How to Install a Fuel Filter on a Voyager

A fuel filter ensures that clean fuel gets from the gas tank to the engine.

A fuel filter is an integral component in a car's fuel system. Contaminants in fuel can clog fuel injectors, and a clogged filter can put undue strain on the fuel pump. So it is important to have a properly functioning fuel filter. Many fuel filters are accessible right under the hood, but the later model Voyagers have their fuel filter at the gas tank, which requires more work and tools to access.

Things You'll Need

• Jack stands
• Wrenches
• Ratchet and socket set
• Pressure release hose tool
• Torque wrench to measure 40 inch-pounds
• Torque wrench to measure 40 foot-pounds
• Torque wrench to measure 250 inch-pounds
• Hydraulic auto jack
• Shop rags
• Gas container
• Safety goggles
• Gasoline-resistant gloves

Instructions

Relieve Pressure

1. Turn off the engine and open the hood. Disconnect the negative battery cable from the terminal.

2. Remove the fuel tank filler cap.

3. Remove the fuel pressure test port cap. The cap is located on the fuel rail just above the intake manifold. You should also see the manifold pressure sensor and the engine coolant temperature sensor nearby.

4. Place one end of the fuel pressure release hose tool into a gasoline container.

5. Place a shop towel under the fuel pressure test port and connect the other end of the fuel pressure release hose tool to the test port.

6. Replace the test port cap once the fuel system pressure is released.

Remove Filter

1. Lift the vehicle with an automotive list or hoist if available. If a full vehicle lift is not available, jack the car and then support it with jack stands. Support the fuel tank with a hydraulic jack.

2. Remove the fuel line from the front of the fuel tank.

3. Remove the fuel tank ground strap.

4. Remove the inboard side of the fuel tank straps and remove the front T-strap fastener.

5. Lower the fuel tank about 6 inches.

6. Remove the fuel lines from the fuel pump module.

7. Unscrew the fuel filter bolts and remove the filter.

Install Filter

1. Install the fuel filter and torque the installation bolts to 40 inch-pounds.

2. Reinstall the fuel lines to the fuel pump module.

3. Raise the fuel tank to its original position and tighten the front T-strap fastener on the fuel tank to 250 inch-pounds. Torque the inboard sides of the main fuel tank straps to 40 foot-pounds.

4. Reinstall the fuel tank ground strap and the fuel line to the front of the tank.

5. Reconnect the negative battery cable.

6. Replace the fuel filler cap and start the engine. Check the fuel filter and fuel line for leaks.

Tips & Warnings

• The safest way to perform this job is to raise the vehicle with an automotive lift, not jack stands.

• Always work on an automotive fuel system in a well-ventilated area. Make sure there are no sparks or open flames of any kind nearby.

• Wear goggles to protect your eyes and gasoline-resistant gloves to protect your skin.

References

• AutoZone: Caravan, Grand Voyager, Autozone: Caravan, Grand Voyager, Town and Country, Voyager, 2000-2004 Repair Guide, Relieving Fuel System Pressure
• AutoZone: Caravan, Grand Voyager, Autozone: Caravan, Grand Voyager, Town and Country, Voyager, 2000-2004 Repair Guide, Fuel Filter Removal and Installation
• Family Car Parts: Fuel System