the fuel system remains under high pressure. Fuel system pressure must be relieved before working on or disconnecting any of the fuel lines, fuel tubes, or fuel system components. Failure to do so may result in accidental spraying of fuel, personal injury, or a fire hazard.

1. Remove Fuel Tank. Fuel Pump
   
   
2. Remove fuel pump lock ring.
3. Remove fuel pump.
4. Remove and discard fuel pump O-ring.

To Install:

1. Install new fuel pump O-ring.
2. Install fuel pump.
3. Install fuel pump lock ring. Tighten to 66 ft-lb (89 Nm).
4. Install Fuel Tank.

Fuel Pump-(test for current at the fuel pump using a multimeter or test light while cranking) Removal & Installation To Remove:

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Relieve fuel system pressure.
3. Disconnect the battery ground cable.
4. Remove the rear seat cushion.
5. Remove the rear floor service cover mounting screws and remove the cover (except '02-'04).
   
   
6. Remove the butyl tape and remove the floor service cover ('02-'04).
7. Remove the fuel pump vapor pressure sensor electrical connector ('02-'04).
8. Remove the fuel line U-clip and remove the fuel line from the fuel pump module.
9. Squeeze the fuel vent line retainer and remove the vent line from the fuel pump module.
   
   
10. Remove the 8 fuel pump module retainer ring mounting screws and remove the retainer ring ('02-'04).
11. Remove the fuel pump module retainer using special tool 09808- 14020 or equivalent (except '02-'04).
12. Remove the fuel pump module.

To Install:

1. Install a new O-ring on the fuel tank.
2. Install the fuel pump module into the fuel tank.
3. Use the following procedure to install the fuel pump module retainer ring (except '02-'04). Fuel pump module installation
   
   
   1. Align the notch in the fuel tank with the tab in the module.
   2. Matchmark a new retainer with the fuel tank.
   3. Using the special tool install and tighten the retainer ring 2 revolutions.
4. Use the following procedure to install the fuel tank module retainer ring ('02-'04).
   1. Install the retainer ring on the fuel pump module.
   2. Fasten the retainer with the 8 mounting screws. Tighten 53 in lb (6 Nm).
5. Install the vent line to the pipe until the fuel vent line connector clicks into place.
6. Install the fuel line with the U-clip.
7. Install the fuel pump vapor pressure sensor electrical connector ('02-'04).
8. Install the floor service cover with butyl tape ('02-'04).
9. Install and secure the rear floor service cover with the mounting screws (except '02-'04).
10. Install the rear seat cushion.
11. Connect the battery ground cable.
12. Check for fuel leaks.

Fuel Pump REMOVAL AND INSTALLATION ES300 CAUTION
Fuel injection systems remain under pressure even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. Relieve the fuel system pressure.
2. With the ignition switch in the LOCK position, disconnect the negative battery terminal. If equipped with an air bag system, wait at least 90 seconds or longer before performing any other work.
3. Remove the rear seat cushion.
4. Disconnect the fuel pump connector. CAUTION
   The Supplemental Inflatable Restraint (SIR) system must be disarmed before removing the fuel pump. Failure to do so may cause accidental deployment of the air bag, resulting in unnecessary SIR system repairs and/or personal injury.
   
5. Remove the floor service hole cover. NOTE: Do not lift the fuel pump assembly up using the wire harness.
   
6. Remove the fuel filler cap. Disconnect the fuel outlet pipe and the return hose from the pump bracket.
7. Remove the 8 screws and lift out the pump/bracket assembly with gasket.
8. Remove the fuel pump lead wire.
9. Pull the lower end of the pump off of the bracket.
10. Disconnect the fuel hose from the pump and remove the pump.
11. Remove the rubber cushion from the pump. To install:
    
