84,300 miles-- ding dong the '04 fuel pump is dead.. i need tips and tricks..

[DZink24]

well, it decided to sputter out on me tonight on a freeway. fortunately i was on a downhill slope and was able to safely coast to a very wide shoulder. last year i purchased an OEM engine mounted pump, to keep for this very day.. it was inevitable. buddy came out and towed it back, and it now sits in my driveway. when i turn the key over, it only makes a clicking sound. are there any tips or advice you guys can give to possibly make this job go easier? knowing this day was coming, i have been making sure the 4 bolts on the back of the pump are oiled up and not corroded on. i will attempt this job on sunday, it is supposed to be about 60, the last nice day for who knows how long.. other than that, am i correct to know that unlike the 2nd gens, the HPCR system won't be damaged by lack of fuel?

 

[goodguys75]

are you sure your battery is not dead, it should turn over....

 

[PDM]

TDR Issue 60 page 30 has an article on the fuel filter mounted pump replacement. Some folks like to drop the plastic inner fender-liner, ~10 plastic rivits to put it back together, rivit kit can be had from Harbor Freight [67566 RIVETS 20 PLASTIC 6.3MMX25.2M + 97757 1 HAND POLY RIVETER]. Most aftermarket pump kits come with a different fuel line connecter which doesn't use the stock plastic retainer.

 

[DZink24]

thank you for the replies so far.. the one time i tried restarting it, on the side of the road, it just turned over and would not catch, the batteries were brand new last fall. all my lights and windows, radio, ect. still work. PDM, thanks for the HF info, and thank you for the TDR info, i was going to ask, what issue #, i knew it has been covered.. but couldn't remember which issue.. i am showing a P0628 code.

 

[MLee]

Just be advised that when you remove the hose from the "in" fuel line that a stream of fuel will run down your arm and continue to siphon. I suggest to get a vacuum cap the size of the line and cap it off. Geno's also has a in-line filter before the pump. After market kits don't (autozone) and these are pricey, geno's has a good price. We did it the hard way on a side road and underneath the truck with the family in tow.

 

[PDM]

Code link: http://www.edgeproducts.com/product_images/customer_support_article-pdf-39.pdf
P0628 Fuel Pump Relay Circ Low (or)
P0628 Fuel Lift Pump Ctrl Circ Low

I would expect the new lift pump to cure your truck.
For your next spare: http://www.equipmentwarehouse.net/products/B008M4RBSK-5 ~$25, don't know if it is the latest "brushless" redesign?

Here is my experience replacing the original lift pump, I did not drop the fender liner, but it might have made it easier:
https://www.turbodieselregister.com...connect-fitting-issues!&p=2364576#post2364576

 

[mfurrh55]

P0628 code= lift pump failure

 

[DZink24]

thanks again.. i am fighting daylight, so today will be tire removal, bolt loosening and canister draining..

 

[Deleted member 995608]

I fought and fought but I finally added a FASS fuel pump recently. After the first engine mounted pump failure and a failure of the upgraded in tank pump, I bit the bullet and went aftermarket. At least now, its easy to super easy to swap filters and or pump if necessary.

 

[DZink24]

thanks for all the help! i changed it yesterday, and should say, the part that i feared would be the worst, was not. the 4 bolts came out relatively easy, but i have also been lubing them with penetrating oil for a year now in preparation for this day. it was indeed a messy job, i let the fuel in the line from the tank run for the 2 hours, just funneled it into gallon washer jugs. got about 2 1/2 gallons fyi. the most difficult issue i ran across was the seating of the new pump. with out the O ring, it seated perfect. with the O ring, i was forced to use the torque from tightening the 4 screws to snug it up. i did not mess with the connector at the end of the line from the tank. i reused it, rust and all. 100 or so miles so far, seems to be running well.

 

[S.Morris]

Now buy another spare