How to replace the fuel pump on a 1996-2002 Caravan, Voyager or Town and Country

This video provides helpful step- by- step tips in replacing the fuel pump on a 1996-2002 Dodge Caravan, Plymouth Voyager or Chrysler Town and Country. The occasional loss of power at highway speeds prompted the recent replacement of the fuel filter and pump on a 2000 Caravan. So far results look promising.

[@michaelkirkpatrick3026]

Already living this video from the start. Depressurization the fuel this way is so simple!

[@mostlymoparih5682]

I used this video three years ago to replace the original fuel pump that went bad after 150 thousand miles and the Delphi pump died after 13 thousand miles and I figured it was because it was made in China so I bought a Carter pump this time and it too is made in China. For someone who needs this video today I thought I would let them know that the new pumps are being made without an external filter ore screen. The Carter pump has an internal screen and I found that out by calling Carter on their help line. They also have two black rubber plugs on near the blue fuel pickup that are bumpers and are there to prevent vibration between the pump and the bottom of the tank. Van is up and running again. Thanks again for a great video. Happy Motoring.

[@user-xk1nk1un5l]

Best and simplest video for accomplishing this task! Thanks!

[@Giltweasel]

Thank you for the video. It's about 5 Xs clearer on this pump replacement than the others on youtube.

[@TheOriginalMechanic]

You're welcome. Thanks for watching and I really appreciate the comment!

[@LANACHAPEL]

Thank you again for sharing your knowledge!! Your video is a godsend! Saved us lots of time and money again! Bless you!

[@guestguide2544]

After cleaning the big top ring lock nut, you can spray silicon lubricant on threads or put silicon grease or dielectric grease on thread of ring. If you have to change it again it will be much easier to get off. Sometimes those rings, on an old vehicle that's never had pump replaced can be very very hard to get ring off.

[@randyh.1073]

Thank you this video helped me so much I was able to do the job right the first time plus it saved me $600 I'm so subscribing

[@TheOriginalMechanic]

Thanks for watching and I'm so glad it helped.

[@poohbearkt23]

This absolutely worked thank you very much my gauge works now and its now shutting down the van every mile. Hopefully the van stays together a little longer till some prices go down!!!

[@jerrynorflet2292]

Excellent video, I'm about to get started on this process. I appreciate the time and effort it must have taken to do this video. I have tried and it always ends up being still photos and a write up. Thanks, Jerry

[@TheOriginalMechanic]

You're welcome. I appreciate your understanding of some of the challenges of making these tutorial videos. Good luck with your pump replacement.

[@rawfoodphilosophy7061]

great job.....very thorough!!!! you saved a lot of people ALOT of money!!!!!!

[@philwarner6604]

Thanks for your video and especially the clear instructions on releasing the electrical connector. I needed to remove the fuel pump from our 1999 Grand Voyager Sport (I thought) because it would crank but not fire with a 1/4 tank of gas (I thought) and there was no pressure at the fuel rail. However, after getting the pump out and testing it in a pan of gasoline it would achieve 70 PSI deadheaded so I put it back in and while wiggling the return line on, the little plastic bib snapped off, so I would recommend some Vaseline or lube on the fuel line connectors when installing them. A new fuel pump may not be as brittle as my 22 year old one, but it is still worth being careful. BTW, when I put the pump unit back in, the gas gauge then read empty and the fuel light was on, so if you can hear your fuel pump run on prime but do not have fuel pressure, do not necessarily believe the fuel gauge and try adding some gas just to see if that helps. I tried to repair my fuel pump return bib and I can report that Loctite super glue and JB Weld Plastic Bonder will not stand up to gasoline (the gas that I added) and will leak as soon as the engine starts. So here I am awaiting a new fuel pump that I apparently did not need and thinking back to that Oh C__P moment that turned out to be a $70 and two days wriggling under the van on gravel mistake. I was surprised that your van started so quickly with an empty fuel pump body; I had to prime mine 25 times before it built up enough pressure to start, But thanks again for the video - it was a big help.

[@TheOriginalMechanic]

Wow, what a tough situation. When these vans reach this stage of life even simple repairs can go bad fast. I've been there, right up to the end at the scrap yard.

[@trshev]

Thanks for the help! Again. Just finished pulling pump and filter. My experience went much smoother than yours. Connections came right apart, bolts all came out smoothly. Just waiting on the replacement parts to come in. Garage wanted $700 plus towing. Parts are less than $100! 😊 Thanks!

