10/19/2017 Fuel Lift Pump

Initial Check
Note : This test only applies to engines equipped with
EGR and Marine engines. Engines not equipped with
EGR do not have a lift pump.
Note : High fuel inlet restriction can result in poor lift
pump performance or in lift pump damage. Before
replacing the lift pump, measure the fuel inlet restriction.
Refer to Procedure 006-020
(/qs3/pubsys2/xml/en/procedures/44/44-006-020.html).

Install a M10 male Compuchek fitting, Part Number 3824842,

on the diagnostic port on the inlet side of the fuel filter. Refer to
Procedure 100-002 (/qs3/pubsys2/xml/en/procedures/44/44-
100-002.html) for port location.
Connect the service tool containing a 1.09-mm [0.043-in]
orifice, Part Number 3164621, to the diagnostic port.
Allow the other end of the hose to drain into a 500-ml
graduated beaker, Part Number 3823705.

This test is performed with the engine not running.

Start the lift pump by using the INSITE electronic service tool
lift pump override test. Refer to Procedure 014-008
(/qs3/pubsys2/xml/en/procedures/44/44-014-008.html) for
INSITE electronic service tool test instructions. Alternatively,
the lift pump can be temporarily activated by turning the
keyswitch on or by bumping the starter without starting the
engine.
Measure the amount of fuel flowed by the lift pump in a 60-
second interval:
Fuel flow rate for lift pump (engine not running) - greater
than 600 ml in 60 seconds or filling a 12-ounce can in 36
seconds or less.

Voltage will only be present when the lift pump is

commanded ON and when the lift pump is connected to the
harness. To measure lift pump voltage , use the INSITE lift

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10/19/2017 Fuel Lift Pump

pump override test and a breakout connector between the lift

pump and the engine harness
Check the voltage and resistance at the lift pump.
If the voltage does not meet the specifications, check the
power supply.

System Voltage Resistance

12 VDC 9 VDC (minimum) 0.5 to 20 ohms
21 VDC
24 VDC 0.5 to 20 ohms
(minimum)

Two additional components that could possibly be included on

24-volt systems are a relay and a voltage regulator.
The 2-pin Deutsch connector for fuel lift pump signal and return
that attaches to the lift pump on 12-volt systems instead
connects to a 24-volt relay. The relay, when switched ON by
the electronic control module (ECM), delivers 24 volts from an
OEM-connected source to the voltage regulator. The voltage
regulator converts the 24-volt input to a 12-volt output. The lift
pump used is a 12-volt lift pump and grounds through an OEM
connection.

The relay is located in the harness between the voltage

regulator and the OEM power supply on the bottom edge
of the ECM. The relay is switched ON for 60 seconds after
the keyswitch is turned ON. It is also switched ON anytime
the engine is cranking or running. The relay must provide
24 volts of power output to the voltage regulator.
The voltage regulator is located just below the ECM. It
receives 24 volts from the relay whenever the relay is
switched ON> The regulator provides 12 volts of power
output to the lift pump.
A 12-volt lift pump is used in vehicles with a 24-volt power
system. It should run any time the relay is switched ON, as
described above.

Clean
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Thoroughly clean the fittings and components before removal.

Make sure that debris, water, steam, or cleaning solution does
not reach inside the fuel system.

Preparatory Steps
Marine Applications
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To reduce the
possibility of arcing, remove the negative (-) battery cable
first and attach the negative (-) battery cable last.

WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights,
arcing equipment, and switches out of the work area and
areas sharing ventilation to reduce the possibility of
severe personal injury or death when working on the fuel
system.

WARNING
Do not vent the fuel system on a hot engine; this can
cause fuel to spill onto a hot exhaust manifold, which can
cause a fire.

CAUTION
Use caution when disconnecting or removing fuel lines,
replacing filters and priming the fuel system that fuel is
not spilled or drained into the bilge area. Do not drop or

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10/19/2017 Fuel Lift Pump

throw filter elements into the bilge area. The fuel and fuel
filters must be discarded in accordance with local
environmental regulations.

