Replacing Fuel Pump In Dodge Van: Step-By-Step Guide

Changing the fuel pump in a Dodge van can be a complex and dangerous task, so it is important to proceed with caution. The fuel tank must be lowered from the body of the van, and fuel is highly flammable, so it is important to work in a well-ventilated area, keeping any sources of heat, fire, and sparks away. It is also recommended to wear safety glasses and gloves that won't dissolve in gas. Before beginning the process, it is important to set the emergency brake, disconnect the battery, and siphon excess fuel from the tank to reduce its weight. Once the fuel pressure has been relieved, the fuel tank straps can be loosened, and the electrical connector and fuel pressure hose can be disconnected. Finally, the fuel pump assembly can be removed and replaced, taking care to transfer over any necessary parts and to install a new rubber O-ring.

Safety precautions

Changing the fuel pump in a Dodge van can be a dangerous task due to the presence of flammable liquid and fuel vapors. Here are some detailed safety precautions to follow when undertaking this job:

Work in a Well-Ventilated Area: It is crucial to work outdoors or in a well-ventilated space to minimize the risk of inhaling toxic fumes and to reduce the chance of fire. Keep the garage doors open if working inside.

Keep Sparks and Heat Away: Any source of heat, fire, or sparks should be kept away from the work area. When using a flashlight, turn it on and off away from the fuel tank and vapors to avoid sparks.

Wear Appropriate Safety Gear: Protective gear such as safety glasses, gloves, and appropriate clothing are essential. The safety glasses should be of the wrap-around kind to protect your eyes from potential gas splashes and falling debris. Gloves that won't dissolve in gas are necessary to protect your hands when handling fuel-exposed parts.

Minimize Fuel Fumes: Keep the fuel system open for as short a time as possible. Have all the required parts and tools ready and close at hand to reduce the time the fuel system is exposed.

Reduce Fuel in the Tank: Before starting, run the gas down to less than a quarter of a tank to avoid spillage and reduce the mass of the tank that you will need to handle. If the vehicle is not drivable, siphon excess gas from the tank using a siphon kit.

Use Proper Tools: Use the correct tools for the job, such as a socket wrench set for removing fuel tank straps and a specialized wrench for unscrewing the fuel pump's plastic nut.

Support the Vehicle Properly: When working underneath the vehicle, ensure it is securely supported. Use ramps or jack stands to elevate the rear of the van, and use scissor jacks to carefully lower the fuel tank.

Disconnect the Battery: Before beginning any work, disconnect the negative terminal of the battery.

Release Fuel Pressure: Undo the tank cap and release the Schrader valve on the fuel rail to relieve fuel pressure in the system.

Be Careful with Electrical Connectors: When removing the electrical connector from the fuel pump head, gently push the locking tab sideways and then pull out the plug. Be cautious not to damage the connector.

Clean the Work Area: Before removing the old fuel pump, clean the area to prevent dirt and debris from falling into the fuel tank.

Handle Fuel Lines with Care: When removing fuel lines, use a fuel line removal tool and have a container ready to collect any fuel that spills out.

Check for Leaks: Once you've installed the new fuel pump, reconnect the fuel lines and electrical connectors. Inspect the system for any fuel leaks before starting the vehicle.

Follow Manual Instructions: Always refer to the vehicle's service manual or online tutorials for specific instructions and safety precautions for your particular model of Dodge van.

Removing the fuel tank

To remove the fuel tank from your Dodge van, you will need to take the following steps:

Firstly, ensure you are working in a well-ventilated area, keeping any sources of heat, fire, and sparks away from the workspace. It is also recommended to wear safety glasses and gloves that won't dissolve in gas.

Next, back your van onto ramps and support the rear axle with jack stands or blocks. Apply the parking brake and place chocks in front of the front wheels. Disconnect the negative terminal of the battery.

Then, relieve the fuel pressure by removing the tank cap and releasing the Schrader valve on the fuel rail. Undo the cap on the valve and depress the pin with a suitable tool, such as a Robertson screwdriver.

The fuel tank is positioned on the driver's side of the vehicle and is held up by two straps, each with a bolt at both ends. To lower the tank, use two scissor jacks to carefully balance the tank, placing wood blocks between the jacks and the tank to spread the load and protect it. Remove the four tank strap bolts using a 15mm wrench.

Now, lower the fuel tank by turning the screws on the jack stands, keeping the tank level. Once you have enough space, disconnect the electrical connector from the fuel pump head by pushing the red locking tab sideways and gently pulling the plug out.

