Chrysler Full-Size Trucks 1997-2000 Repair Guide

Diesel Injection Pump

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REMOVAL & INSTALLATION



1997-98 Models

NOTE
The Bosch® VE lever is indexed to the shaft during pump calibration. Do NOT remove it from the pump during removal.

  1. Disconnect the negative battery cable(s).
  2.  
  3. Remove the throttle linkage and bracket.
  4.  
  5. Disconnect the fuel drain manifold.
  6.  
  7. Remove the injection pump supply line.
  8.  
  9. Remove the high pressure lines.
  10.  
  11. Disconnect the electrical wire to the fuel shut off valve.
  12.  
  13. Remove the fuel air control tube.
  14.  
  15. Remove the pump support bracket.
  16.  



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Fig. Remove the throttle linkage and bracket from the engine-1997-98 models

  1. Remove the oil fill tube bracket and adapter from the front gear cover.
  2.  
  3. Place a shop towel in the gear cover opening in a position that will prevent the nut and washer from falling into the gear housing. Remove the gear retaining nut and washer.
  4.  
  5. Install the turning tool into the flywheel housing opening on the exhaust side of the engine. Place a 1 / 2 in. drive universal joint in the turning tool and attach enough extensions to the joint to make it convenient to turn the tool.
  6.  



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Fig. Detach the connector and lines shown when removing the injection pump

  1. Using a ratchet to turn the barring tool, turn the engine until the keyway on the fuel pump shaft is pointing approximately in the six o'clock position.
  2.  
  3. Locate TDC for cylinder No. 1 by turning the engine slowly while pushing in on the TDC pin. Stop turning the engine as soon as the pin engages with the gear timing hole. Disengage the pin after locating TDC and remove the turning equipment.
  4.  
  5. Loosen the lockscrew, remove the special washer from the injection pump and wire it to the line above it so it will not get misplaced. Retighten the lockscrew to 22 ft. lbs. (30 Nm) to lock the driveshaft.
  6.  
  7. Using a suitable puller, pull the pump drive gear from the driveshaft.
  8.  



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Fig. Exploded view of the oil filler tube and bracket


NOTE
Be careful NOT to drop the drive gear key into the front cover when removing or installing the pump. If it does drop in, it must be removed before proceeding.

  1. Remove the 3 mounting nuts and remove the injection pump from the vehicle.
  2.  
  3. Remove the gasket and clean the mounting surface.
  4.  



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Fig. Use the barring tool to rotate the diesel engine

To install:

  1. Install a new gasket.
  2.  


NOTE
The shaft of a new or reconditioned pump is locked so the key aligns with the drive gear keyway with cylinder No. 1 at TDC.



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Fig. Loosen the injection pump shaft lockscrew and remove the special washer shown

  1. Install the pump and finger-tighten the mounting nuts; the pump must be free to move in the slots.
  2.  
  3. Install the pump drive gear, washer and nut to the driveshaft. The pump will rotate slightly because of gear helix and clearance. This is acceptable providing the pump is free to move on the flange slots and the crankshaft does not move. Tighten the nut to 11-15 ft. lbs. (15-20 Nm). This is NOT the final torque; do NOT overtighten.
  4.  
  5. If installing the original pump, rotate the pump to align the original timing marks and tighten the mounting nuts to 18 ft. lbs. (24 Nm).
  6.  



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Fig. Use a puller tool as shown to remove the injection pump timing gear

  1. If installing a replacement pump, take up gear lash by rotating the pump counterclockwise toward the cylinder head, and tighten the mounting nuts to 18 ft. lbs. (24 Nm). Permanently mark the new injection pump flange to match the mark on the gear housing.
  2.  
  3. Loosen the lockscrew and install the special washer under the lockscrew; tighten to 13 ft. lbs. (18 Nm). Disengage the TDC pin.
  4.  
  5. Install the injection pump support bracket. Finger-tighten the bolts initially, and then tighten them to 18 ft. lbs. (24 Nm) in the following sequence:
    1. Bracket to block bolts.
    2.  
    3. Bracket to injection pump bolts.
    4.  
    5. Throttle support bracket bolts.
    6.  

