Took me from 1 pm Sunday till 7 pm to get the fuel pump installed,hooked up & running..
I could have just slapped it back on where the old one was that fried,but I didn't like it being higher than the fuel tank,I had it mounted to the bottom of the truck bed..
The old pump fried,smelled like a burnt out ballast from a flourecent light..that roached electrical transformer stench..the ground wire had came right out of the housing ,like it melted off whatever it went to inside--the "can" is filled with some type of tough gelatin stuff that surrounds whatever else is in there for electrical parts,and all there is for a "pump" is a steel rod with a plastic check valve on one end,in a cylinder.
Basically its just a solenoid !..
It said on the label it was a 5 to 9 PSI version...one I bought is rated for 2.5 to 5 PSI..should be good enough,I've read the IP only needs enough pressure and volume to avoid going "negative"...
I would have bought the pump GM put on later models,but it is rated at 10-14 PSI and has metric thread fitttings,that aren't supplied with it--and the cheapest price locally for one was over $60..(no one had one either!)..so I went with the Spectra one from Autozone for $26.99..
I used vise grips to pinch off the fuel feed hose from the tank and the one going to the firewall filter--that avoided a bath in diesel fuel when I took the pump off,but some managed to get on me anyways..not much came out,but it only takes a few drops---.
I found a 5/16" hole in the bottom of the frame rail already drilled in the perfect spot under the tank to mount the new pump,so I put it there instead,now its almost level with the bottom of the tank,as the instructions said is the preferred location,and "no more than 24" from the tank"..the old pump was about a foot higher than the tank and 18+" away..
One setback,I wasted $16 buying five feet of 3/8" and 1/4" fuel line hose,and then found out the new pump fittings are 5/16"..

:
I figured the 3/8" hose would fit tight enough on 5/16" barb fittings,but not tight enough to inspire confidence..
I figured it would leak or suck air in..
I could have gone hunting for two 3/8" barb fittings with 1/8" NPT threads,but the truck was apart now,and I doubt I'd have had much luck on a Sunday finding those at Lowe's or Home Depot,the stores like Autozone rape you for such things too,IF they happen to have any..I knew I had none,I already pawed thru my 5 gallon pail full of spare fittings ,none were for 3/8" hose..had everything BUT..of course..
I could have just re-used the 1/8"NPT pipe nipples I had used from the old pump in it,but I don't like trusting just a clamp with no "barb" on a diesel (though it worked fine for years that way)..
So I tore the truck apart looking for some fuel hose I knew I had stashed in it somewhere,and found a few feet of 5/16"..
I had to use a 3/8" barb "hose splicer" fitting on the main fuel feed hose from the sending unit,which was barely long enough to reach over the frame rail,and I was able to shove the 5/16" hose over it,and the 3/8" copper fuel line to the firewall filter ,being soft and fresh..used new worm clamps,not those cheesy spring type ones supplied with the pump..
I used the dinky pre-filter supplied with the pump that has a 1/8" NPT thread ,I don't like using suck a dinky filter knowing diesel can be dirty sometimes,but the warranty is void if you don't run one..since I didn't put one on the old pump,that may had led to its demise,but it was old enough to die anyways..
I have 2 bigger fuel filters that were used on older VW's with 5/16" barb fittings I can use later on if the small one clogs up..they are about as big as a oil filter,but it would be best to rig up a mount to hold them,rather than let them hang free supported only by the hoses..
I then inspected the wires I used to power the old pump,it was just ordinary 2 conductor lamp or extension cord,but it was still in excellent shape,not all brittle or corroded--I made sure it had a good ground (I grounded it to a bracket above the gas pedal,didn't trust using the frame its so rusty and old),and I also added a 10 amp fuse to the power wire from the fuse box..
I never had put one on it before,I had just tapped into an existing fuse in the fuse box that had power only in the "on" position..now it has it's own fuse,and it's power is gotten from another spot in the fuse box that had a factory tap for some other option..
I have a toggle switch on the dash to shut the pump off--I know the "right" way to wire the pump up is to use an oil pressure switch to kill power to it if the engine stalls (after a crash,etc),but I got by for so long without one I don't see the need for for all that extra wiring and work..
Well,after all was done,I tried firing it up--it started faster and only did the funky idle/loping thing for about 30 seconds and did not stall when I took my foot off the throttle right after it started, like it would before..
It idled kind of rough for about a minute,then it smoothed out a lot,probably had an air bubble in the lines from them being disturbed I assume..it also didn't belch white smoke out of both tailpipes like before too..checked everywhere for fuel leaks,didn't see any..
One thing I noticed,the 3/8" copper tubing I used from the firewall filter to the tank ,flattened out a lot where I had to make a 90 degree bend in it to get into the filter base..its not "kinked",but it is probably restricted some,it didn't seem to bother it with the old electric pump on it the 5+ years since I put the copper line in though..
I might try to see if I can un-flatten it using the flaring tool clamp or pliers,but I may end up mucking it up worse if I do..
The 1/4" fuel hose running to the IP looks petrified and old,I should replace that soon-that looks like a "fun" job..

.-would have done it yesterday but I was running out of daylight and rain was moving in--supposed to be cold,drizzly & dreary here until Thursday now..

...
The engine sounds more responsive and though I didn't take it for a ride,I am pretty sure it will be OK now..I hope..after $75 worth of new fuel filters,fuel pump,hose,etc,it better be!..worst part is it only got it back to running like it used too--not "better"..and the rest of the truck is still a p-o-s that needs 100 other things fixed..
I could barely get out of bed and walk this morning--left leg,hip,and lower back is fubared...my kness are junk too,I may need to go get some cortisone injections --probably going to spend the next few days in bed recovering...getting up from under the truck 50 times got me so sore I should have just stayed in bed longer this morning..