Finally, remove the fuel lines by releasing the "window" connectors at the fuel pump heads by pressing inwards on their tabs. With the fuel lines disconnected, you can now carefully remove the fuel tank from the vehicle.

Note: It is recommended to keep the fuel tank as low as possible before removal, as each gallon of fuel weighs approximately six pounds, making the tank very heavy and difficult to handle.

Disconnecting the battery and siphoning fuel

Disconnecting the Battery:

• Locate the negative (black) battery cable. It is usually identified by a minus (-) sign or a black cover on the terminal.
• Use a 10mm wrench to loosen the nut or bolt holding the cable in place.
• Carefully remove the cable from the battery terminal.
• Place the disconnected cable in a safe area away from the battery to prevent accidental contact. You can also wrap the terminal end of the cable with electrical tape for added safety.

Siphoning Fuel:

• Before attempting to siphon the fuel, ensure you have a suitable siphon pump. This can be purchased from an auto parts store or online.
• Position the siphon pump in the fuel tank. Follow the specific instructions provided with your siphon pump for proper placement.
• Activate the siphon pump to remove excess fuel from the tank.
• Continue pumping until the fuel level is as low as possible. The less fuel in the tank, the lighter it will be, making it easier to handle during the fuel pump replacement.

Remember, always exercise extreme caution when working with fuel. Work in a well-ventilated area, keep sources of heat and sparks away, and wear appropriate safety gear, including gloves and eye protection.

Replacing the fuel pump

Precautions and Preparations

• This job should be done in a well-ventilated area, keeping the area free from any sources of heat, fire, and sparks.
• Wear safety glasses and gloves that won't dissolve in gas to protect your eyes and hands.
• Keep fuel fumes to a minimum by having the fuel system open for as short a time as possible.
• If possible, run the gas down so you have less than a 1/4 tank to avoid spillage and reduce the tank mass. Alternatively, siphon excess gas from the tank using a siphon kit.
• Back the vehicle onto ramps and support the rear axle with jack stands and blocks of wood.
• Disconnect the negative terminal of the battery.
• Release the fuel pressure by removing the tank cap and releasing the Schrader valve on the fuel rail.

Lowering the Fuel Tank

• Loosen the fuel tank straps using a 15mm socket, but do not completely remove them.
• Remove the skid plates on the front and side of the fuel tank.
• Disconnect the fuel filler neck from the body of the truck by loosening the fuel filler hose and vent hose clamps.
• Lower the tank down carefully, ensuring you do not damage the hoses attached to the fuel pump.

Removing the Old Fuel Pump

• Disconnect the electrical connector and fuel pressure hose from the fuel pump.
• You will see a plastic lock ring surrounding the fuel pump assembly. It can be removed with a strap wrench tool or a screwdriver/punch and a hammer.
• Pry the fuel pump assembly away from the rubber O-ring and lift the fuel pump out of the tank.

Installing the New Fuel Pump

• Before installing the new fuel pump, make sure any parts that were not included with the new assembly are transferred over.
• Install the new rubber O-ring onto the tank, ensuring it stays level and in place.
• Position the new pump at an angle to first insert the sending unit's float, then press the fuel pump down onto the O-ring.
• Tighten the plastic lock ring.

Reinstalling the Fuel Tank

• Raise the tank and reconnect the electrical connector and fuel pressure hose to the fuel pump.
• Continue raising the fuel tank and reconnect the fuel filler hose and vent hose.
• Attach the fuel filler neck to the body of the truck and slide the skid plates back into place.
• Tighten the tank straps to secure the fuel tank to the truck.

Final Checks

• Reconnect the negative battery cable.
• Turn the ignition on and inspect around the fuel tank for any fuel leaks. If none are found, the installation is complete.

Reattaching the fuel tank and reconnecting hoses

Once you have successfully replaced the fuel pump, you can begin the process of reattaching the fuel tank and reconnecting the hoses.

First, you will need to raise the tank high enough to begin tightening a fuel tank strap. Ensure you keep enough space between the tank and the van to connect the electrical connector and the fuel pressure hose to the fuel pump. Continue raising the tank until you can reconnect the fuel filler hose and vent hose. Once connected, attach the fuel filler neck to the body of the van. Slide the skid plates back into place and tighten the tank down to the van with the tank straps.

Next, reconnect the negative battery cable and install the fuel pump fuse. Turn the ignition on and inspect around the fuel tank for any leaking fuel. If none is found, the installation is done. However, if you do see fuel leaking from the tank, clean the area and tighten the fuel pump lock ring. If fuel is still leaking, the rubber O-ring will need to be replaced.

Frequently asked questions