[@zerodineromechanic8777]

The thought of removing a fuel pump on any fuel injection vehicle can cause many a FML moment, but I followed this excellent video step-by-step and the fuel pump was a sinch to remove. It took longer to put the car on blocks and stands than it did to remove the pump.Unfortunately for me, the plastic fuel pipes poking out of the fuel pump were so brittle, I accidentally broke both of them of whilst removing the power connector. This was a double pain as I only wanted to replace the pump and not the whole unit, so beware of brittle plastic on older cars. Oh, and I also used the rubber strap wrench, which I got for about five dollars, and it worked a treat.

[@rogerd4559]

Can you please tell me where I can get that rubber strap wrench? Five dollars is a great deal. Im afraid I will be cheated into paying much more

[@williamhaskellhaskell3162]

It comes as a whole unit pump and guage. Right? I'm doing my 98 voyager today. Bill

[@everymanforthemself]

Thanks, using this vid to work on 2006 Town and Country. Only problem is how to remove the locking mechanism. Chrysler genius's changed to difficult metal lock that needs brass punch to remove by pounding on it with hammer. Stupid but probably more safe.

[@roccit]

Awesome video, thanks for putting this together!! Subscribing!

[@76markez76]

another thanks a million video! and $58 is better than the $180 they trying to self off shelf

[@TheOriginalMechanic]

You're welcome. I was impressed with both the price and quality of this pump.

[@lillianmoore6007]

david that was awsome . best vidio iv seen with no hokee hipe. great job. wish u were here to help me with mine..... i need my exahaust welded to the muffler but ii hav no tools. im a female hairdresser. thanks for showing me how its done so the mechanics dont rake me over the coals for. cash......

[@eddiesantos574]

Great video! Thanks for sharing it!

[@TheOriginalMechanic]

You're welcome. Thanks for watching and for the feedback.

[@jasonlopez4855]

I'm glad I don't have to deal with rusty bolt 🔩 good video

[@lestypes]

beautiful video 👌

[@lokeycarter6679]

Great Job!! Thanks 👍

[@RMNPBETA]

Thanks for the video. Great help in guiding me through this $400 repair turning it into $120. Pretty much everything went according to plan except my electrical didn't disconnect easily and I had to force it out. Also both of my fuel lines broke off the old unit so retrieving the plastic connector pieces was a bit unexpected. Note: I just used a tiny Allen wrench instead of a tooth scraper to unlock electrical unit. Overall informative and with a little tinkering one should figure this fix pretty easily.

[@TheOriginalMechanic]

You're welcome and thanks for sharing your experiences with this replacement.

[@rogerd4559]

thanks I have plenty of tiney allen wrenches but tooth scrapers are rare and hard to find

[@vitaliyberlov4629]

Thank you . Well done.

[@richardgardner5568]

I used this video for my fuel pump and filter replacement. A few comments: The Dodge red tab electrical connector was my biggest challenge (never used one before), and is covered twice in the video (the second time is clearer). After first failing under the vehicle, I then practiced on the more accessible similar connector on the distributor. Work access is from the passenger side if that affects how you position the vehicle. Note your fuel level before starting to check how the new sensor compares (my old was 1/4, after 3/8). Take care you don't cross-thread the pump going in, and don't pinch the gasket. I had to kick the tank a couple of times to get it aligned (half inch off) to get the strap bolts back in. My tool list: Jack and 4 jack stands, strap wrench (6" Dia), 10mm (1xfilter) and 15mm (4xtank strap) sockets, ratchet wrench, persuader/breaker bar, socket extensions, fuel line disconnect tool (optional), needle nose pliers, creeper, flashlight.

[@TheOriginalMechanic]

Thanks for sharing your detailed and helpful comments!

[@rogerd4559]

that red locking tab is used all over the van I had one on the radiator fan relay that I had to pry the connector apart before I could figure out how it worked on the new replacement connector that came with the relay

[@jbodden6977]

I knew one guy who got fed up with this routine and removed the rear seats and cut a hole in the floor so he could easily reach the fuel pump.

[@TheOriginalMechanic]

Now that's extreme and kind of funny.

[@mostlymoparih5682]

Good video.

[@LyricsNinyo]

Do you have a link where I can get the replacement?

[@DM-pv1ql]

A tip For this work Make sure alignment whit the small plastic ranures ... They help assure the pump don't move of the correct position when you spin the nut. Sorry if I have something sintax or orthographic fails. I don't speak English. But I hope will help you. Have a good day.

[@wcjcnc]

I bought a pump for my van but it doesn’t have the pick up tube and filter on it and there’s nowhere to put one. There’s no where for it to suck up fuel?

