This is how I replaced the lift pump on my ’99 QC, 4×4. Not sure what variations may or may not accure on other models.
Parts list…………..New lift pump, lift pump wire pig tail, banjo bolts washers (8), dielectric grease and approx 1/2 gallon of clean diesel.
Tools ………. 3/8″ drive ratchet, 3 or 4 6″ long ratchet extensions, 10mm socket, 11mm socket, 1/2″ socket, 7/16″ socket, 19mm combination wrench and a 3/8″ “swivel”.
Basically what I did was remove the Fuel filter housing and then the Lift pump, installing the new Lift pump and then the Fuel filter housing.
First I disconnected the “water in fuel” electrical connection from the bottom of the Fuel Filter canister. Next was the electrical connection that comes out of the top of the Fuel Filter housing (not sure what it does), then disconnecting the Lift pump electrical lead that comes from the bottom of the lift pump.
Using the 19mm combination wrench I loosened all the Lift Pump (LP) inlet/outlet and Fuel Filter Housing (FFH) inlet/outlet banjo fittings (mine are Geno’s large port items) and removed the FFH inlet/outlet ones and the LP inlet along with all 8 banjo bolt seal washers. I left the LP outlet fuel line in place on the LP to use as a handle to hold the LP up when unbolting from bracket. Set these aside in a secure spot where they can’t be misplaced.
Next I unbolted the Fuel Filter Housing (FFH) from the engine by removing the two bolts on the to of the FFH bracket with a 10mm socket and the ratchet.
This opens up the Lift Pump (LP) for very easy access. The first item removed from the LP is a bolt that holds the Inlet fuel line in place, I used the 10mm socket and extensions. Next I used the 1/2″ socket, four 6″ long extensions and the “swivel” to removed the 3 nuts that hold the LP to the bracket. One of these bolts unscrewed from my LP and was left in the bracket after I removed the LP. I had to use a pair of “Vise Grips” to hold the bottom side of this stud in order to remove the nut on top.
I installed the new “pig tail” onto my new LP using dielectric grease on the connection and then installed the OUTLET fuel line using 2 new seal washers and the banjo bolt. Holding the fuel line I lowered the LP in place and installed all 3 nuts that hold the LP to the bracket. Using two new seal washers reinstall the INLET fuel line along with the bolt that holds this line onto the bracket.
Next is the FFH, if you need to replace the filter, now is a great time to do so by loosening the nut on top of the FFH and pulling the cannister off. Make sure the new “O” ring is installed, cover all “O” rings and gaskets with clean diesel and reinstall on the FFH. Do not over tighten.
Lower the FFH down and reattach to the engine bracket using the two bolts. Reinstall both the INLET and OUTLET fuel lines using new seal washers.
Tighten all Banjo bolts, all bracket bolts and make sure all electrical connections are put together firmly with dielectric grease.
I pulled the FFH outlet side port plug from the top of the FFH with the 11mm socket and ratchet and using a “Gatorade” bottle with a twist top, refilled the FFH with clean diesel thru this port.
Leaving the plug out I had my 7 yr old assistant watch as I cycled the new LP 3 times and tried to purge all the air from the system.
Holding our breath I cranked it. It started with no problems.
My old lift pump was the original LP, it held about 10 lbs of pressure at idle and 7 lbs at 2000 rpm.
The new LP holds almost 16 lbs at idle and above 14 lbs at 2000 rpm.
My pressure readings are taken POST filter from a 1/8″ NPT port in the top of my Geno’s banjo bolt.
If you have any questions………..feel free to ask. I don’t know much but am enjoying learning more and more about my “new” CTD.
