1994 - 1999 7.3L Power Stroke Fuel Pump Information
The 1994 - early 1999 model year 7.3L Power Stroke diesels (all "OBS" trucks and early Super Duty) utilize a two stage, camshaft driven mechanical fuel pump. A lobe on the camshaft operates a plunger protruding from the bottom of the fuel pump and through the engine valley. The 1st stage of the fuel pump is the vacuum side; it creates between 4 and 6 psi of negative pressure to draw fuel from the fuel tank and into the fuel water separator. The 2nd stage of the fuel pump is the pressure stage, where fuel is pressurized in the 40 to 70 psi range and delivered to each individual injector.
The fuel pump on all 7.3L Power Strokes is located in the engine valley just in front of the turbocharger. There are two separate configurations - Federal emissions engines and California emissions engines. On Federal emissions engines, the fuel pump can be removed and replaced without removing the turbocharger. On California emissions engines, the turbocharger must be removed in order to access the fuel pump. In either instance, the task is much easier if the turbocharger is removed first. You are much less likely to bend a fuel line of break the fuel pump plunger off in the engine valley with the turbocharger removed.
To verify that the fuel pressure requires replacement, see: 7.3L Power Stroke fuel pressure test instructions.
7.3L Power Stroke Fuel Pump Replacement Instructions
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• Disconnect both negative battery cables.
• Remove the fuel filter housing/fuel bowl: 1994 - 1997 7.3L Power Stroke fuel filter housing removal instructions
• Remove the turbocharger: 1994 - 1999 7.3L Power Stroke turbocharger removal instructions
• Remove the blue fuel line from the vacuum side (towards driver) of the fuel pump.
• Thoroughly clean the area around the fuel pump. The fuel pump is cam driven and the crankcase will be exposed through the engine valley once the fuel pump is removed. Cleaning the area will reduce the risk of dropping debris into the engine.
• Remove the banjo bolt at the rear of the fuel pump using a 1-1/4" socket. Gently separate the fuel line connection from the fuel pump once the banjo bolt is removed.
• Remove the two bolts securing the fuel pump to the engine block with a 10mm socket, alternating between the left and right bolts.
• Pull the fuel pump straight upwards (perpendicular to engine valley) to remove. This may require a fair amount of force. You may rotate the fuel pump slightly as you pull, but do not rock the assembly side-to-side; this may cause the plunger on the bottom of the fuel pump to break off flush with the engine valley.
• Lubricate the o-ring on the fuel pump plunger assembly with clean motor oil.
• Reinstall the fuel pump using new banjo bolt washers/seals on the rear fuel line. Torque banjo bolt to 37 ft-lbs (50 N-m).
• When tightening down the fuel pump, alternative between the left and right bolts frequently. Torque fuel pump retaining bolts to 18 ft-lbs (24 N-m).
• Reinstall turbocharger and fuel filter housing/fuel bowl assembly.
• Note that the engine will require a significant amount of cranking to bleed air from the fuel lines.
• Start the engine, check for leaks, and verify fuel pressure.