[@williamhaskellhaskell3162]

Will my 98 voyager be the same? What of the pipe joint between the filler pipe and tank. ? Remove it or loosen clamps? Thanks. Bill

[@andrewlabat9963]

Thanks.. all the info and nothing more.. gonna be changing out my neighbors one..

[@TheOriginalMechanic]

You're welcome. Thanks for watching and good luck with job.

[@lillianmoore6007]

more ....more two thumbs up man.

[@matthewleslie1008]

I just finished the process. My fuel pump was on/off but it still started. Now that ive replaced it, it wont turn over. I have to leave tomorrow too. Yikes! Any advice on the process of elimination to discover why its now not turning over even though I just replaced it and the old one was working but poorly. This would be a huge help as I have to figure it out before tomorrow noon.

[@Jose_Altuve_]

Excellent video ......My 2001 Chrysler T&C Van has a symptom pointing to Gas Pump and I wanted to know how to replace it in case it is failing

[@lashaunazurdia7035]

Thanks for the video I am going to change my filter this weekend.... Do I need the mesh filter, because the filter I brought does not have one?..

[@TheOriginalMechanic]

I don't know if it matters. I would double check with the store that it is the right one though.

[@kentmcbride8699]

Thank you for the great video. QUESTION please anyone - I can't get the red locking lever/slide to move to the lock position. I noticed on the video you had a problem as well but did not say how you fixed it. Does anyone know? Thank you.

[@jbodden6977]

weld a large nut onto that jack, a ratchet then makes easy work of raising and lowering.

[@annkruml]

This is a great video. Tank you for making this video. Question: I had a brand new fuel pump and fuel filter put on mine and it's not turning over. We are putting spark plugs on if that does not work what do you think it could possibly be the reason why is not turning over?

[@TheOriginalMechanic]

So many possibilities. Check the basics. You need spark and gas together at the plugs. I would check for fuel right there. Pull a plug and crank it and look (and smell) for gas. If that's there, check for spark. They ,make inexpensive test tools for that. Good luck and thanks for watching the video.

[@rogerd4559]

what does that mean its not turning over its not cranking at all? or the engine is not starting the engine starts but does not continue to run? the fuel pump is not turning over?

[@secundariafederal9951]

thank you bro....

[@TheOriginalMechanic]

You're welcome

[@damienmckenna8774]

Anyone have any issues after install with the fuel lines emptying? Should I replace my filter for new fuel lines but the old one isn't leaking I'm confused

[@rogerd4559]

@@jgrillo4841 ah yes maybe it needs to be primed If you look closely the old pump has fuel inside it like a reserviour

[@juanvillareal9610]

Muy bueno...

[@biosmoney]

I used the fuel filter video to replace the fuel filter. In doing so I broke both fuel connectors at the pump. This video helped me finish replacing both. I would've never tried this without your video. Thank you so much.The engine still cuts out at highway speeds. Now what? Any ideas?

[@Eeropolvasti]

I noticed those 2 clips for fuel lines did not lock ....in the end??? Are they leaking now??

[@TheOriginalMechanic]

They did not leak although the van developed problems a year later and now resides in the junkyard.

[@titolindj]

Thank you... great video, I'll be replacing both the pump and the filter tomorrow. I'm trying to figure how to drain the tank at least a bit, I think its about half full. Any ideas? Also, how high did you lift the van? a pair of ramps on the back will be enough? Thanks !

[@TheOriginalMechanic]

You're welcome. You would have to siphon the gas with a pump. I did the job on ramps.

[@titolindj]

Just finished both !! I might have to lower the tank again, because the retainer ring was broken, I could not find one locally so I ordered one, and "Franken patch" the old one meanwhile. Thank you again, great tips !! (That stupid connector sucks !!)

[@TheOriginalMechanic]

I agree about the connector. You're welcome.

[@rogerd4559]

I have an idea.drive the car until the gage says nearly empty, then do the work. unfortunatly my gas guage isnt working so I need to carry a 5 gallon can of gas around

[@tinytim9453]

@@rogerd4559 Me too, lol. my guage hasn't worked in 2 years and now the pump seems to be getting weaker especially on cold mornings. Gonna test the pressure next time it gets cold.

[@fvrrljr]

HAHAHAHAHA OK I see that you're also great at Editing Video. same footage from your fuel filter video posted 7 days apart. When you changed the fuel filter you should have changed the pump. maybe you did or maybe pump went out 7 days later. The World May Never Know... unless you tell us. But The Video Editing is Thumbs Up! i Like, OLE!

[@manze8344]

I thought I had the same problem because my van had no fuel pressure, I check the fuse, check the relay those two things were fine so my next guess was the fuel pump I replace it everything went fine but I still have no fuel pressure any thoughts?

