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Engine/Transmission (1994 - 1998) Replaced lift pump today

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Bought new pump from Case-IH dealer today. great price. :D Thanks, bramage for the part #s.



http://turbodieselregister.com/forums/showthread.php?s=&threadid=92913



My pressure was definantly low (haven't installed the guage I have yet). It now idles smooth and the ticking noise is gone. :) The boot on the primer buttom was cracked on the bottom and the gaskets where it bolts up were seeping oil too. The spring inside of the pump was to short from age/use. New one is about 1/2" longer. I can hear fuel going through the return now. Couldn't before.
 
"I can hear fuel going through the return now. Couldn't before. "



That's the first thing Dad said after he installed his and started to prime it.



When you're priming them - the new lift pump puts out enough fuel to make the overflow valve 'sing'. That's usually my cue that it's pretty well primed... I make it 'sing' 10-15 times and then crank it over.



Matt
 
Originally posted by HoleshotHolset

[BWhen you're priming them - the new lift pump puts out enough fuel to make the overflow valve 'sing'. That's usually my cue that it's pretty well primed... [/B]



That's what I always do. Never have had to crack a line to bleed air out of it.



I could always hear it when priming after a filter replacement or other work, never with it running.
 
I wondered what that ticking sound was... Looks like i`m gonna be replacing mine soon... How big of a job was it bmoeller? Thanks



-J
 
Gary, 176k on the original.



Pretty easy to do. Worst part for me was getting the bolts started. I did mine from the top. Didn't have to pull the starter that way to make room. If I hadn't had trouble with starting the bolts, it would've been a 45 min job.



The fuel heater is attached with the same bolts. That is why you need 2 gaskets.



Need to remove the fuel filter, the steel line that runs from the top of the lift pump to the fuel filter housing. The rest is pretty obvious.



The fitting that the 90* elbow (goes to the fuel heater) is screwed into will need to be swapped over to the new one.



Make sure to wipe EVERYTHING off so you won't get dirt in there.
 
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If you turn the engine over a little bit... getting the bolts started is much easier. Turn the engine over so that the lobe on the camshaft that drives the lift pump is pointing away from the lift pump... it'll go in a whole lot easier.



Matt
 
It was, I checked. Was having trouble because the gaskets had four little corners on the inside that the bolt had to be threaded through. Wasn't a smooth hole like the old ones. Was also having to move the fuel heater bracket to the left a little at the same time. Once I rounded out the holes on the gasket in between the block and heater, they went halfway easy.
 
Originally posted by bmoeller

Bought new pump from Case-IH dealer today. great price. :D Thanks, bramage for the part #s.



http://turbodieselregister.com/forums/showthread.php?s=&threadid=92913



My pressure was definantly low (haven't installed the guage I have yet). It now idles smooth and the ticking noise is gone. :) The boot on the primer buttom was cracked on the bottom and the gaskets where it bolts up were seeping oil too. The spring inside of the pump was to short from age/use. New one is about 1/2" longer. I can hear fuel going through the return now. Couldn't before.
Hey guys, I read somplace where you have to be careful while removing the pump not to let the plunger shaft fall or it might get into the oil pan. Is this true?

I will be replacing my pump soon.
 
It is possible if you catch it on the way out. There isn't much holding it in. Just a couple of o-rings was all I could see. Pull straight out, and you should be just fine.
 
They just replaced the lift pump on mine today, but i couldn't tell that there was a problem. i don't have a fuel pressure gague. will it run better?
 
Anyone have any good illustrated guidelines for this pump replacement?? How hard is it to hear that ticking your describing?? Also, where is a good place to tap in a line for a fuel pressure gauge..... is there a fuel line off the lift pump of fuel filter housing I could run a "T" off of to the gauge??



Thanks, Joe
 
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Some of the info below is cut and paste from http://www.dodgeram.org/tech/dsl/fuelpump/replace.htm I simplified it/made some changes from what CJ did. He did a few steps that he could've skipped and made it easier on himself.