Disconnect the battery. Refer to Procedure 013-009

(/qs3/pubsys2/xml/en/procedures/44/44-013-009.html).
Shut off the fuel supply and return lines. Refer to the OEM
service manual.
Remove the fuel lift pump inlet and outlet fuel lines. Refer
to Procedure 006-024
(/qs3/pubsys2/xml/en/procedures/44/44-006-024.html).
Remove the ECM cooling plate. Refer to Procedure 006-
006 (/qs3/pubsys2/xml/en/procedures/44/44-006-
006.html).

Remove
With EGR
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To reduce the
possibility of arcing, remove the negative (-) battery cable
first and attach the negative (-) battery cable last.

Disconnect the battery.

Remove the fuel lift pump inlet and outlet fuel lines.

Remove the fasteners holding the lift pump to the back of the
ECM cooler plate.

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10/19/2017 Fuel Lift Pump

For 24-volt systems with voltage regulators , remove the

voltage regulator from the bottom edge of the ECM by
removing the lower two ECM mounting capscrews. The relay is
fastened to the wiring harness near the ECM connectors.

Marine Applications
Remove the fasteners holding the lift pump to the back of the
ECM cooling plate.

Install
With EGR
Make sure the inlet and outlet are properly oriented with the
thin brass outlet section pointing toward the rear of the engine.
Check the lift pump for labeling of inlet and outlet ports. Verify
that the correct pump (12 VDC or 24 VDC) is installed.
Install the lift pump on the mounting bracket behind the ECM
cooling plate.
Torque Value: 7 nm [ 62 in-lb ]

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10/19/2017 Fuel Lift Pump

WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights,
arcing equipment, and switches out of the work area and
areas sharing ventilation to reduce the possibility of
severe personal injury or death when working on the fuel
system.

Install the fuel lift pump inlet and outlet fuel lines.
Torque Value: 24 nm [ 212 in-lb ]
For 24-volt systems with voltage regulators , install the
voltage regulator at the bottom edge of the ECM and install
the lower two ECM mounting capscrews.
Torque Value: 25 nm [ 221 in-lb ]

WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To reduce the
possibility of arcing, remove the negative (-) battery cable
first and attach the negative (-) battery cable last.

Connect the battery. Refer to Procedure 013-009

(/qs3/pubsys2/xml/en/procedures/44/44-013-009.html).

Marine Applications

Note : Be sure to verify the correct lift pump is being

installed for the application voltage in use.
Make sure the inlet and outlet are properly oriented with the
thin, brass outlet section pointing toward the rear of the engine.
Check the lift pump for labeling of inlet and outlet ports.
Install the lift pump on the mounting bracket behind the ECM
cooling plate. Tighten the capscrews.
Torque Value: 7 nm [ 62 in-lb ]

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10/19/2017 Fuel Lift Pump

Finishing Steps
Marine Applications
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To reduce the
possibility of arcing, remove the negative (-) battery cable
first and attach the negative (-) battery cable last.

WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights,
arcing equipment, and switches out of the work area and
areas sharing ventilation to reduce the possibility of
severe personal injury or death when working on the fuel
system.

Install the ECM cooling plate. Refer to Procedure 006-006

(/qs3/pubsys2/xml/en/procedures/44/44-006-006.html).
Connect the batteries. Refer to Procedure 013-009
(/qs3/pubsys2/xml/en/procedures/44/44-013-009.html).
Prime the fuel system. Refer to Procedure 005-016
(/qs3/pubsys2/xml/en/procedures/44/44-005-016.html).
Operate the engine and check for leaks.

Prime
With EGR
WARNING
The fuel pump high-pressure fuel lines and fuel rail
contain very high-pressure fuel. Never loosen any fittings
while the engine is running. Personal injury and property
damage can result.

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10/19/2017 Fuel Lift Pump

It is not necessary to vent air from the high-pressure fuel

system before starting the engine. Crank the engine to prime
the fuel system.
For engines with EGR, allow the lift pump to run by turning the
keyswitch ON and waiting 30 seconds before starting.

Last Modified: 11-Jan-2005

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