Fuel Pump install how to (gone wrong)
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More Turbo
Joined: Dec 2003
Posts: 571
Likes: 4
From: hondo
Fuel Pump install how to (gone wrong)
Alright gentlemen,
If you read my last post you will see that I'm not a very smart guy. So as I mentioned I broke the stud to the black wire. Now I have a new fuel pump that I can't use. Was wondering if this has every happened to anyone and if there is a fix. It looked Like I could remove the broken stud but when I place in my vice and tried to remove it would not budge. I still have the old pump and it works so I can just put it back.
Have a Happy Fourth
Gilbert
If you read my last post you will see that I'm not a very smart guy. So as I mentioned I broke the stud to the black wire. Now I have a new fuel pump that I can't use. Was wondering if this has every happened to anyone and if there is a fix. It looked Like I could remove the broken stud but when I place in my vice and tried to remove it would not budge. I still have the old pump and it works so I can just put it back.
Have a Happy Fourth
Gilbert
Hotshot
Joined: Nov 2006
Posts: 11,286
Likes: 263
From: North of Greenville
Pump is located on the inside of the driver side frame rail, right beneath the driver seat.
Some would suggest disconnecting the ground from EACH battery before beginning. Diesel is not nearly as flammable as gasoline, though, so I'm not sure that it's absolutely necessary.
Two wires to remove and re-connect.
Need to get a quick-disconnect fuel line tool.
Clamp the fuel lines on each side of the pump before disconnecting.
Remove pump.
Install new pump.
Re-connect pump wires.
Remove clamps.
Reconnect battery grounds (if you disconnected them).
Cycle the pump 3-5 times before starting the engine.
Run another 50-100 miles to eliminate all the air from the fuel injectors.
Some would suggest disconnecting the ground from EACH battery before beginning. Diesel is not nearly as flammable as gasoline, though, so I'm not sure that it's absolutely necessary.
Two wires to remove and re-connect.
Need to get a quick-disconnect fuel line tool.
Clamp the fuel lines on each side of the pump before disconnecting.
Remove pump.
Install new pump.
Re-connect pump wires.
Remove clamps.
Reconnect battery grounds (if you disconnected them).
Cycle the pump 3-5 times before starting the engine.
Run another 50-100 miles to eliminate all the air from the fuel injectors.
Post Fiend
Joined: Mar 2007
Posts: 26,966
Likes: 50
From: Texas
Like Pete said, not really a big deal. Just like changing a fuel filter on a gas engine truck with the addition of 2 electric lines on it. No where near as tough as the 95 other than the part about laying under the truck and trying to not get diesel to drip on you.
Laughing Gas
Joined: Nov 2010
Posts: 1,159
Likes: 33
From: Utah
I removed the entire fuel pump bracket from the frame which made it pretty easy. 3 nuts on the outboard side, disconnect the lines, wires, and swap in the new pump. Make sure the nipple is free from debris. Mine punched a hole through the protective orange cap and the "hole" was lodged inside the nipple. I used a scribe to extract it, glad I noticed that.
Hotshot
Joined: Nov 2006
Posts: 11,286
Likes: 263
From: North of Greenville
Yeah... the last time I inspected my tool bag in the truck, I made sure it still had the two small clamps for any similar fuel system repair when I'm away from the tool boxes at the house.
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Go Bills !
Joined: Jan 2008
Posts: 2,778
Likes: 65
From: Buffalo, NY
Just did another one last weekend . I find it easy to just remove the clamp screw entirely (7mm if I remember).
Unhook fuel lines
Pull down on the bottom side of clamp and slide pump out rear side of clamp.
Then unhook wires. . Wires are long enough to pull out before disconnecting . Harder in the clamp to get to wire connection nuts with brake lines and such.
Oh. You need To pinch off the tank side fuel line or The fuel will keep coming and coming. .
Unhook fuel lines
Pull down on the bottom side of clamp and slide pump out rear side of clamp.
Then unhook wires. . Wires are long enough to pull out before disconnecting . Harder in the clamp to get to wire connection nuts with brake lines and such.
Oh. You need To pinch off the tank side fuel line or The fuel will keep coming and coming. .
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Thread Starter
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More Turbo
Joined: Dec 2003
Posts: 571
Likes: 4
From: hondo
Thanks everyone great advice. BUT... y'all forgot to mention not to over tighten the nut on the stud because they break very easy... Lol. Yep that's what I did. Now I have a new fuel pump with a broken stud on the black wire side. Not sure what to do now. I guess I can't return. Will have to order another one. I tried to take stud off and replace it with my old one but it wouldn't budge. Any ideas? Bobs going to be out till Monday will give him a call and see what he say. Have a Happy Fourth of July
Gilbert
Gilbert