Tools needed-



trouble light

10mm socket - for lift pump bolts (1/4" drive ratchet/6" long extention and socket will work also. )

14mm socket - for fuel filter canister (or 14mm universal socket)

3/8 ratchet

6" 3/8 extension

3/8 universal joint - makes filter nut easier

3/4" (19mm) open end wrench - for fuel inlet nut

14mm open end wrench - for fuel outlet fitting

19mm open end wrench - injector line nuts (only if you need to loosen lines to bleed out air, I didn't have to)

12mm socket - upper banjo on fuel filter inlet

17mm open end - lower banjo on fuel filter inlet (These 2 are for when removing the steel fuel line between the filter housing and

pump)

cresent wrench (if pump was purchased from Case/C-IH dealer)

pliers (spring clamps)

--------------------------------------



Note: After starting, if you remove the air intake horn it will give you a little more room to work. I did not, no trouble for me. Be careful with the gasket on top of grid heater so it can be reused. Cover the openings so nothing will fall into them.



Unhook water in fuel sensor connector (WIF).



Remove the fuel filter canister after draining the fuel out of filter canister. Use 14mm socket, U-joint, and extension.



Disconnect (or remove) the rubber hose that goes to the fuel heater from lift pump on pump end. (spring clamps)



Remove little banjo bolt for small steel line, carefully bend out of way.



Remove the big banjo bolt from steel line from the LP to the filter canister head. (Be careful not to loose any of the sealing washers!) Disconnect the line from the top of the pump and take out line.



Use a 10mm socket, 6" extension and 3/8 ratchet handle. There are 2 bolts, one to the right of the pump, the other between the pump and the strainer/heater. There's not a whole lot of room between the strainer and pump, but unless you have really huge sockets, there's plenty of room. These 2 bolts hold both the fuel strainer/heater and the pump in place. (The lines will hold the fuel heater/strainer in place when the pump bolts are removed) It may be necessary to turn the camshaft when removing the pump, or if you have difficulty reinstalling the pump. The cam lobe needs to be at its lowest position. Carefully remove the pump, making sure to pull it staight back from the block so the rod doesn't get pulled out and drop into engine.



Remove the elbow from old pump and install onto the new one. Use some thread sealant on the threads to prevent leaks. (If you bought the pump from Case/C-IH, you will need to swap the fitting that the elbow is screwed into. There is a thin sealing washer, so don't lose/damage it. )



Remove the 2 gaskets. One between the block and the heater/strainer bracket, the other between the bracket and the pump. If they don't come in one piece, carefully scrap off the gasket(s). May need to remove fuel heater strainer to do this if needed.



If the plunger rod on the old pump in in good shape, reuse it with the new pump since it's worn into the cam in the engine. The rod just pulls straight out of the pump. Put oil on the rod before installing into pump.



After installing the gaskets, install the new pump. (Starting the bolts can be tricky. )



Reinstall the lines/hose and banjo bolts, taking care not to lose the washers.



Reinstall the filter and canister. Plug the WIF sensor back in.



If you took the air horn off, reinstall that.



Prime fuel system by pushing the primer buttom (rubber top). Pump 'til you hear fuel make the overflow (OF) valve sqeak/chatter. Them pump some more. It will take at bit to fill the filter canister and purge air through the OF valve.



Attempt to start truck. If it doesn't fire up shortly, repeat the prior step, may need to do this a couple of times.



If it still will not start, you may need to bleed the injector lines. Loosen 2 or 3 of the fittings at the top of the injectors with a 19mm wrench. They don't need to be removed, just loosen a bit. Crank the engine until fuel comes out of the fittings on the injectors. This may take bit of cranking, so it'd be a good idea to have a set of jumper cables and another vehicle available, especially if it's cold and/or your batteries aren't in tip top shape. Follow the general precautions on excessive cranking to avoid overheating your starter - don't crank for more than 30 sec. , let things cool for a few minutes before cranking again. Once fuel is to the fittings, tighten the fittings on the injectors. Go back to cranking again. The engine will likely sputter to life and promptly die a few times before it takes off and runs. It may run rough for a few seconds, but will eventually smooth out.
 
Joe, for the gauge, some have drilled/tapped the fuel inlet banjo on the fuel injection pump to attach the gauge. http://dodgeram.info/tsb/1996/14-07-96.htm



I couldn't hear it very well from the outside, but could on the inside. Even over the straight-piped truck. The noise level/pitch of the ticking would change depending on engine fuel demands. It wasn't overly loud, just enough to be noticed.



http://www.dodgeram.org/tech/dsl/Facts/96specs.html



Fuel Pressure: 18-24 psi at idle, 28-36 at 2000 rpm with no load.
 
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