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Need instructions to replace fuel pump 1994 Caravan 3.8L

6 messages,  Last post on Feb 23, 2012 at 5:12 PM

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What is this discussion about? Dodge Caravan, Chrysler Voyager, Plymouth Voyager, Auto Repair, Van

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#1 of 6 Need instructions to replace fuel pump 1994 Caravan 3.8L by johnhubertz

Dec 17, 2009 (9:15 am)

I need to remove and replace the fuel pump on my beloved AWD 1994 Caravan
 
Vehicle runs well for about 10-20 minutes, then begins to sputter, then stalls,
 
restarts after 15 minutes - i think my pump is overheating
 
Questions:
 
1. Anyone have the shop manual on PDF or that they can link me to?
 
2. If it is pretty basic - I just need step by step instructions
 
3. If it is a tough tank to drop, can I cut an access hole inside the van or would this be dumb to do?
 
John H
Ft Wayne Indiana

#2 of 6 Re: Need instructions to replace fuel pump 1994 Caravan 3.8L [johnhubertz] by shipo

Dec 17, 2009 (10:02 am)

Replying to: johnhubertz (Dec 17, 2009 9:15 am)
I think that before I went through the aggravation of dropping the tank I'd get some confirmation that the pump was indeed the problem. Have you put a pressure gauge on the fuel rail yet to confirm that pressure is in fact dropping after the engine warms up?

#3 of 6 Re: Need instructions to replace fuel pump 1994 Caravan 3.8L [johnhubertz] by reon

Dec 17, 2009 (3:01 pm)

Replying to: johnhubertz (Dec 17, 2009 9:15 am)
I replaced my my fuel pump in my 1994 Caravan by cutting a hole in the floor pan.
 
The metal is pretty thin and I had no trouble using sheet metal airplane snips.
 
I used a piece of sheet metal to cover the hole and sealed the edges.
 
Start with a small hole where you think the pump is and enlarge it carefully so you don't damage the fuel lines running across the top of the tank.
 
Disconnect the battery before starting the job. Took me 2 hours to do, I probably can do the whole job now in 20 minutes.

#4 of 6 Re: Need instructions to replace fuel pump 1994 Caravan 3.8L [reon] by xwesx

Dec 17, 2009 (7:21 pm)

Replying to: reon (Dec 17, 2009 3:01 pm)
Compared with dropping the tank, that sounds like a very fine plan!

#5 of 6 Re: Need instructions to replace fuel pump 1994 Caravan 3.8L [reon] by hamrt

Feb 23, 2012 (4:24 pm)

Replying to: reon (Dec 17, 2009 3:01 pm)
Cutting a hole in the floor where you think the pump may be located? That sounds like a crazy idea and could create even more problems. I think it best to stick with dropping the tank.

#6 of 6 Re: Need instructions to replace fuel pump 1994 Caravan 3.8L [hamrt] by reon

Feb 23, 2012 (5:12 pm)

Replying to: hamrt (Feb 23, 2012 4:24 pm)
You must be a car repair station.
 
I haven't had a seconds worth of problems since I did the job.
 
I would do it again in a heart beat. Saved time, saved aggravation, saved money too.

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