6.9L IDI & 7.3L IDI Fuel Pump Replacement

How to Replace the Fuel Pump on the 6.9L and 7.3L IDI Diesels

The 6.9L and 7.3L IDI diesels utilize a simple, mechanical fuel pump design that is driven off a lobe on the camshaft. The fuel pump is mounted near the front of the passenger side of the engine block just below the vacuum pump. This fuel pump is simple enough to replace and relatively inexpensive. Low (or zero) fuel pressure can manifest itself in a number of driveability concerns (no start, hard start, low power, engine stall, etc) and can lead to premature injection pump failure.

Applicable model years: 1983 - 1994 6.9L/7.3L IDI diesel (naturally aspirated & turbocharged engines)
6.9L/7.3L IDI fuel pump: Carter M60278 (Ford E3TZ-9350-B, International 1804495C93)
6.9L IDI fuel filter (1983 - 1987): Motorcraft FD811
7.3L IDI fuel filter (1988 - 1994): Motorcraft FD3375

 

Do not be alarmed if the armature that drives the fuel pump is a different design than the OEM pump. Pictured below is the OEM Ford/International pump and the correct Carter brand replacement. The armature is the same length on both pumps, however their designs differ. With both pump designs it is imperative that the tip of the armature be installed beneath the lobe on the camshaft.

6.9L/7.3L IDI diesel fuel pump armature designs

OEM vs replacement fuel pump for 6.9L/7.3L IDI diesel.
Despite the differences in armature design, this is the correct replacement fuel pump.

Click any thumbnail to view fullsize, detailed image

Front fender

• Disconnect both negative battery cables.

• Remove the inner fender on the passenger side (optional, but vastly increases accessibly).

vacuum pump on IDI diesel

• Remove the vacuum pump (mounted below the alternator on the front of the engine block). It is held in place by (2) bolts requiring a 10 mm socket and has a single hose that must be removed and set aside.

6.9L and 7.3L IDI diesel fuel pump location

• Disconnect the low pressure (standard hose clamp) and high pressure fuel lines (5/8" flare nut wrench) at the fuel pump.

Fuel pump mounting bolts

• Remove the (2) bolts securing the fuel pump to the engine block using a 9/16" socket, then pull the pump away from the engine block to remove. The arm of the fuel pump may be under tension depending on the position of the camshaft lobe, so don't be alarmed if it begins to tilt or remains tight until both bolts are completely removed.

Fuel pump removed

• Carefully plug the hole through the engine block with a lint free rag and remove all gasket material from the engine block. A perfectly clean mounting surface is desired to ensure that the new fuel pump seals completely.

fuel pump camshaft lobe

• Next, you'll need to locate the fuel pump camshaft lobe into the correct position so that the new fuel pump can be installed. The armature of the fuel pump must be inserted below the cam lobe. If installed incorrectly, damage will occur to the fuel pump and parts of the pump may end up in the crankcase when it fails.

• While using a flashlight, look through the hole in the engine block and locate the camshaft. The camshaft lobe that drives the fuel pump will be straight through the hole in the block that the pump mounts through. Note the position of the camshaft lobe and "bump" the engine over using a remote starter until the peak (tallest part) of the lobe points upwards. It may take several attempts to line up the cam lobe properly. Disconnect the negative battery cables once again after the camshaft has been positioned properly.

Note - Do not use the ignition key to turn the engine over during this process, a remote starter must be used. If you do not have experience in performing this task, seek the help of a professional.

Preparing new fuel pump

Optional step: Apply a small amount of RTV silicon (recommend Permatex 82180) to the gasket mounting surface on the fuel pump, then install the gasket onto the fuel pump and allow the silicon to become tacky (or cure) before attempting to install the fuel pump. This is entirely optional, but installing the fuel pump will be significantly easier as the gasket will already by oriented properly. Furthermore, the fuel pump gasket will have a greater tendency to stick to the fuel pump and not the engine block if it is removed in the future. Do not use RTV silicon to seal the gasket to the engine block.

New fuel pump installed

• When installing the fuel pump, the armature must be positioned beneath the camshaft lobe. Point the fuel pump armature downwards while sliding it into the engine block, then tilt the pump into position and install the (2) bolts to secure it to the block. Depending on the orientation of the camshaft lobe, you may need to overcome some spring tension when tightening the bolts down. A torque wrench will not fit near the fuel pump hardware; snug the bolts up moderately.

• Install the low pressure and high pressure fuel lines, ensuring that the clamp and flare nut are both tight.

• Reattach the vacuum pump in reverse order.

• Reinstall the inner fender in reverse order.

• Replace the fuel filter. Fill the replacement filter with clean diesel fuel before installing.

• Reconnect both negative battery cables.

• Crank the engine over for 10 seconds, followed by a 30 second cool down if the engine does not start. Repeat until engine starts. If the fuel system does not self prime recheck tightness of fuel lines at the pump.

• With engine running, check for leaks at the fuel pump and around the fuel filter housing.