Dodge 24V Cummins Lift Pump Replacement

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.

1. Lay a non-conducting material over the battery posts (fender cover, etc)
2. Make sure you have the new pump and eight banjo washers
3. Remove the two banjo bolts from top of the fuel filter housing using a 17 mm wrench
4. Remove the old banjo washers from the fittings
5. Disconnect the water in fuel sensor at the bottom of the fuel filter housing
6. Disconnect the fuel filter heater element plug at top of the filter housing
7. Remove the drain tube from the bottom of the filter housing drain
8. Remove the two manifold bolts holding the filter housing to the intake manifold
9. Remove the entire filter housing being careful not to drain the fuel from it
10. Remove the banjo bolt holding the solid fuel line that goes the inlet of the filter housing using a 17 mm wrench
11. Remove the banjo bolt on the suction side of the lift pump
12. Remove the 10 mm bolt holding the suction line to the pump bracket
13. Unplug the electrical connector to the lift pump
14. Remove the three nuts holding the lift pump in place
15. Remove the lift pump
16. Install the new pump and the two back nuts loosely just to hold the pump in place
17. Install a new banjo washer on the suction bolt
18. Install the bolt in the suction fitting and install another washer on the bolt
19. Thread the bolt into the pump suction while the two nuts are loose on the pump
20. Connect the power to the pump
21. Install the cable support and the third nut on the pump bracket
22. Tighten the pump suction banjo bolt, and the three nuts holding the pump in place
23. Tighten the bolt holding the suction hose in place
24. Install a washer on the pump discharge banjo bolt
25. Install the bolt in the discharge tubing and install another washer
26. Install the discharge to the pump but do not tighten
27. Set the fuel filter housing back in place with the two manifold bolts but do not tighten
28. Install a washer on the filter inlet banjo bolt
29. Install the bolt far enough to get another washer on the other side and thread the bolt into the filter inlet
30. Install a washer on the filter outlet banjo bolt
31. Install the outlet banjo bolt in the outlet tubing and install another washer on the other side
32. Thread the outlet bolt into the filter housing
33. Tighten to two filter housing intake manifold bolts
34. Tighten the two 17 mm inlet and outlet bolts on top of the housing
35. Tighten the 17 mm bolt on the discharge of the lift pump
36. Connect the fuel grid heater wiring at the top of the housing
37. Connect the fuel in water wiring to the bottom of the housing
38. Install the plastic housing drain tube
39. Loosen the inner or outer plug on top of the housing with a 7/16 socket
40. Bump the key like you are going to start the truck and bleed the system (may need to do this several times)
41. Do a double check and make sure everything is tight and there are no leaks
Drain the filter housing and watch to keep diesel off starter. Disconnect power to pump, located on bottom.

Deano Kothe procedures for 1999 Ram

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.

Procedures for a 2000 Ram

To make the removal and installation easy take the 2 bolts(10mm) that hold the filter housing loose and moved the housing to the side, this makes it easier to get at the pump.

Then removed the 3 bolts(1/2) that hold pump to pump bracket,then removed one more bolt(10mm)that holds the supply line to the pump. With this being done you can move the pump around to finish removal easier.

Then remove the banjo bolt(11/16) that holds the supply line to the pump, be careful to get both washers.

On the opposite side of the pump coming from the filter housing is the last of the hoses, I opted to take the black hose off the pump, leaving the banjo bolt and fitting on pump.

Pull the old pump and clean all parts that will be reused(banjo bolts).

Attach banjo to the “out” side of pump with new washers and leave a little loose, Attach supply side banjo bolt to pump with new washers also, tighten up to specs.

Slide the new pump in and bolt all 3 nuts down tight, watch for clearance on “out” side against pump bracket.

Tighten down “out” side of pump to spec now.

Replace bolt that holds supply line to pump bracket and tighten.

Now you can attach power to the pump and clean up your mess, and yes you will have one .

Start it just like you would after filter install, might sputter for a second.

Cummins Lift Pump part #3990105
Price: $145.00
No special tools needed.

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