Do one thing at a time and make sure it is correct before going on to something else so if there is a problem you know exactly where to look for it.

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Barr
06 JLL CRD 04/06/06 23K+ mi., Amsoil, Racor Fuel Filter, EHM, ORM, 3" SS exh from Turbo back, Fumoto, 245/70/16 Grabber AT2
Waiting for installation: TransGo 45RFE-HD2, S&B Air Filter, ProVent
06 Jetta TDI/DSG, RC1+, VAG-COM,
V-65 Drag Bike

My parts are back ordered till the end of the month, seems there is a shortage, imagine that.
I would run the stock one so that we have one with a stock unit out there to compare with ones
that are not stock. Since you have a brand new one, might as well see how it does.

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2005 Silver Limited CRD 53,000 miles
GDE EcoTune / Trans tune
PML Differential Cover/Crankcase Mod
Tal & Hadas Grill Guard/TransGo Shift Kit
V-6 AirBox/Lunar Boost & EGT
Lund Cold Weather Grill Insert
OEM updated Filter Head, Cummins Lift Pump

thanks for the feedback guys. I will run the stock one for a while at least for the reasons ya'll point out. Will report.

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2005 CRD rolled August 2009

Ripster,

I ordered mine beginning of the month and had to wait 8 days as they were non-stock items, hopefully the warehouse isn't out till the end of the month.

Now I just need it to warm up a bit and lighten the tank some. Anyone tried siphoning out the fuel or does it have a baffle in the fill tube?

guess I got lucky- ordered pump, harness, and airbox parts Thurs nite (6 Mar) and they all just arrived. Jeep still has 1/2 tank of fuel though...

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2005 CRD rolled August 2009

I ordered mine last night.

I have to do about 3 cycles (pump - bleed - pump) every single week on my filter head.
It will be nice to finally 'solve' that problem.

You'll be supprised how good your jeep will run with the proper amount of fuel. I thought mine was a dog based on my experience with many smaller VW diesels. Now it's fantastic with just my tywrapped on Faucit pump. When warmer weather arrives I'll put on the Cummins in tank pump

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Atlantic Blue 06 CRD Limited (his)
Joined by a 2000 XJ Classic (hers)

If so many are just removing the wires from the V6 harness and adding them to the CRD harness, then can't we not buy the harness, just buy the required repair wires and add them?

Outside of that one harness, nothing more is needed to add? Does the connector on the engine side have enabled power for the lift pump?

X2

i was just about to post the same question.

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Trevor

'05 Limited CRD Inferno Red Pearl Coat
Home made provent installed @ 35443, SEGR installed @ 35466, Fumoto valve @ 37500, trans and transfer case skid, In tank pump installed @ 43500, Suncoast TC & Transgo Shift Kit @ 44730, EGT, Boost, Trans temp gauges, Samco hoses, Rebuilt Trans w/ HD454RFE kit @ 56K, Inmotion Stage 2 @ 56K

I've wondered about getting left over wires and sharing the cost Or maybe 06 owners getting the less expensive 05 harness and just using those wires Everything is ready for the pump to right under the back seat. Fuse, relay and all

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Atlantic Blue 06 CRD Limited (his)
Joined by a 2000 XJ Classic (hers)

The neat part of this swap is that the power is there - Jeep wired it in and it has the same startup priming that the Cummins does.
Wires are only sold as a complete harness - you don't have to use the harness - it's just to make it look factory - you can easily route your own wires - but you will need the connectors (you can easily wire around the connector inside the Jeep - but it would be difficult to wire around the connector at the pump)

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2005 CRD
stuff
Skeptic quod gratis asseritur, gratis negatur

Got it...

Just put in my order as well, I'll report when its in.

I posted this back on 2/11:



The fuel pump came relatively quickly, but I'm still waiting on the harness. I'm not quite sure what's going on with that.

To folks that have been under this rig poking around - would you expect that I could order the 2005 gasser hardness and steal the needed ground/power pump wires, and the lengths and terminals should translate over to my vehicle's current 14-pin 2006 harness? I don't know what's going on with my order, but if a 2005 donor harness will work, it'll save me a few bucks too.

- Chris

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Used to own:
2006 CRD Sport
Suncoast TC, Transgo shift kit, Inmotion, ORM, EHM, Magnaflow SS exhaust, Fumoto valve, EVIC added, Hensley TruControl brake controller, Pirelli Scorpion ATR LR-D in spring/summer/fall, FIA winter front and Blizzaks in winter

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Atlantic Blue 06 CRD Limited (his)
Joined by a 2000 XJ Classic (hers)

I used the '07 fuel pump wires in our '05 harness, so vice versa shoulda be gooda - matter of fact, what I did was use the '07 fuel module connector complete with 2 lift pump wires and 2 fuel sender wires - removed the '05 fuel sender connector and wires, inserted all four '07 wires in the '05 rear harness connector inside the cabin, and we were good to go...............

