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This repair was done on a V6-powered minivan, but most cars will have a similar process.
by Ron Wirth. Also see the main minivan repairs section.
Gus Causbie wrote: “The cause of failing electric in-tank fuel pumps in minivans is often the loss of good ground contact. This increases the amperage to the pump and burns out the motor. The solution to this is the addition of another separate ground wire. This I learned from my independent mechanic at Ivie's Auto Repair. Since this modification I've burned out no more fuel pumps. Also, according to him, the after-market pumps do not last. He insisted on a genuine MoPar pump even though the cost was considerably greater.”
I change the Caravan in-tank fuel pumps by first making sure the tank is full, then I carefully cut through the floor pan just above, and centered over the fuel pump mounting position on the tank, using a Moto tool cutting disc, being careful not to cut too deeply and damage the rubber fuel lines below the area. Don't use a reciprocating saw. And, of course, don't use the grinder either if you smell gasoline anywhere around the tank area. I advise doing job on level ground.
The section, approximately 6" x 6" is then discarded and replaced with a fabricated, overlapping steel panel, that gets sealed and screwed down over the service port. Changing the fuel pump then becomes a piece of cake, with little or no danger of exploding fumes, like one would encounter taking the tank out of the vehicle. The in place, full tank, produces very little fumes from the small surface exposed through the fuel pump mounting portal, making the whole procedure far safer and much quicker than the traditional tank removal. (I did the latter twice before coming up with the floor access method.)
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