Fuel pump replacement '96 Voyager 3.3
 

I searched the forum but was unable to find anything about fuel pump replacements, but I'm sure that I missed something because fuel pumps are broken very often I'm told.

Now, what I was wondering is; do I need special tools to replace the fuel pump motor/filter. Is this something I can do myself?

I already have one so the work can start as soon as I'm sure what to do, and this is the first one after over 330.000KM so we can't really complain.

Many thanks in advance for your help and tips!

I have not changed the fuel pump myself but here are the instructions taken from the workshop manual for my 1999 3.3l - note:- To release pressure from system start engine and remove fuel pump relay until engine stops.

Hope this helps - no pics though.

FUEL PUMP MODULE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.

REMOVAL
(1) Remove fuel filler cap and perform Fuel System
Pressure Release procedure.
(2) Disconnect negative cable from battery.
(3) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(4) Drain fuel tank dry into holding tank or a
properly labeled GASOLINE safety container.
(5) Raise vehicle on hoist.
(6) Use a transmission jack to support the fuel
tank. Remove bolts from fuel tank straps. Lower
tank slightly.
(7) Clean area around fuel tank module and tank
to keep dirt and foreign material out of tank.
(8) Disconnect fuel lines from fuel pump module by
depressing quick connect retainers with thumb and
fore finger (Fig. 14).
(9) Slide fuel pump module electrical connector
lock to unlock.
(10) Push down on connector retainer (Fig. 15) and
pull connector off module.
Fig. 13 Fuel Filter
Fig. 14 Fuel Line Retainers and Pump Connector
Lock
Fig. 15 Pump Module Connector Retainer and Lock
NS FUEL SYSTEM 14 - 13
(11) Using Special Tool 6856, remove plastic locknut
counterclockwise to release pump module (Fig.
16).
(12) Carefully remove pump module and O-ring
from tank (Fig. 17).
(13) Discard old O-ring.

INSTALLATION
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel pump in tank with locknut.
(3) Tighten locknut to 53 N·m (43 ft. lbs.).
(4) Connect fuel lines.
(5) Plug in electrical connector. Slide connector
lock into position.
(6) Raise fuel tank, install bolts into fuel tank
straps and tighten.
(7) Lower vehicle on hoist.
(8) Connect negative cable from battery.
(9) Fill fuel tank. Check for leaks.
(10) Install fuel filler cap.

Thank you very much! And do I really need that "Special Tool 6856" or not? Otherwise I am s...... well you know what I mean.

Thanks again!

I don't think you will be able to do it without this tool its shaped like a U with a grove on both legs, this releases the pump module.

Probably better to take to a dealer

hammer and a screw driver. the tool just makes it easy

Thanks guys. I will give it a go week and report back afterwards.

The fuel is pump installed and the car starts again, but I can't floor the pedal without stalling the engine. Like it isn't getting enough fuel. What should the pressure be on the injection rail?

54psi. what do you mean buy stalling? does it intake backfire? is it like really doggy? need way more specific details of what it does.

We checked the pressure earlier today, and there's only 15psi on the fuel rail. That must be why it has troubles running on petrol – it runs fine on LPG.

Wiring to the pump is fine. Must be some other stupid error on my side.

pinched line, fuel filter and 2 things that come to mind for this problem.