1992 3.0L Caravan SE, won't start (fuel?!)



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Thread: 1992 3.0L Caravan SE, won't start (fuel?!)

  1. #1
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    1992 3.0L Caravan SE, won't start (fuel?!)

    Came home yesterday and parked the van. Came out today hopped in and it cranked just fine, just no start :-(.

    Checked the spark, got spark from coil and to plugs.

    With all the cranking, no smell of raw gas at the tailpipe.

    No error codes read off the check engine light (Other than 55: end of diagnostics).

    Suspect bad fuel pump.

    Looked in the manual and it is in the gas tank(!) so I guess that lets me out of dealing with it myself. It is in a basement garage and has almost a full tank.

    So, it looks like it goes to the shop (getting it there should be exciting).

    Any ideas as to what I can expect this to cost?

    Thanks & take care, Chris.
    1992 Dodge Grand Caravan SE (2nd Gen)
    3.0L V6 SFI SOHC 12V - 3 speed automatic
    Aprox. 132000 miles.
    Pictures of my pet :-)

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    There's a number of things that could cause this, but since the computer isn't throwing a code, it most likely is the fuel pump.

    If it IS the fuel pump, I remember reading something about pulling up the carpet in the rear and CAREFULLY cutting an access port through the floor that greatly simplifies the fuel pump replacement process, now and in the future. You'd then fabricate a cover that you attach with a few sheet metal screws and some sort of gasket under it.

    This procedure was for the 1st-gens, but I'm pretty sure it's applicable to the 2nd-gens as well. Someone can probably provide measurements so you know exactly where to cut, and how big. Be careful cutting the hole, since the gas tank IS right under it.
    "Ahab knew, baby...I lust." -- Vet-san

    1990 Dodge Caravan SE, 3.0L 3-speed, 130,000 miles
    1995 Plymouth Neon, 2.0L SOHC base model, 134,000 miles
    2004 Honda Element EX, 70,000 miles

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    Quote Originally Posted by arex View Post
    There's a number of things that could cause this, but since the computer isn't throwing a code, it most likely is the fuel pump.

    If it IS the fuel pump, I remember reading something about pulling up the carpet in the rear and CAREFULLY cutting an access port through the floor that greatly simplifies the fuel pump replacement process, now and in the future. You'd then fabricate a cover that you attach with a few sheet metal screws and some sort of gasket under it.

    This procedure was for the 1st-gens, but I'm pretty sure it's applicable to the 2nd-gens as well. Someone can probably provide measurements so you know exactly where to cut, and how big. Be careful cutting the hole, since the gas tank IS right under it.
    Thanks for the reply! Would love to give that a go.

    Problem is that I don't have any place to work on it. The basement here screwing around with 20 gals of gas (of course it would happen just after fillup :-) ) with all the buildings electrical stuff down there it sounds like a great way to understand a fuel-air explosion from the inside. Not to mention management having heart failure to see anyone with so much as a screwdriver down there.

    Called our mechanic, he can't get to it until middle of next week as he is buried at the moment.

    I suspect it is going to be a shock...
    1992 Dodge Grand Caravan SE (2nd Gen)
    3.0L V6 SFI SOHC 12V - 3 speed automatic
    Aprox. 132000 miles.
    Pictures of my pet :-)

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    Quote Originally Posted by arex View Post
    There's a number of things that could cause this, but since the computer isn't throwing a code, it most likely is the fuel pump.

    If it IS the fuel pump, I remember reading something about pulling up the carpet in the rear and CAREFULLY cutting an access port through the floor that greatly simplifies the fuel pump replacement process, now and in the future. You'd then fabricate a cover that you attach with a few sheet metal screws and some sort of gasket under it.

    This procedure was for the 1st-gens, but I'm pretty sure it's applicable to the 2nd-gens as well. Someone can probably provide measurements so you know exactly where to cut, and how big. Be careful cutting the hole, since the gas tank IS right under it.
    That is extremely unwise!!!!!!!!!

