dillenger1

can the plunger fall out of the lift pump into the block when removing it?

BigIron70

Maybe I was wrong has been a while since I changed one, but I never had one drop in engine.
Try putting a little greese on it to keep it pushed up into the block before installing new pump. Sometime it will slide down. I would change the hose also with the pump. Clean the screen on the fuel heater when you are changing the pump. Check the return hose and the supply hose for cracking and splitting if you have not replaced them you should.

1.Disconnect both negative battery cables at both batteries.
2.Remove starter motor. Refer tofor procedures.
3.Place a drain pan below the pump.
4.Remove the fuel line fittings at the top of both the fuel pump and fuel heater housing Pump Removal/Installation
5.Remove the fuel hose clamps and rubber fuel hose (fuel heater housing-to-fuel pump) Pump Removal/Installation
6.Remove the two mounting bolts Pump Removal/Installation
7.Remove the fuel pump and fuel heater assembly from the engine as one unit
CAUTION: Do not allow pump plunger to catch on edge of hole in cylinder block during removal. Plunger may slide out and drop into engine.

INSTALLATION
1.Clean the mating surfaces of the fuel heater mounting bracket, the fuel pump and the engine block of any gasket material.
2.Position the new gaskets, the fuel heater housing mounting bracket and the fuel pump to the engine.
3.Install the two mounting bolts into the engine. Tighten to 24 N·m (18 ft. lbs.) torque. As these bolts are tightened, the plunger within the fuel pump is being compressed. Tighten these two bolts alternately to prevent damage to the fuel pump housing.
4.Install fuel line fittings to pump and fuel heater. Tighten to 24 N·m (18 ft. lbs.) torque.
5.Install starter motor. Refer tofor procedures.
6.Connect battery cables at both batteries.
7.Bleed air from fuel system. Refer to the Air Bleed

dillenger1

whats suspose to keep the plunger in the lift pump?

infidel

Yes the piston can fall into the engine from when removing a worn pump.
All that really holds the piston in is a o-ring.
You just have to be careful when removing the pump by tilting it back a bit while pulling it out.

Dr. Evil

So how would you get that out of the engine?

infidel

You remove the oil pan or pretend it never happened.
Guess you could get lucky with a magnet.

dillenger1

So this o ring is internal in the lift pump?

infidel

Yes.....