My truck is a California model, there is a fuel dampner directly behind/ontop of the pump where the lines feed the fuel galleys in the head. This dampner and fuel line assy, position the banjo bolt to be below the turbo, if yours is not a Calif.truck you will not have this dampner allowing you to use a "tweeked" 1 1/4" box wrench to remove the banjo bolt. If you read the post I refered to, it will pretty much walk you through the process, the fuel hoses I refered to are from the pump to the fuel canister. These are special hoses I got from the local Ford dealer, 3 hoses approx.3 inches long each were about 9 dollars. Also replace the crush washers when replacing the banjo bolt. Below I am reposting the thread after I had everything finished.Hope this will shed some light on your project.
Join Date: May 2006
Finally finished my fuel pump replacement on my California 97 psd,without removing the turbo! Marc, and Fordnut85, thanks to you both for your patience, and helpful suggestions.
The process was time consuming, but as Marc said,"duable". I bought a 1/2 " drive, impact socket 1-1/4" and tack welded it to a piece of 1-1/4" black pipe, put it in a mateal band saw and cut off the socket leaving only enough to grab the banjo bolt, then ground the tack welds off and ended up with a socket short enough to reach in and unscrew the banjo bolt. Using a 3/8 drive swivel head ratchet and a 3/8 to 1/2" drive adaptor, I managed to break the banjo bolt loose,and finally get it out. I loosened the fuel filter canister and slid it towards the fan, replaced all the fuel lines with Ford factory lines,and new crush washers on the banjo bolt, cleaned the screen on the FPR while I was there. To re-assemble I used a plastic tip off a silicone tube, (new here not used) shoved that into one of the holes of the banjo bolt and then a screwdriver into the tip of the tube,(sounds wierd but it worked) shoving the banjo bolt into the fuel line assembly and the pump. Best part of all the truck fired right up with no leaks. Hope this info will help someone on their fuel pump replacement.