[@TheOriginalMechanic]

If the pump is running there must be a gas line blockage somewhere. If the pump is not running there may a pump cut-off keeping it from running.

[@rogerd4559]

@@TheOriginalMechanic does the pump need to be primed first?

[@ubermenschmexa]

Hello! I just have a question, the sending unit is a part of the fuel pump? I have a problem with the gauge of my Caravan '96 not reading correctly. Must I replace the whole pump or is the sending unit a different thing? And how do I access it?

[@TheOriginalMechanic]

Yes, the sending unit is built into the fuel pump. It must be replaced as an assembly.

[@rogerd4559]

as far as I can see in the video and other videos, the sending unit is mouted integrally on the side of the pump housing so with a new pump you get the sending unit but in the video, you must transfer the old rod and float to the new unit

[@NoneMechanic101]

Great video

[@carlosventuramoralesarce4627]

Hi ! Can You tell me please, what's name from special red tool ?

[@TheOriginalMechanic]

Oh, that's a strap wrench. You should be able to find one at any hardware, Lowes or other home improvement big box or auto parts store.

[@user-wy1gr9qu1j]

I made pressure gadge out of old 12 air gadge hose and compressor gadge

[@exavierdotnet]

Would this be the same process on a 1993 dodge GRAN Caravan. ..???

[@TheOriginalMechanic]

No it isn't

[@rogerpowell23]

What size strap wrench is this? Or what will fit for the job?

[@TheOriginalMechanic]

It's a medium-sized wrench, for diameters from around 7 to 20 inches.

[@TheOriginalMechanic]

Correction: that's the circumference.

[@gmrtech187]

Great video! What brand fuel pump? How many miles and how long did it last ? I'm going to change mine...a ton of fuel pump brands out there with bad reviews. Again great video!

[@TheOriginalMechanic]

It was just a cheap Amazon pump. It lasted for a couple of years until the van had to be junked for other reasons.

[@gmrtech187]

Two years is good for a cheap Amazon pump. What was the brand name of the pump?

[@TheOriginalMechanic]

@@gmrtech187 I don't know but Amazon is still selling it: www.amazon.com/dp/B016V3U69E/ref=as_sl_pc_qf_sp_asin_til?tag=theorigmech-20&linkCode=w00&linkId=c1c898920561b98002d18d9e2c004ce5&creativeASIN=B016V3U69E

[@johnnytodd9328]

great video everything went perfect with both the fuel filter and fuel pump but for some reason the fittings from the fuel filter leak like a sieve where they attach to the fuel pump, I bought new plastic sleeves for the inside put them on just like the video shows, the pump nipples are identical to the pump I replaced, so I am at my wits end trying to figure out why they leak, they go on and snap just like they should, they just don't seem to have any seal

[@TheOriginalMechanic]

The only thing I can think is that those sleeves you bought must be the wrong ones. My pump came with new sleeves. I would compare them with the originals.

[@johnnytodd9328]

thanks I bought another fuel filter and it snapped right on and didn't leak a drop.........the other filter fittings might have dropped an interior o-ring or something when I removed the plastic clips, when replacing the fuel pump ..........I watched another video that showed you don't need to remove the clips to push them down on the fuel pump nipple,

[@rogerd4559]

hmmm maybe you should check them for O rings or seals , could be some dumb ass that manufactured them didnt put them in? Oh wait these are your old fuel line fittings? in that case maybe the O rings inside dried up cracked and fell out when you disturbed them?

[@lashaunazurdia7035]

OK, I will thanks

[@williamhaskellhaskell3162]

Your pump has 3 wires and the van wire has 4?

[@socalmonk]

Bro, I felt bad watching you struggle with those quick connectors. Special tool, little split ferrule, wraps around the fuel line, slides inside the connector and spreads it. Slips right off.

[@TheOriginalMechanic]

Thanks for watching and adding the tip.

[@PCHERE]

HI, where did you get the special tool ? is there a special name for it when i ask for the tool ?

[@autwalla1]

socalmonk ppl

[@rogerd4559]

Yes please tell us where to get this tool or maybe post a picture of it if it can be hand made?

[@johnthrockmorton2678]

But, what if the sending unit WAS off? i.e. reading 1/8 tank when empty?

[@TheOriginalMechanic]

if the new one is off, you might have to send it back.

[@rolandcoon4088]

This is a great Video!! Can you please tell me where and the part number of the pump you ordered?

[@TheOriginalMechanic]

I found the pump on Amazon. I usually put the part number in the video.

