How do you change the fuel pump on a 1996 grand voyager?

Answer 1

To replace the fuel pump you need to empty the tank of as much fuel as possible (completely empty preferred but very difficult) If you can raise the vehicle it will be easier to use a siphon to drain. Once the tank is empty place a tranny jack or floor jack under the center of the tank. Remove the tank straps (2, each with 2 bolts) and the lower clamp from the fuel filler tube. Lower the tank a little (2 - 3 inches) to allow room to disconnect the fuel lines and vapor / vent lines. The vapor and vent lines are force fit and may not remove easily. In this case you need to make a judgment call to either cut the line just before a fitting and refit once done (if there is enough spare line to allow losing an inch or two of line) or cut a couple of inches away and splice back when done. With all lines removed finish lowering the tank. Use a strap or chain wrench to remove the retaining ring (6 inches in diameter so you will need a large wrench) I needed a cheater bar with my strap wrench as the factory over tightened the ring. Remove ring, fuel pump assembly, and o-ring. Inspect and replace as needed. This is also a perfect time to clean any dirt or other undesired artifacts from the tank. On reassembly - If splicing use a rigid line or pipe that just fits inside the line being spliced. Insert into one side and tighten the hose clamp for that side before beginning reassembly, you may well appreciate this later. For the larger vapor recovery line I have used the body of an old sharpie® marker, it fits well and is just rigid enough. If you cut the lines and are refitting then many of the lines will be eased by a little petroleum jelly on the fitting and soften the line by heating it. Never use flame or spark around a fuel tank, even empty tanks can have enough vapor to cause an explosion. I use a cup of water heated to boiling then insert the line into the cup of water for 15 - 30 seconds. Now push the line onto the fitting quickly as it will cool before you know it.