QuestionQUESTION: I've been told by a mechanic that tested it that the fuel transfer pump on my 2001 Dodge Ram 3500 is no longer putting out any pressure and needs to be replaced. He recommended the FASS DDRP 02 replacement pump. He also told me that the pump is not located in the fuel tank. I have Chilton's manual that shows the pump in the fuel tank so I'm a little confused. I'm also confused as to whether the lift pump and fuel transfer pump are the same unit as I've heard both terms. I need to get the thing running again but have been told not to drive it or I risk ruining the injector pump which I can't afford to replace at this time. Can you lend some clarity? I'm not a diesel mechanic but worked as an Airframe and Powerplant Mechanic years ago so I have basic knowledge regarding mechanics. Thank you advance for your help.
ANSWER: The fuel transfer/lift pump is located on the left side of the engine block. The fuel level sending unit and pickup tube are in the fuel tank. I would guess that your problem started when the fuel filter was replaced. Since the lift pump failed the fuel system can't be primed or purged of air, therefore the injection pump cannot receive the proper amount of fuel and can lead to cavitation within the pump. Which will lead to injection pump failure. Hope that clears matters up for you.
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QUESTION: Thank you. The fuel filter was replaced after the problem (loss of power at high rpm, balking etc)I took the truck to a mechanic and he tested the lift pump fuel pressure and it was 0 p.s.i. He told me not to drive it anymore until the lift pump was replaced or I risk damaging the injector pump. The truck runs fine except under load and at high rpm so I don't think it is a problem with air in the system. I'm unemployed so I have to do this work myself. Where can I find easy to follow step by step instructions to replace the lift pump. My Chilton's manual is useless as it doesn't even show this unit. Thank you again for your help.
AnswerThe following is copied from a Dodge service manual. There are no pictures but it should be of some help.
REMOVAL
The fuel transfer pump (fuel lift pump) is located on left side of engine, below and rearward of fuel filter (Fuel Transfer Pump Location).
Disconnect both negative battery cables at both batteries.
Thoroughly clean area around transfer pump and fuel lines of any contamination.
Remove starter motor. Refer to Starter Removal/Installation in 8, Starting System for procedures.
Place a drain pan below the pump.
Disconnect fuel line quick-connect fitting at fuel supply line (Fuel Transfer Pump Location) at rear of pump.
Remove support bracket bolt at top of pump (Fuel Transfer Pump Location).
Remove front and rear banjo bolts at pump (Fuel Transfer Pump Location).
Disconnect electrical connector at side of pump (Fuel Transfer Pump Location).
Remove three pump bracket nuts (Fuel Transfer Pump Location) and remove pump from vehicle.
INSTALLATION
The fuel transfer pump (fuel lift pump) is located on left side of engine, below and rearward of fuel filter (Fuel Transfer Pump Location).
Install new gaskets to fuel supply line/support bracket and banjo bolt at rear of pump. Install line and banjo bolt to pump. Do not tighten banjo bolt at this time.
Install new gaskets to fuel line and banjo bolt at front of pump.
Position 3 pump studs into pump mounting bracket and install 3 nuts. Do not tighten nuts at this time.
Install support bracket bolt (Fuel Transfer Pump Location). Do not tighten bolt at this time.
Tighten 3 pump nuts to 12 N·m (9 ft. lbs.) torque.
Tighten both banjo bolts to 24 N·m (18 ft. lbs.) torque.
Tighten support bracket bolt 12 N·m (9 ft. lbs.) torque.
Connect electrical connector to pump (Fuel Transfer Pump Location).
Connect fuel line quick-connect fitting to fuel supply line at rear of pump.
Install starter motor. Refer to Starter Removal/Installation in 8, Starting for procedures.
Connect both negative battery cables at both batteries.
Bleed air at fuel supply line at side of fuel injection pump. Refer to the Air Bleed Procedure.
Start engine and check for leaks.
STANDARD PROCEDURE - AIR BLEED
A certain amount of air becomes trapped in the fuel system when fuel system components on the supply and/or high-pressure side are serviced or replaced. Primary air bleeding is accomplished using the electric fuel transfer (lift) pump. If the vehicle has been allowed to run completely out of fuel, the fuel injectors must also be bled as the fuel injection pump is not self-bleeding (priming).
Servicing or replacing components on the fuel return side will not require air bleeding.
WARNING: DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE.
Loosen, but do not remove, banjo bolt (test port fitting) holding low-pressure fuel supply line to side of fuel injection pump (Fuel Supply Line Banjo Bolt). Place a shop towel around banjo fitting to catch excess fuel.
The fuel transfer (lift) pump is self-priming: When the key is first turned on (without cranking engine), the pump operates for approximately 2 seconds and then shuts off. The pump will also operate for up to 25 seconds after the starter is quickly engaged, and then disengaged without allowing the engine to start. The pump shuts off immediately if the key is on and the engine stops running.
Turn key to CRANK position and quickly release key to ON position before engine starts. This will operate fuel transfer pump for approximately 25 seconds.
If fuel is not present at fuel supply line after 25 seconds, turn key OFF. Repeat previous step until fuel is exiting at fuel supply line.
Tighten banjo bolt at fuel supply line to 24 N·m (18 ft. lbs.) torque. Primary air bleeding is now completed.
Attempt to start engine. If engine will not start, proceed to following steps. If engine does start, it may run erratically and be very noisy for a few minutes. This is a normal condition.
Continue to next step if:
The vehicle fuel tank has been allowed to run empty
The fuel injection pump has been replaced
High-pressure fuel lines have been replaced
Vehicle has not been operated after an extended period
CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals.
Perform previous air bleeding procedure steps using fuel transfer pump. Be sure fuel is present at fuel supply line (Fuel Supply Line Banjo Bolt) before proceeding.
Crank the engine for 30 seconds at a time to allow air trapped in the injection pump to vent out the drain manifold.
WARNING: THE FUEL INJECTION PUMP SUPPLIES EXTREMELY HIGH FUEL PRESSURE TO EACH INDIVIDUAL INJECTOR THROUGH THE HIGH-PRESSURE LINES. FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE THE SKIN AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING AND AVOID CONTACT WITH FUEL SPRAY WHEN BLEEDING HIGH-PRESSURE FUEL LINES.
WARNING: ENGINE MAY START WHILE CRANKING STARTER MOTOR.
Engine may start, may run erratically and be very noisy for a few minutes. This is a normal condition.
Thoroughly clean area around injector fittings where they join injector connector tubes.
Bleed air by loosening high-pressure fuel line fittings (Bleeding High-Pressure Fuel Lines at Injectors) at cylinders number 3, 4 and 5.
Continue bleeding injectors until engine runs smoothly. It may take a few minutes for engine to run smooth.
Tighten fuel line(s) at injector(s) to 38 N·m (28 ft. lbs.) torque.