[@christophersly3579]

I got the same 3 prong connector from amazon.. did your gas guage work for you w the amazon 3 prong pump??

[@mark9559]

good vid but its better to drop the hole tank down that way you get the pump in the right way also cant hurt to look in the tank and see if there is any think like dirt that is going to ruin your new pump

[@rogerd4559]

wont that screen filter stop any dirt?

[@gmrtech187]

There's many cheap online fuel pumps and they have very bad reviews. If you know the brand of a low cost fuel pump that is reliable for this vehicle please tell us the brand name. Thanks for the video!

[@alexrubio9804]

Where can I get a tool like that one u used to remove fuel pump

[@rogerd4559]

I want to know also

[@alexrubio9804]

@@rogerd4559 i ended up getting one one amazon for like $20.00 if you like. www.amazon.com/gp/product/B004FDL3BS/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8&psc=1

[@japsiperez4764]

Buen video pero un buen mecánico cuando cambia la bomba de gasolina igual cambia filtro y lava el tanque para evitar el mal funcionamiento por residuos en el tanque y no acortar la vida de la misma

[@jwells3315]

What about a vehicle this old cleaning the tank?

[@TheOriginalMechanic]

Wouldn't hurt I'm sure.

[@jerrykegel2678]

About to undertake the task of replacing fuel pump, 1996 original pump: let it be known, you must work from the passenger side to fulfill this task.

[@rogerd4559]

good tip thank you

[@virginiaflores3713]

My older neighbor says it's a two man job for him and another older man. They want to charge me $150. I looked online and saw that labor alone is $250+, so I figure it's better to let my neighbor do it.

[@smokestakz]

Virginia Flores good choice....not only did you save 100 on labor but you would've had to double your parts cost at the shop....every shop chRges at least double of the parts cost....that's why front disc breaks can cost up to 400 dollars...more than half that is parts.

[@alexaarchila3799]

"

[@Bigpoppi1469]

changed mine out on a 94 caravan & now it wont start. gauge reads empty. think its time for the junkyard crusher.

[@TheOriginalMechanic]

'94 is getting up there. I scrapped the 2000 in this video this past August.

[@williammartin1001]

Where is fuel pressure regulator on that van??

[@Alanderson1976]

William Martin I had that same question. My mechanic said it’s part of the fuel pump. Mines 96 grand caravan le 3.3L

[@user-wy1gr9qu1j]

Must prime pump manually

[@rogerd4559]

YIKES! did everyone see the pile of corrosion on those battery terminals

[@vegetablehead]

ok, i'm sure i need a new fuel pump. the fuel gauge on the dash stays on E, and i know there is gas in the tank. engine cranks and cranks but won't start. my main question is HOW DO I TEST THE FUEL PRESSURE? WHERE IS THE SCHRADER VALVE?! 2000 plymouth grand voyager 3.0 liter v6.

[@TheOriginalMechanic]

You need to get a gauge and find a port to attach it to.

[@smokestakz]

None of the relay pulling and running out the pressure is needed. Just fyi....disconnect the battery and get it done

[@forgeignchavez9032]

Vent line is stuck hard to move

[@georgethomashangliterjunio4643]

If you're not a cheapskate, do yourself a big favor and install a quality fuel pump such as the OEM Walbro or a Delphi.

[@wtfman5313]

I think you later this same video last week my friend.

[@TheOriginalMechanic]

Yeah, this one and the previous fuel filter video do share some clips, but they are different. I decided to make two stand-alone videos this time instead of a two part series. Thanks for watching and have a good one.

[@wtfman5313]

Oh shoot! I'm sorry. :)

[@rodneyalberta2020]

part number for new fuel pump

[@TheOriginalMechanic]

I used an aftermarket part I found on Amazon.

[@robertridder6543]

cut a HOLE in the floor. 10 min job

[@stevecobb76]

This is a fuel pump sssembly.. NOT A FUEL PUMP

[@RGE_Music]

thats how this pump is in this model of car

[@markdierker4292]

@@RGE_Music you can actually do it either way. not sure why you would just do the pump though other than to save a few bucks.

[@stomabag7127]

It's always a good idea to change the fuel filter also when replacing a fuel pump. Trump 2020

[@Eeropolvasti]

Fuck idiot Trump=)((((

[@rogerd4559]

yes my oppinion too! wish he did a video on changing the fuel filter as well

[@nandansho]

Dude your logic is wrong,You run the engine then pull the fuel relay. That way the engine consumes the fuel left in the lines. Pulling the relay and tuning over the engine, does not consume fuel. At best the injectors won't open, at worst the cylinders get flooded with fuel.