Read my thread on the 96 Voyager sputtering and stalling.....
Use the Bosch Pump ($207 at Auto Zone), don't be fooled that other pumps fit. Read the other thread! Watch what you buy off ebay... you can't return it! (see the fine print....and they're the wrong pump!!!)
What tools?
- A $10 chain wrench or a $25 strap wrench (chain wrench must be bigger than 5", most are NOT! (you can extend the chain, however...)
- 15mm socket (straps)
- needle nose pliers (red lock clip, fuel lines)
- Jack, jack stands, maybe an extra jack too
- waterproof (all plastic or rubber, etc..) flashlight
- Safety glasses/goggles
- Fire extinguisher (just in case)
As far as how easy it is?
This is from the perspective of a Layman, not a shop:
(I'm a "layman", I crawl under my cars and "lay" there to fix them, I don't have the space or money for a lift!
)
- jack up the left rear of the van, high enough to work under it comfortably and safely.
- secure the tank (hopefully empty, or close to empty) DO NOT use a "Jack only" in the very center of the tank, you will bind the pump!
- remove the inside (center of Van) strap bracket bolts and let the straps hang down.
- Remove the fuel pump wire connector (have to remove the red lock clip first)
- Lower the tank about 4"-6"...the lines will let you lower it.
- unclip the fuel lines. (if you happen to replace the external filter, you won't have to salvage the clips if you buy it from Chrysler)
- Using a strap wrench, or a chain wrench wrapped in a rag for safety(6" diameter) loosen the retaining ring. (the manual says to use a "manufactured tool".. well I don't have the money for tool fabrication, so I used a chain wrench covered in a rag.) This can be pretty tight, so expect an apply a little elbow grease. it unscrews! If the tank is propped up in the center, you will have great difficulty removing the ring. It does turn COUNTERCLOCKWISE, as you would expect.
- remove the pump assembly. Wipe off the ring, and retrieve the round gasket (but don't re-use it!)
- install the new gasket provided with the new pump (goes along the outer ring of the threaded collar on the tank....and yes, it will fit!)
- install the pump... be sure the float is right side up, and once installed, twist the pump left and right, there is a keyway where ir sets right.
- Re-install the ring. Tighten with the wrench again, not just by hand.
Reassemble in the same manner you took it apart.
These instructions are included with the new pump.
This is really pretty simple, and best done when you have the tank as empty as possible. But there is no need to drain the tank completely (and where would you store 16 gallons of gas, and how would you put it back?!)
I recommend changing the external filter, because it probably has never been changed. Buy it from a Chrysler dealer.
AS IT SHOULD BE YOUR CONCERN AND MINE,
SAFETY! SAFETY! SAFETY!
NEVER WORK AROUND OPEN FUEL SYSTEMS WITHOUT ADEQUATE SAFETY.
KEEP A tybe ABC FIRE EXTINGUISHER CLOSE. WEAR PROTECTIVE CLOTHING AND GLOVES. EXTINGUISH ALL OPEN FLAMES, TORCHES, CIGARETTES, EVEN CITRONELLA CANDLES AND MOSQUITO COILS. REMOVE INCANDESCENT ELECTRIC DROP LIGHTS FROM THE AREA PRIOR TO REMOVING THE PUMP. NEVER OPEN A FUEL TANK IN AN ENCLOSED (HOME GARAGE) AREA (YOUR DRIVEWAY IS OK, BUT BEST TO BE A DISTANCE AWAY FROM THE HOUSE. ALWAYS HAVE A HELPER PRESENT, EVEN IF JUST FOR MORAL SUPPORT.
DON'T HURT YOURSELF.
I'm not saying you're not versed in common sense, and take these safety concerns into consideration already.
I just want everyone to play it safe. The life you save will be your own!
Tom