1999 lift pump install step by step - Dodge Cummins Diesel Forum

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Old 04-11-2012, 10:48 PM   #1 (permalink)
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1999 lift pump install step by step

So after days of looking on 5 different forums i finally found the best step by step write up on how to change the lift pump on a 1999 24v.
due in part to this link. FAQ

I will be installing a DDRP-02 tomorrow morning I will let you all know how accurate this is.

*note* I have never worked on a diesel and will be doing this all based on text.
and mechanical ability.

Procedure for a 1999 Ram

NOTE: You may be able to improve this but this is exactly what we did and changed two pumps in less that two hours)
TOOLS: 17 mm wrench & socket, 10 mm wrench & socket, 7/16 socket, inch socket

*Lay a non-conducting material over the battery posts (fender cover, etc)

*Make sure you have the new pump and eight banjo washers

*Remove the two banjo bolts from top of the fuel filter housing using a 17 mm wrench

*Remove the old banjo washers from the fittings

*Disconnect the water in fuel sensor at the bottom of the fuel filter housing

*Disconnect the fuel filter heater element plug at top of the filter housing

*Remove the drain tube from the bottom of the filter housing drain

*Remove the two manifold bolts holding the filter housing to the intake manifold

*Remove the entire filter housing being careful not to drain the fuel from it

*Remove the banjo bolt holding the solid fuel line that goes the inlet of the filter housing using a 17 mm wrench

*Remove the banjo bolt on the suction side of the lift pump

*Remove the 10 mm bolt holding the suction line to the pump bracket

*Unplug the electrical connector to the lift pump

*Remove the three nuts holding the lift pump in place, socket inch I believe

*Remove the lift pump

*Install the new pump and the two back nuts loosely just to hold the pump in place

*Install a new banjo washer on the suction bolt

*Install the bolt in the suction fitting and install another washer on the bolt

*Thread the bolt into the pump suction while the two nuts are loose on the pump

*Connect the power to the pump

*Install the cable support and the third nut on the pump bracket

*Tighten the pump suction banjo bolt, and the three nuts holding the pump in place

*Tighten the bolt holding the suction hose in place

*Install a washer on the pump discharge banjo bolt

*Install the bolt in the discharge tubing and install another washer

*Install the discharge to the pump but do not tighten

*Set the fuel filter housing back in place with the two manifold bolts but do not tighten

*Install a washer on the filter inlet banjo bolt

*Install the bolt far enough to get another washer on the other side and thread the bolt into the filter inlet

*Install a washer on the filter outlet banjo bolt

*Install the outlet banjo bolt in the outlet tubing and install another washer on the other side

*Thread the outlet bolt into the filter housing

*Tighten to two filter housing intake manifold bolts

*Tighten the two 17 mm inlet and outlet bolts on top of the housing

*Tighten the 17 mm bolt on the discharge of the lift pump

*Connect the fuel grid heater wiring at the top of the housing

*Connect the fuel in water wiring to the bottom of the housing

*Install the plastic housing drain tube

*Loosen the inner or outer plug on top of the housing with a 7/16 socket

*Bump the key like you are going to start the truck and bleed the system (may need to do this several times)

*Do a double check and make sure everything is tight and there are no leaks
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