Procedures for a 1999 Ram
NOTE: You may be able to improve this but this is exactly what we did and changed two pumps in less that two hours)
TOOLS: 17 mm wrench & socket, 10 mm wrench & socket, 7/16 socket, 1/2 inch socket.
- Lay a non-conducting material over the battery posts (fender cover, etc)
- Make sure you have the new pump and eight banjo washers
- Remove the two banjo bolts from top of the fuel filter housing using a 17 mm wrench
- Remove the old banjo washers from the fittings
- Disconnect the water in fuel sensor at the bottom of the fuel filter housing
- Disconnect the fuel filter heater element plug at top of the filter housing
- Remove the drain tube from the bottom of the filter housing drain
- Remove the two manifold bolts holding the filter housing to the intake manifold
- Remove the entire filter housing being careful not to drain the fuel from it
- Remove the banjo bolt holding the solid fuel line that goes the inlet of the filter housing using a 17 mm wrench
- Remove the banjo bolt on the suction side of the lift pump
- Remove the 10 mm bolt holding the suction line to the pump bracket
- Unplug the electrical connector to the lift pump
- Remove the three nuts holding the lift pump in place, � socket inch I believe
- Remove the lift pump
- Install the new pump and the two back nuts loosely just to hold the pump in place
- Install a new banjo washer on the suction bolt
- Install the bolt in the suction fitting and install another washer on the bolt
- Thread the bolt into the pump suction while the two nuts are loose on the pump
- Connect the power to the pump
- Install the cable support and the third nut on the pump bracket
- Tighten the pump suction banjo bolt, and the three nuts holding the pump in place
- Tighten the bolt holding the suction hose in place
- Install a washer on the pump discharge banjo bolt
- Install the bolt in the discharge tubing and install another washer
- Install the discharge to the pump but do not tighten
- Set the fuel filter housing back in place with the two manifold bolts but do not tighten
- Install a washer on the filter inlet banjo bolt
- Install the bolt far enough to get another washer on the other side and thread the bolt into the filter inlet
- Install a washer on the filter outlet banjo bolt
- Install the outlet banjo bolt in the outlet tubing and install another washer on the other side
- Thread the outlet bolt into the filter housing
- Tighten to two filter housing intake manifold bolts
- Tighten the two 17 mm inlet and outlet bolts on top of the housing
- Tighten the 17 mm bolt on the discharge of the lift pump
- Connect the fuel grid heater wiring at the top of the housing
- Connect the fuel in water wiring to the bottom of the housing
- Install the plastic housing drain tube
- Loosen the inner or outer plug on top of the housing with a 7/16 socket
- Bump the key like you are going to start the truck and bleed the system (may need to do this several times)
- Do a double check and make sure everything is tight and there are no leaks
