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8.1 Returnless Fuel Pump removal

D

deuce_is_wild

New member
I have a model year 2001 8.1. It has the old style Return less fuel system. (puck filter to fuel pump in cooler to water separator to fuel rail back to cooler) The fuel pump has pinhole leak just above the cooler. I have removed the pump and cooler assembly. Just how does that pump come out of that cooler?

Thanks in advance.

Chris
 
Mako mark,

i have that drawing and I have removed the retention clip. The pump is firmly seated in the cooler. Most likely corroded in. Should this normally be pushed, pulled, or twisted out? I would like to avoid damaging the cooler assembly.

Thanks

Chris
 
To be honest, I can't remember the specifics for your setup....the early fuel injection configurations changed pretty often. I don't ever remember seeing one that threaded in...most that I've touched weren't threaded....Safest best is call crusader tech support with your serial number....they'll give you the straight scoop...and usually are more responsive than your typical dealer at this time of year.
 
I'm still working on this. Two voice mails to Crusader have not been responded to. I know this is not typical for them because I have had good response in the past. I was able to get a look at a new pump at Engine Distributors in Ft Lauderdale. The new one comes with a rubber like sleeve (like a beer koozie) that is a little snug but slides off easily. There are no threads on this pump so it does not screw out. My best guess is it is bonded to the sleeve which is bonded in the fuel cooler. I also guess that this sleeve acts as a bushing inside the cooler to keep the raw water from leaking out the top and bottom of the cooler. I have tried gently twisting the pump with channel locks and pushing it up from the bottom to no avail. Several applications of PB Blaster haven't helped. Any other ideas before I resort to brute force? Thanks Chris
 
I received this response from an email to Crusader."The pumps come with the rubber boot for external installation, yours was
coated with a lithium grease to help reduce corrosion to the pump and help with getting it out later....but it still must be stuck in the hole.
Disconnecting the bottom fuel line carefully tap the pump from the bottom to loosen it up it should just slide out depending just how corroded it is in there. Be sure not to damage the inlet fitting on the pump." I had already been using PB Blaster every other day for the last few weeks. Yesterday I began to tap gently with a hammer and the pump began to slowly move. At a certain point the end of the pump was now inside the can. I use a socket extension to continue tapping. A snug fit all the way but eventually it came out. The pump has a good bit of corrosion on it and you can clearly see the hole where is was leaking. Also the inside of the can is fairly clean. Alfter a good cleaning and some repainting I'll get the new pump installed. Thanks Chris
 
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