12. Install the filter and rubber cushion on the new pump and install the pump on the bracket.
13. Connect the fuel hose and the wire connector on the pump.
14. Using a new gasket, install the pump and tighten the eight screws to 35 inch lbs. (4 Nm).
15. Connect the fuel pipe and return hose to the pump and tighten the bolts to 22 ft. lbs. (29 Nm).
16. Connect the wire, install the service cover and replace the rear seat.
17. Connect the negative battery cable.
18. Start the engine and check for leaks. Fig. 1: Fuel pump assembly - ES300
    

GS300, LS400, SC300 and SC400

1. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
2. Remove the trunk floor mat.
3. Remove the trunk trim cover.
4. Disconnect the fuel pump electrical connector.
5. Remove the rear seat bottom and seat back.
6. Remove the partition cover.
7. Remove the mounting bolts and remove the fuel pump set plate.
8. Remove the three nuts and disconnect the fuel pump bracket from the tank.
9. Disconnect the fuel hose from the bracket. Remove the pump, bracket and set plate as an assembly. To install:
   
10. Install a new gasket on the set plate. Connect the fuel hose to the pump and bracket,
11. Install the pump and bracket assembly with the three nuts; tighten the nuts to 48 inch lbs. (5 Nm). Install the set plate and tighten the bolts to 26 inch lbs. (3 Nm).
12. Install the panel partition
13. Install the rear seat cushion and back.
14. Connect the fuel pump electrical connector.
15. Install the trim panel.
16. Install the spare tire and the trunk floor mat.
17. Connect the negative battery cable.
18. Start the engine; check the fuel system for leaks
19. Road test the vehicle for proper operation.

Fuel Pump Module-in tank, no compartment to replace fuel pump Removal & Installation To Remove:
WARNING
Highly flammable mixtures are always present in any fuel related component. Smoking or carrying lighted tobacco or an open flame of any type may ignite the flammable mixtures.
WARNING
Even when the engine is not running, fuel in the fuel system remains under high pressure. Fuel system pressure must be relieved before working on or disconnecting any of the fuel lines, fuel tubes, or fuel system components. Failure to do so may result in accidental spraying of fuel, personal injury, or a fire hazard.

1. Remove Fuel Tank. Fuel Pump
   
   
2. Remove fuel pump lock ring.
3. Remove fuel pump.
4. Remove and discard fuel pump O-ring.

To Install:

1. Install new fuel pump O-ring.
2. Install fuel pump.
3. Install fuel pump lock ring. Tighten to 66 ft-lb (89 Nm).
4. Install Fuel Tank.

Removal & Installation WARNING Extreme caution should be taken when removing the fuel tank from the vehicle! Ensure that all removal procedures are conducted in a well ventilated area! Have a sufficient amount of absorbent material in the vicinity of the work area to quickly contain any fuel spillage. NEVER store waste fuel in an open container, as it presents a serious fire hazard!

This procedure will require a new fuel pump gasket for pump installation, so be sure to have one before starting.

1. Relieve the fuel system pressure.
   
2. Disconnect the negative battery cable.
   
3. Remove the rear seat cushion and unplug the electrical connectors from the fuel pump.
   
4. Unfasten the four pump access cover screws and remove the cover.
   
5. If equipped, unplug the pump electrical connector located under the cover.
   
6. Unfasten the fuel line clip(s) and disconnect the line(s) from the pump.
   
7. Use a fuel pump locking ring removal tool or a brass drift and a hammer to unfasten the pump locking retaining ring.
   
8. Remove the fuel pump and the gasket from the tank.
   

To install:

1. Install a new gasket and place the pump into position in the tank.
   
2. Install the pump locking retaining ring.
   
3. Connect the fuel line(s) to the pump and install the line retaining clip(s).
   
4. If equipped, attach the fuel pump electrical connection(s).
   
5. Install access cover, then tighten the retainers.
   
6. Attach the pump electrical connector(s).
   
7. Install the rear seat cushion.
   
8. Connect the negative battery cable.
   
9. Start the car and check for proper operation.
   

300M, Concorde, Intrepid, LHS, 1998-2004 - Fuel Filter Removal & Installation The fuel filter mounts to the frame rail in front of the fuel tank. The inlet and outlet ends of the filter are marked for installation purposes. Install the fuel filter making certain that it is properly orientated.

