1997 Plymouth Voyager Replace a Fuel Filter

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The fuel filter on your Voyager over time clogs up with dirt and rust particles that it filters from the gas in the tank. You should replace the fuel filter every 30,000 miles, as part of regularly scheduled maintenance. On the 97, Plymouth Voyager the fuel filter mounts on the top-side of the fuel tank. You can do the repair at home, but you should plan to spend at minimum of an hour doing it.

[edit] Tools Used

Tools
Relay-puller pliers
Socket wrench set
2 wheel blocks
Hydraulic jack
2 jack stands
Block of wood
Metal catch pan

[edit] Replace a Fuel Filter

  • Raise the hood on your Voyager and locate the power distribution center on the left side of the engine compartment. Remove the cover on the "PDC" and read the label inside of the cover to determine which of the relays operates the fuel pump. Remove the fuel pump relay with a pair of relay-pullers.
  • Remove the fuel cap, then start the engine and let it idle until it stalls. Make four additional attempts to start the engine, to depressurize the fuel system. Turn the ignition off.
  • Remove the negative cable from the battery with a socket wrench and then position the cable away from its post. The cable shouldn't be near any other metal or the engine.
  • Firmly place a wheel block in front of both front tires and then raise the van at the rear with a hydraulic jack. Place a jack stand on both sides, under the frame rail near the rear tires, to support the weight of the van. Slowly lower, the hydraulic jack until the van rest on both jack stands, then remove the hydraulic jack.
  • Place a block of wood on the jacking point of the hydraulic jack and then raise the jack until it makes contact with the fuel tank. Loosen each of the fuel tank strap's securing bolt six full turns with a socket wrench. Lower the hydraulic jack slowly to allow the slack in the straps to be taken up by the weight of the fuel tank. Do not, what ever you do, remove the hydraulic jack or let it drop below its support level of the fuel tank.
  • Locate the fuel filter; it will look like a mini octopus with only three legs--which are the fuel lines. Remove the retaining bolt holding the fuel filter in place and then carefully pull it toward you. The fuel lines on the filter itself don't come off now; you will have to disconnect the quick-connect fittings attached to the fuel filter's fuel lines.
  • Place a metal catch pan beneath the fuel filter and gas tank. Remove each of the three fuel lines from the filter by squeezing in the tabs on the quick-connect fitting while pulling the fuel line away from the fitting. Remove the lines one at a time to allow each of them to drain any remaining fuel into the catch pan. The fuel lines are three different sizes. This eliminates confusion when installing the new fuel filter. Once you remove the filter, set it in the catch pan.
  • Install the new fuel filter just as you removed the old fuel filter. Push each of the filter's quick-connect fittings together until you hear a click. Return the fuel filter into its mounting position and tighten its retaining bolt until snug, only.
  • Raise the fuel tank into its original position and then tighten each of the strap's bolts to 40 ft-lbs. with a torque wrench. Raise the van again to remove both jack stands then safely lower it back down. Remove both wheel blocks from the front tires and then place the gas cap back on securely. Install the fuel pump relay, then reconnect and secure the negative battery cable. Start the Voyager's engine and then check the fuel filter mounting area for leaks.

[edit] Tips & Warnings

  • Starting the engine after the repair may take a few attempts. This only has to do with the fuel system having low to no fuel pressure. Every time you attempt to start the engine, the fuel pressure builds and once high enough the engine will start just fine.
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