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'05 CRD Limited
Pricol EGT, Boost
GDE Hot '11; EDGE Trail switched
SEGR; Provent; Magnaflow;
Suncoast T\C, Transgo Tow'n'Go switch;
Cummins LP module, Fleetguard filter, Filterminder
2.5" Daystar f, OME r; Ranchos; K80767's, Al's lifted uppers
Rubicons, 2.55 Goodyears
Four in a row really makes it go

Well, my return to town coincided with the Wife's CRD low fuel light coming on so I went ahead and installed the in-tank lift pump last night. The info in this post was very helpful. I will post some pics of things not already shown that I think might help others understand the details.

--the pump module install was really straight-foward, I found it helpful to remove the three torx screws in the filler area prior to dropping the tank so the hose range of motion was increased.

--I completely removed the rear harness from the vehicle.

--the 05 gasser harness is in-fact about six inches shorter than the CRD harness. I soldered in one 6"(hot) and one 8"(ground) splice mid-wire and the fit was perfect

--I ended up just removing the two needed wires from the gasser harness and installing them in the CRD harness.

two wires from gasser harness prior to splicing and installation into CRD harness:

The ground wire above had a second wire going to the extra sensor on the gas harness, I cut this out and used an eight inch splice on the ground wire.

Here are the gasser and CRD under-seat connectors side by side:


here is the backside of my 05 CRD under-seat connector:


backside of the at-tank gasser connector- power far right, ground far left


front view of gasser under-seat and at tank connectors after the red and blue inserts were removed. tabs to release pins are clearly seen:

*note: I removed two wires from the left connector above prior to pic*

The harness looks OEM after reinstall. The pump works as described and the engine does seem to run smoother, start more readily, and lack hesitation.

The bad news: it appears that the new fuel manager head installed under warranty less than one tank ago is leaking at the heater puck after a 15 mile test run. Not sure exactly what to do about this since I'm still under warranty for a while.


If anyone is planning for this install and wants to save a few bucks on the harness, I have enough wire/connectors from the gasser harness for at least one more install on a CRD like mine, PM me. EDIT: One set already shipped (that was quick!) The connectors for the extra gasser plug are the same as the pump connection, so I have enough connectors/wire left to make one more complete set if anyone's interested. EDIT #2: Both are gone!

It would be great if someone would compile all the info in this thread into a single-post how-to to aid others.

Now I never have to show my wife how to operate the bleeder valve!!!

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2005 CRD rolled August 2009

I popped the fuel pump fuse in the fuse box by the battery and took mine in.
They replaced the fuel filter head under warranty as a leaker and when I was about a 1/4mile away, I reinstalled the fuse.
Since they did not notice my Carter pump, the chance of them noticing you in tank pump is nill. with the fuse popped, they will have no way to know you have a lift pump.
Dealership techs get paid by the flat rate so going on a CSI mission to terminate your warranty is a waist of time for them.
But showing up with an EDGE module plugged in and filing a warranty for a new torque converter will make them suspicious and try to pull the Warranty is Void gig.

Steve

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2006 Pearl Green CRD
Magnaflow 2 1/2" Cat Back
KJ Extra Leg Room Brackets, Carter Lift Pump, V6 Airbox, ORM
Fuel cooler, Oil Separator, Progard 7
Gauges EGT Boost Trans Temp Oil Pres, Michelin LXT AT2 245 70 R16
7,000# Draw Tight hitch, PML EX Deep Trans Pan
Centrifuge, SunCoast, Transgo, RAM TCM, InMotion Stage 2
Wife's 99 TDI VW Beetle

But the one that is on there is brand-new with less than 300 miles on it! I had it replaced because the old one was leaking at the plug and to prepare for this lift pump. I'd rather fix it or replace with something that works better since the brand-new one with new filter is leaking right out of the box.

Is it possible that the puck is loose or could be fixed with a thicker gasket off an oil filter or something?

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2005 CRD rolled August 2009

Chances are you have a defective puck. I have been both a factory rep and a shop owner and seen stuff like this before, many times. The Bean Counter assumption of 2% warranty on parts is a stretch at best, some parts fail more often others never fail. Most likely, there were several fuel heater pucks that left the factory as junk and the plastic did not properly bond to the two metal spades of the plug, I suspect as do others the design is a poor design.
If this were an antique Jeep restoration forum, we could discuss the best urethane sealant to used to seal the puck spades, what solvent works best to prep, and how much vacuum is needed to draw the urethane sealant into the leaking gap.
Since all you want is for your Jeep to run like you want, cash in the warranty.
Besides, what do you have to loose telling the dealer the replacement part failed?
He will get paid for replacing it and put the money in his bank account, you will be doing him a favor!

Steve

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2006 Pearl Green CRD
Magnaflow 2 1/2" Cat Back
KJ Extra Leg Room Brackets, Carter Lift Pump, V6 Airbox, ORM
Fuel cooler, Oil Separator, Progard 7
Gauges EGT Boost Trans Temp Oil Pres, Michelin LXT AT2 245 70 R16
7,000# Draw Tight hitch, PML EX Deep Trans Pan
Centrifuge, SunCoast, Transgo, RAM TCM, InMotion Stage 2
Wife's 99 TDI VW Beetle

Steve:

That's good insight, I'll see what they can do over at the dealer next week.

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2005 CRD rolled August 2009