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How to Change a Fuel Lift Pump on a Ford 6.9 IDI Diesel

Updated on May 21, 2017

Changing the Primary Pump on a 6.9 IDI Engine Ford F250 Diesel: A Tutorial

If you are fitting a new diesel primary lift pump on a 1983 Ford 6.9 truck with the Navistar 6.9 or 7.2 diesel engine, then reading this article could save you a lot of work, grief, and big money, not to mention bad language!

1. Removing the Old Primary Lift Pump

OK, so let me start by saying that I am not a qualified mechanic so anyone following this advice does so at their own risk!.

The primary lift pump on these engines is located on the right-hand side of the engine block near the front. It has two pipes attached. One is the feed from the fuel tank—it's a rubber pipe—while the outlet is usually a steel pre-formed pipe that goes up to the fuel filter.

  • The first task (after removing the keys from the ignition) is to remove the steel bracket that clamps the battery to starter motor cable to the engine cross member by undoing the two nuts. This gives you much better access to the pump.
  • Next you will need to have on hand a suitable receptacle to catch the diesel fuel that will leak out of the open fuel lines.
  • Remove the rubber fuel feed pipe and then attempt to loosen the union nut on the steel line going up to the filter. (I must say that this proved unsuccessful in my case, as it had probably never been removed before and was seized solid—so solid, in fact, that I thought that the bottom of the pump would snap off before it came loose. So my solution was to undo the steel pipe from the filter end remove the pump by removing the two retaining nuts, then lifting out the pump, taking care not to damage or distort the steel pipe that was still attached. Once the pump was removed I then clamped the union nut in a vice and unscrewed the pump off the pipe.)
  • After removing the lift pump you then you need to clean up the gasket surface on the engine block by removing any old gasket material with a scraper, solvent, or whatever you find works best for you.

2. Fitting the New Lift Pump—Getting it on the Right Side of the Cam!

Cam position
Cam position

Now Comes the Important Bit!

You REALLY need to make sure that the cam that operates the lift arm on the new pump is resting in the correct position (cam lobe pointing upwards) BEFORE you fit the new pump with the arm underneath the cam.

It is very difficult to see inside the pump aperture to check the position of the operating cam. My tip is to use a digital camera with flash to see what is what! The correct position is with the cam lobe pointing upwards (see picture above). If you find that the cam is not in this position you can "nudge" it round using the ignition key.

Once you are sure the cam is correctly positioned you can the proceed to fit the new gasket & pump.

The reason that you take all this care is because if you don`t ensure the cam lobe is pointing upwards it is quite easy to fit the pump operating arm above the cam by mistake. If you do that, then once the engine starts it wrecks the pump and dislodges the pivot pin, which then drops inside the engine sump pan—thus creating a lot of unnecessary work & expense.

The operating arm on the new lift pump may be a different shape (my old one was straight and the new one was shaped) but as long as it is the correct one supplied it will be fine.

Additional Notes!

Because it is not unknown for the operating cam to wear on these engines you may decide to use an electric fuel pump in place of the mechanical lift pump.

You could just cut off the pump operating arm and use the old pump body as a cover, but make sure that you bypass the lift pump with the fuel lines, because you don`t want the diaphragm puncturing under pressure and filling the crankcase with diesel.

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Just for Fun: My Old Ford F250 Diesel Truck Videos

Starting Our 1983 F250 Diesel Truck

Did You Find This Helpful? Why Not Leave Your Comment? I Would Love to Hear From You

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    • profile image

      anonymous 6 years ago

      Welcome to Squidoo. Should I ever need to know how to change a fuel lift pump on on a 1983 Ford 6.9 IDI Diesel engine, I will know where to come for information (love Diesel Fords, btw - partner has many as he is a dealer).

    • Pixelhound profile image
      Author

      Wayne 6 years ago from west vancouver BC Canada

      @anonymous: Thanks for your comment, I love Ford diesels too especially these older trucks they can rack up huge mileages but just keep going & going I doubt that the newer ones will still be rattling round in 27 years time.

    • thesuccess2 profile image

      thesuccess2 6 years ago

      People may smile but this type of lens is a life-safer for someone actually has a problem with their 1983 Ford 6.9 IDI Diesel engine. (Good Niche!)

    • Pixelhound profile image
      Author

      Wayne 6 years ago from west vancouver BC Canada

      @thesuccess2: Thank you.

    • Nimblepins profile image

      Nimblepins 6 years ago

      Oh....so that's how you do it! I wasn't sure!!

      This lens is very informative - and you have great step by step instructions (seriously)

      Well done, pixelhound

    • Senora M profile image

      Senora M 6 years ago

      Cool lens! I look forward to more lenses from you!

    • Pixelhound profile image
      Author

      Wayne 6 years ago from west vancouver BC Canada

      @Senora M: Thank you ! I hope that someone finds the info in my lens helpful.

    • journey103 profile image

      journey103 5 years ago from USA

      Good niche topic!

    • TTMall profile image

      TTMall 5 years ago

      Great lens with excellent pictures. Thanks for sharing!

    • TransplantedSoul profile image

      TransplantedSoul 4 years ago

      I love D.I.Y lenses. Well done.

    • Pixelhound profile image
      Author

      Wayne 4 years ago from west vancouver BC Canada

      @TransplantedSoul: Thanks for checking out my lens!

    • curtmaxwall profile image

      curtmaxwall 4 years ago

      Easy to replace after reading this lens. It would be even better if you can add symptoms of a bad fuel lift pump

    • profile image

      Bernd 2 years ago

      Hi, looks like this site is no longer maintained (last comment 2 years ago).

      Anyway, You just saved my life, at least the life of my 1983 6.9 IDI. (fuel lift pump replacement). Many thanks from Germany.

    • Pixelhound profile image
      Author

      Wayne 2 years ago from west vancouver BC Canada

      Hey Bernd...Thanks for your comment that is exactly why I built this webpage I am so pleased that it was helpful to you and I hope you can keep your truck running for many years, My truck has sadly ended up parked up with a blown head gasket.

    • profile image

      456-sign 2 years ago

      I just got my first 84 ,350 with a 6.9 and i love it.it scares me to work on it cause everything is so big and so rusted together.im about to tackle the fuel pump and your advice kinda put me at ease.thanks for the post.also going to yank the orig. tank and use an auxiliary bed mount...since the sending unit is no longer available.northern has a d.o.t. apprvd. 18 gal. aux for 320.00. Thnx agn!

    • Pixelhound profile image
      Author

      Wayne 2 years ago from west vancouver BC Canada

      I am glad you found my hubpages post helpful and good luck with your truck.

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