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    Quote Originally Posted by idkanything View Post
    That is extremely unwise!!!!!!!!!
    Perhaps, but... http://www.dodgetalk.com/forums/show...ht=access+door
    "Ahab knew, baby...I lust." -- Vet-san

    1990 Dodge Caravan SE, 3.0L 3-speed, 130,000 miles
    1995 Plymouth Neon, 2.0L SOHC base model, 134,000 miles
    2004 Honda Element EX, 70,000 miles

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    Quote Originally Posted by arex View Post
    I did do this a couple of years ago with no problem. I used my air hammer with a metal cutting chisel on it so it didn't cut deep. It worked perfectly and after cutting the hole I discovered that the solid fuel line had a splice in it in another spot. Needless to say I had to remove the tank to get to that coupling. Then I discovered that with the twist and pull method to remove the pump, could not have taken place through the hole because there wasn't sufficient space. So I suggest you look at it real good before cutting the hole. Patching it was the easiest part. I hope this helps.
    2000 Caravan 3 L. 17-20 MPG. 134,000 klm. New tranny at 97 K. Tires are P205 70R14 Bridgstone M+S. 123,800 KM. replaced tensioner pulley, serpentine belt, and power steering pulley.
    Old reliable - 1982 Dodge Ram Long Box 318 Auto 3 speed transmission 66 K.

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    that sure was a waste of time and hacking up a vehicle vs. just doing it right. Really how many times are you planning on replacing a fuel pump. once or twice tops? Get real. Do the job right once then you don't have some cobbled pile.

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    Also notice, in that DodgeTalk article, the guy was talking about removing the tank first and taking far away from the work area.

    Yes, it can be done, other car forums have discussions on the same topic. However, anything that COULD generate any sparks in the vicinity of a gas tank (full of fuel or, worse, full of fumes) is not a good idea. Either figure out a way to drop the tank, or have a professional do it.
    I feel more like I do now than I did when I got here.
    '92 PGV SE 3.3 4spd auto 178,000 miles
    '05 Dodge Caravan SXT 3.3 4 spd auto 80,000 miles

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    Fuse????

    Several people have asked if I checked the fuse. Makes sense, we got electrical stuff in the fuel tank, it would be fused, right?

    Looked in every manual I have (including the Dodge Shop Manual) and nothing points to a fuel pump fuse?!?

    Am I just missing something or is there no fuse on this thing!?!?

    Thanks much in advance.
    1992 Dodge Grand Caravan SE (2nd Gen)
    3.0L V6 SFI SOHC 12V - 3 speed automatic
    Aprox. 132000 miles.
    Pictures of my pet :-)

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    Have you replaced the fuel filter? It would really suck to drop the tank or pay to have the tank dropped when it was just the fuel filter. You can check the filter by removing it and turning the ignition on to see if you get fuel. Two warnings I give you, one is that removing the filter you might get sprayed because the fuel might be under pressure. Two is that IF the pump is working, it's going to spray fuel when you turn the key on. You should have someone in the driver's seat turning the key as you watch. Also, you'll probably need to buy tank straps, bolts and the recepticles or anchor nuts (the clips the bolts thread in to). When I changed mine, I had to cut my straps because the hardware was rusty and I snapped one of the clips. Had to use vise grips once the tank was clear. I used regular nuts with lock washers and a wrench when I put the tank up. I agree with IDKANYTHING, do the job right. You only get one shot at cutting the floor right and not hitting the tank. With a floor jack, a piece of wood (prefferably a 1X8 the width of the tank), and some tin snips you could have the tank down in 5 minutes. Oh by the way, there might be a check ball at the bottom of the filler so siphoning the tank through the filler is out.
    Luis Q.
    US Marines (1995-2003)
    83 Fifth Avenue, 85 Diplomat (Police Interceptor),
    95 Voyager 3.0L, 95 Impala SS, 99 Yukon
    Past Mopars
    99 Plymouth Neon SOHC, 02 Intrepid SE 2.7L, 02 Grand Cherokee 4.0L, 96 Caravan 2.4L

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