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Old 11-29-2012, 09:06 PM
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Changing my fuel pump, any tips?

Hey all,

So I had the problem before of my fuel filter light coming on and after changing both my fuel filter and fuel water separator filter I am still having the fuel filter light coming on. I was told on a previous thread that it may be my fuel pump is going. Well I noticed the pump is leaking fuel into the engine valley so I figure it is time to change. Never changed it out before, any tips, write ups I can take a look at or pointers would be great.

Last edited by TruckLiddell; 11-29-2012 at 09:35 PM.
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Old 11-30-2012, 12:50 AM
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how much $$ to replace fuel pump

This one's a start. If you hit the search function in a couple of the OBS forums and search "fuel pump" you'll get some hits.
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Old 11-30-2012, 07:12 AM
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Overall, it's not a hard job. Best bet it to rebuild/re-oring the fuel bowl and change the hoses while you're in there since you'll be taking that stuff out to get to the pump. If they are not leaking now, they will be soon enough. Swap them out with viton and never look back. The pump you want to use is the newer Navistar pump. It has a diaphragm that is allegedly more suited to the ultra low sulfur diesel fuel. It costs about $130. Cheapo O'Reilly reman lasted less than 5k miles while Navistar pump still going strong and dry.



Good website to see a fuel bowl refurb/writeup is at DieselOrings
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Old 12-01-2012, 01:15 PM
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Thanks for the pointers gaspipe. I ended up ordering a fuel pump and the o-ring kit off dieselorings. Way cheeper than local purchase even with the shipping. Plus I needed a exhaust back pressure sensor also so I was able to get that too. Should give me a bit of time to research how to change out the pump in the meantime.
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Old 12-01-2012, 05:44 PM
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I made a wrench to get the banjo bolt off w/o removing the pedestal. I copied one found in another thread. If you do it this way, be prepared to have a helper with small hands help you reinstall the banjo bolt and gaskets. I couldn't get my big hand to make it happen. Luckily the misses was able to get the bolt started.
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Old 12-01-2012, 05:46 PM
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What's the deal with the pushrod for the fuel pump coming out I hear about on here? Is this a common issue?
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Old 12-01-2012, 11:19 PM
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There's a tappet that pumps the diaphragm in the pump body that can fall into the motor if your cam isn't pushing it up when you pull the fuel pump out. I believe the common practice is to unbolt the fuel pump and rotate the engine until the cam pushes up the tappet which pops the fuel pump out and keeps the tappet from falling in.
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Old 12-02-2012, 07:07 PM
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If you're not pulling the turbo I recommend having a small handed female around to get the banjo bolt back into the new pump.....
I also found an 1 1/4" closed end/open end wrench at oreillys auto parts that could get into said banjo bolt without any modification.
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Old 12-02-2012, 07:35 PM
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If that wrench doesn't work you could grind some of the Turbo pedistal down enough to get a proper wrench in there.

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Old 12-02-2012, 07:42 PM
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I would also recommended replacing the high pressure fuel hoses, they attend to crack and get briddle with age.

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