NOTE The fuel filter is part of the fuel pressure regulator mounted on the fuel pump module.

1. Before servicing the vehicle, refer to the Precautions section.
2. Properly relieve the fuel system pressure.
3. Lower the fuel tank.
4. Remove or disconnect the following:
   Negative battery cable Purge and vent lines Fuel line from the pressure regulator Filter/regulator by pushing in the locking tab, turning the regulator to unlock it and pulling the it straight up

To install:




Fig. Cut away view of the fuel filter/pressure regulator

1. Push the fuel filter/regulator into the fuel pump module and turn to lock it into position.
2. Connect the fuel lines and install the tank.
3. Start the engine, check for leaks and repair if necessary.

Fuel Pump - Removal & Installation
The in-tank fuel pump module contains the fuel pump and pressure regulator which adjusts fuel system pressure. Fuel pump voltage is supplied through the fuel pump relay.

The fuel pump is serviced as part of the fuel pump module. The fuel pump module is installed in the top of the fuel tank and contains the electric fuel pump, fuel pump reservoir, inlet strainer fuel gauge sending unit, fuel supply and return line connections and the pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module.

1. Before servicing the vehicle, refer to the Precautions section.
2. Properly relieve the fuel system pressure.
3. Remove or disconnect the following:
   Negative battery cable Fuel tank
4. Clean the top of the tank to remove any loose dirt.
   Fuel lines from the fuel pump module by squeezing the quick-connect fitting with thumb and forefinger
   
   
   
   
   Fig. Using special tool 6856, remove the fuel pump module locknut
   Fuel pump module electrical connector from the top of the fuel pump module
5. Using special tool 6856, remove the fuel pump locknut by turning it counterclockwise.
   CAUTION The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed.
6. Remove the fuel pump and O-ring from the tank and discard the O-ring.
   

To install:

1. Thoroughly clean all parts. Wipe the seal area of the tank clean. Place a new O-ring on the ledge between the tank threads and the pump module opening.
2. Position the fuel pump module in the tank. Be sure the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank.
3. While holding the fuel pump module in place install the locking ring and torque to 40 inch lbs. (5 Nm) using special tool 6856 or a spanner-type tool.
4. Install or connect the following:
   Fuel tank Fuel pump module electrical connector Negative battery cable
5. Fill the fuel tank with fuel. Install the fuel filler cap. Turn the ignition switch to the ON position to pressurize the system. Check the fuel system for leaks.

Hope this helped.

Removal & Installation

1. Relieve the fuel system pressure.
   
2. Disconnect the negative battery cable.
   
3. Remove the rear seat.
   
4. Remove the fuel pump access cover.
   
5. Disconnect the electrical connector at the fuel pump assembly.
   
6. Disconnect the fuel line.
   
7. Remove the fuel pump assembly clip.
   
8. Remove the fuel pump assembly from the tank.
   
9. Remove and discard the gasket.
   

To install:

1. Clean the gasket mating surface on the fuel tank.
   
2. Position the new gasket in place.
   
3. Install the fuel pump into the fuel tank in the same location as removed for ease of line and connector installation.
   
4. Install the fuel pump assembly clip.
   
5. Connect the fuel pump assembly connector.
   
6. Install the fuel pump line.
   
7. Install the fuel pump access cover.
   
8. Install the EF10 fuse.
   
9. Connect the negative battery cable.
   
10. Perform an operational check of the fuel pump.
    
11. Install the rear seat.
    

Hi, I hope this helps...

