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Old 08-11-2017, 04:55 PM   #1
1madmouse
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Default fuel pump problems

Ok I have a 91 D21 2 wd, 4cyl, 5spd, with about 172,000 on it. I was driving to a job and the truck just started losing power like running out of gas. Would turn over, but not start, so got a ride and my towbar , towed it home. Checked relay, its ok, but don't hear fuel pump. So I checked the service manual and started doing the checks. relay ok, have spark, but no fuel. Checked plug at pump, book says 6 wires, mine has 5 and the one missing is the one I need for the test. Called shop they said $500 for pump and another $300 to do the work. I don't want to replace the pump if thats not the problem. Is there any good way to make sure the pump is really dead? I'll do the work, but just want to be sure.
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Old 08-11-2017, 05:10 PM   #2
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You can get the pump for under a $100. Only way I would now to check it is to jump the power and ground an see it it runs.
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Old 08-11-2017, 08:35 PM   #3
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I'm going to try that hoping to identify the wires at the plug and check for power at the pump. I have seen many people change the pump then find out that wasn't the problem. Can't hurt , thanks.
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Old 08-11-2017, 10:36 PM   #4
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Ok went by the service manual and the fuel pump plug should have 6 spots or pins. Mine seems to be missing pin B , might be a difference between 90 and 91 as there is no manual for 91 so I'm using the 90. Also the pump is dead no continuity between A and C when there should be per EF & EC -317. Its too bad they don't show the plug as its mounted on the frame upside down to the book, just saying. So I 'm going to pull the tank and replace the pump. Anyone know why there are so many different pumps, from about $38.00 to $400.00. Quite the spread on prices. Want to use Rockauto, but not sure how long they take to ship. At least they go by VIN #s
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Old 08-12-2017, 12:26 AM   #5
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Some are probably the pump and some are the pump and sender assembly.
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Old 08-12-2017, 03:34 AM   #6
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What I am seeing is some are USA made and some are Japan made, Vin with J as first letter , made in Japan, start with 1, made in USA. I guess they are different or pressure are different. I would like to smack the guy that decided the tank can't come straight down, you have dismantle half the underside to get the tank to slide forward , then drop out. If I didn't have side boxes and a cross box, plus a lumber rack on mine, I would just pull the bed. Also some pumps come pump only, pump with screen, pump with sender, low pressure pump , high pressure pump, etc .
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Old 08-12-2017, 09:53 PM   #7
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take the bed off. its 6 bolts, a wire harness connection in the pass fender well area, a ground strap underneath, and three bolts that hold the fuel filler neck to the bed. you and two friends can pick it up and walk it off the frame.
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Old 08-23-2017, 06:03 AM   #8
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Default Truck starts but sputters badly

I can't determine what is wrong. I initially thought fuel pump as I was driving and she just died in the middle of the road. Pushed her over and she started again but very rough and just dies. Stinks of gas. It will start but not driveable. My mechanic friend thought coolant temperature sensor.

GUYS where do I start? I don't want to do fuel pump to find out it's a simple sensor. Will swap out coolant temperature sensor first.

Thanks guys,

Last edited by British Columbia Bandit; 08-23-2017 at 06:31 AM.
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Old 08-25-2017, 06:34 PM   #9
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Hey, I'm about to replace the fuel pump on my 92. I got a good deal on a Bosch fuel pump on Amazon. I'm replacing it because I can clearly hear it struggling when I turn the ignition to,on, and I hear it buzzing loudly when I listen down the fuel filler tube!

By the way, I don't think you have to take the bed completely off. (Tilt bed method) I think you can loosen the three on one side as far as they will go without taking them off, remove the three on the fuel pump side, connectors, etc., then tilt the bed up and support it with two by fours cut to size. At least I hope that works!

Last edited by Emendia; 08-26-2017 at 05:45 AM.
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Old 08-25-2017, 06:37 PM   #10
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For what it's worth, here's the pump I got... these normally go for double. Bosch is, obviously, a reputable brand.

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
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