I know this applies to my 98. 5, don't know about the newer ones.
1-Unplug the fuel pump harness on top of the lift pump
2-remove the inlet fuel line rubber hose quick disconnect. There are 2 tabs you push in, and the line will pull off the pump fitting, while the 2 tabs will stay on the pump fitting. (easer said then done with one hand.
The next steps I found easyist with my Knee on the valve cover.
3-Remove the 10MM head bolt on top of liftpump that holds the fuel inlet in place. rotate this bracket on the fuel inlet tube up just a little.
4-Remove the 3 -1/2" nuts on top of the lift pump.
5-remove the Banjo bolt on the inlet of the fuel filter. This is the rear bolt, where the fuel line goes down to the outlet of the lift pump. This Banjo fitting needs a 17mm wrench unless you have Rays's bolts, then its a 19mm. Be sure you see where that bottom sealing washer goes from under this fitting.
6-Remove the lift pump by sliding it down and away from the motor, you may have to twist the bracket on the fuel inlet line just enough so it clears the top of pump bracket. Fish pump outlet line away from wire going into top of filter.
7-Pump is now out! change fuel lines over to new pump, install wire harness adaptor onto new pump if needed. Install new banjo bolt washers but do not tighten up the inlet and outlet fittings on the pump all the way yet. Position pump back onto block being sure to route fuel outlet pipe in correct location around wire going into fuel filter.
8-Using the fuel outlet pipe to hold fuel pump into location while you get one hand down into the darkness to put the 1/2' nuts back on. tighten these 1/2" nuts.
9-Put 10mm head bolt back into fuel inlet pipe bracket.
10-using 2 new sealing washers re-install banjo bolt through pump outlet pipe into filter and tighten (look up specs if needed)
11-Tighten banjo fittings on both inlet and outlet of pump, hook up wire and fuel line.
Pump is now Installed! Should take under 1/2 hour with just wrenches!
Priming.
This is best done with 2 people.
Have one person turn the key on, then "bump" the key torwards start which will start a cycle of the lift pump. While the pump is running loosen the outlet line on the fuel filter, yes it will make a mess, good luck trying to catch it with a rag. Once the lift pump picks up fuel, you can tell, it gets louder and slows down, (don't forget to tighten outlet banjo fitting on filter.
Once it has picked up fuel cycle the pump about 10 times by "bumping" the key to the start position. The pump should keep its prime and sould like it did in step above when fuel really started spraying everywhere. Then try to start truck!
(maybe you should spray the hose under hood to rince off all that fuel before starting it?)
I would not recomend trying to change the filter in the same opperation, if you do, you should fill the filter housing with diesel before trying to prime pump. The guy at Cummins said if you open the filter up to add fuel, the O ring will swell and never go back together, (yes, I had mine apart, and No it did not swell, but its only about a month old)
The problem I had was I had a test fuel pressure gauge installed, which has 3' of 3/8" line. As the lift pump would pick up fuel, the air in the 3/8" line would pressurize and act like an
'accumulator", as soon as the lift pump would stop, the air in the line would force the fuel, and air back into the liftpump loosing the prime.
Have Fun
1-Unplug the fuel pump harness on top of the lift pump
2-remove the inlet fuel line rubber hose quick disconnect. There are 2 tabs you push in, and the line will pull off the pump fitting, while the 2 tabs will stay on the pump fitting. (easer said then done with one hand.
The next steps I found easyist with my Knee on the valve cover.
3-Remove the 10MM head bolt on top of liftpump that holds the fuel inlet in place. rotate this bracket on the fuel inlet tube up just a little.
4-Remove the 3 -1/2" nuts on top of the lift pump.
5-remove the Banjo bolt on the inlet of the fuel filter. This is the rear bolt, where the fuel line goes down to the outlet of the lift pump. This Banjo fitting needs a 17mm wrench unless you have Rays's bolts, then its a 19mm. Be sure you see where that bottom sealing washer goes from under this fitting.
6-Remove the lift pump by sliding it down and away from the motor, you may have to twist the bracket on the fuel inlet line just enough so it clears the top of pump bracket. Fish pump outlet line away from wire going into top of filter.
7-Pump is now out! change fuel lines over to new pump, install wire harness adaptor onto new pump if needed. Install new banjo bolt washers but do not tighten up the inlet and outlet fittings on the pump all the way yet. Position pump back onto block being sure to route fuel outlet pipe in correct location around wire going into fuel filter.
8-Using the fuel outlet pipe to hold fuel pump into location while you get one hand down into the darkness to put the 1/2' nuts back on. tighten these 1/2" nuts.
9-Put 10mm head bolt back into fuel inlet pipe bracket.
10-using 2 new sealing washers re-install banjo bolt through pump outlet pipe into filter and tighten (look up specs if needed)
11-Tighten banjo fittings on both inlet and outlet of pump, hook up wire and fuel line.
Pump is now Installed! Should take under 1/2 hour with just wrenches!
Priming.
This is best done with 2 people.
Have one person turn the key on, then "bump" the key torwards start which will start a cycle of the lift pump. While the pump is running loosen the outlet line on the fuel filter, yes it will make a mess, good luck trying to catch it with a rag. Once the lift pump picks up fuel, you can tell, it gets louder and slows down, (don't forget to tighten outlet banjo fitting on filter.
Once it has picked up fuel cycle the pump about 10 times by "bumping" the key to the start position. The pump should keep its prime and sould like it did in step above when fuel really started spraying everywhere. Then try to start truck!
(maybe you should spray the hose under hood to rince off all that fuel before starting it?)
I would not recomend trying to change the filter in the same opperation, if you do, you should fill the filter housing with diesel before trying to prime pump. The guy at Cummins said if you open the filter up to add fuel, the O ring will swell and never go back together, (yes, I had mine apart, and No it did not swell, but its only about a month old)
The problem I had was I had a test fuel pressure gauge installed, which has 3' of 3/8" line. As the lift pump would pick up fuel, the air in the 3/8" line would pressurize and act like an
'accumulator", as soon as the lift pump would stop, the air in the line would force the fuel, and air back into the liftpump loosing the prime.
Have Fun