1994-96 Engines
See Figures 3 and 4



Fig. Fig. 3: Details of the fuel pump assembly-1994-96 diesel engine



Fig. Fig. 4: View of the fuel pump-1994-96 diesel engine

1. Remove the turbocharger assembly.
2. Remove the fuel line banjo bolt at the pump.
3. Remove the fuel line fittings at the rear of the cylinder heads.
4. Remove the fuel lines assembly.
5. Loosen the two hose clamps at the fuel pump fittings.
6. Disconnect the water drain hose at the fuel filter.
7. Disconnect the filter and position it forward.
8. Remove the fuel pump retaining bolts, then lift the pump out of the crankcase bore.
9. Remove the fuel pump tappet from the crankcase bore.

To install:

1. Rotate the engine so the fuel pump eccentric is on the base circle.
2. Install the fuel pump tappet in the base of the fuel pump.
3. Replace the O-ring on the fuel pump base.
4. Install the fuel pump and bolt it in place.
5. Install the fuel filter and connect the water drain hose.
6. Connect the two fuel hoses at the front of the fuel pump.
7. Tighten the fuel line clamps and install the fuel filter retaining bolts.
8. Install the fuel line assembly and new seal rings at the rear of the pump.
9. Loosely install the fuel line fittings at the rear of the cylinder heads.
10. Install the fuel line banjo fitting at the pump. Tighten the fitting to 40 ft. lbs. (54 Nm).
11. Tighten the fuel line fittings.
12. Install the turbocharger assembly.

Removal & Installation


Exploded view of the fuel sender, including the fuel pump


Click to Enlarge

1. Properly relieve the fuel system pressure
   

1. If not already done, disconnect the negative battery cable.
   
2. Raise and safely support the vehicle with jackstands.
   
3. Safely drain and remove the fuel tank assembly as outlined later in this section.
   
4. Detach the quick-connects from the fuel sender assembly and remove the fuel lines.
   
5. Using tool J 35731, or an equivalent spanner wrench, remove the fuel sender lockring.
   
6. Lift the sender assembly carefully out of the fuel tank.
   
7. Remove the sender O-ring from the top of the sender and discard.
   

WARNING Do NOT run the fuel pump unless it is submerged in fuel. Running the pump dry will cause serious damage to the fuel pump and may cause the pump to explode due to the oxygen in the air.

1. Note the position of the fuel pump strainer on the fuel pump and, while supporting the pump assembly in one hand, twist the strainer off the pump and discard the strainer.
   
2. Detach the fuel pump electrical connector.
   
3. Remove the clamp from the fuel line at the top of the pump.
   
4. Hold the fuel sender upside down on a work bench and pull the fuel pump out of the lower mounting bracket. Once the pump is clear of the lower mounting bracket, tilt the pump outward and disconnect the pump from the sender assembly.
   

To install:

1. Replace any attaching hoses or rubber sound insulators that show signs of deterioration.
   
2. Install the rubber bumper and insulator on the fuel pump.
   
3. Hold the fuel sender upside down and install the fuel pump between the fuel pulse dampener and mounting bracket.
   
4. Attach the fuel pump electrical connector.
   
5. Install the retaining clamp on the fuel line.
   
6. Install a new fuel pump strainer on the outer edge of the ferrule until fully seated. The strainer must be facing the same direction as it was before removal.
   
7. Position a new O-ring on the top of the fuel tank and install the sender assembly.
   
8. Install the lockring using J-35731, or an equivalent spanner wrench.
   
9. Install the fuel tank as outlined later in this section.
   
10. Refill the gas tank.
    
11. Connect the negative battery cable.
    
12. Turn the ignition switch to the ON position to pressurize the fuel system and check for leaks.
    

REMOVAL

1. Relieve fuel system pressure.
2. Disconnect battery ground cable.
3. Remove fuel filler door.
4. Remove fuel cap.
5. Remove fuel tank filler neck housing and disconnect drain hose.
6. Remove screws attaching fuel meter/fuel pump to tank.
7. Disconnect fuel lines, fuel vapor line and electrical connector.
8. Remove fuel meter/fuel pump and gasket.
9. Replace fuel pump.

INSTALLATION

1. Reverse procedure to install.