  6.  
  7. Now perform the final tighten of the pump drive gear retaining nut to 48 ft. lbs. (65 Nm).
  8.  
  9. Install the oil filler tube assembly and clamp. Tighten the bolts to 32 ft. lbs. (43 Nm).
  10.  
  11. Install all fuel lines and the electrical connector to the fuel shut off valve. Tighten the high pressure lines to 18 ft. lbs. (24 Nm).
  12.  



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Fig. Be careful NOT to lose the injection pump key

  1. Install the fuel air control tube. Tighten the banjo fitting bolt to 9 ft. lbs. (12 Nm).
  2.  
  3. Install the throttle bracket and linkage. When connecting the cable to the control lever, adjust the length so the lever has stop-to-stop movement.
  4.  
  5. Connect the negative battery cable.
  6.  


CAUTION
Do NOT place any part of the hand near the base of the high pressure line. A fuel leak from a high-pressure fuel line has sufficient pressure to penetrate the skin and cause serious bodily harm. Do NOT bleed the lines if the engine is hot. Fuel spilling onto a hot exhaust manifold creates the danger of fire.

  1. To bleed air from the system, run or crank the engine and carefully loosen the high pressure fitting from each injector one at a time. Retighten the fitting after the air has expelled before going on to the next injector fitting. The operation is complete when the engine runs smoothly. If the air cannot be removed, check the pump and supply line for suction leaks.
  2.  
  3. Adjust the idle speed if necessary.
  4.  

1999-00 Models
  1. Disconnect the battery negative cables.
  2.  
  3. Clean all fuel line and fitting ends to prevent possible contamination.
  4.  
  5. Disconnect the 9-way electrical connector at the fuel pump control module.
  6.  
  7. Remove the fuel line return line at the side of the injection pump by removing the overflow valve.
  8.  
  9. Remove the supply line banjo bolt.
  10.  
  11. Remove high pressure lines, intake air tube, throttle sensor, air intake housing, dipstick tube, cables and clips, and engine lifting bracket.
  12.  
  13. Unscrew the plastic access cap at the front gear cover.
  14.  


WARNING
To prevent pump/gear keyway from falling into gear housing, the engine must be rotated until the keyway is at 12 o'clock.

  1. Remove the nut and washer retaining injection pump gear to shaft.
  2.  
  3. Rotate the engine until the keyway is at 12 o'clock.
  4.  
  5. Use a puller to separate the gear from the shaft. Attach two M8 x 1.24mm screws through the puller and into the threaded holes in the pump gear. Pull gear forward until loose. Move only enough to free it.
  6.  
  7. Remove the three lower pump bracket bolts and the bracket. Loosen, but do NOT remove, the two engine bracket bolts.
  8.  
  9. Remove the four injection pump-to-gear housing mounting nuts. Remove the injection pump.
  10.  

To install:

  1. Use new O-rings and gaskets. Machined tapers must be clean and dry before installation.
  2.  
  3. The pump/gear keyway has an arrow and a three-digit number stamped at the top edge. Position the keyway into the pump shaft with the arrow pointing to the rear of the pump. Be sure keyway and pump data plate have the same number.
  4.  
  5. Position pump assembly to mounting flange while aligning pump shaft through back of injection pump gear. Dowel on mounting flange must align with hole in front of pump.
  6.  
  7. Install and tighten four pump mounting nuts finger tight only.
  8.  
  9. Tighten injection pump shaft washer and nut finger tight.
  10.  
  11. Position lower pump bracket and install three bolts finger tight only.
  12.  
  13. Tighten shaft nut to 15-22 ft. lbs. (20-30 Nm). This is NOT the final torque.
  14.  
  15. Tighten the four pump mounting nuts to 32 ft. lbs. (43 Nm).
  16.  
  17. tighten the three lower pump bracket-to-pump bolts to 18 ft. lbs. (24 Nm).
  18.  
  19. Tighten the two engine bracket-to-engine bolts to 18 ft. lbs. (24Nm).
  20.  
  21. Final tighten the injection pump shaft nut to 125 ft. lbs. (170 Nm).
  22.  
  23. The remainder of the procedure is the reverse or removal.
  24.  



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Fig. Fuel pump control module (FPCM) 9-way connector-1999-2000 models



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Fig. Injection pump installation-1999-2000



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Fig. Injection pump keyway and number-1999-2000

INJECTION PUMP TIMING



1997-98 Models
  1. Install the barring tool into the flywheel housing opening on the exhaust side of the engine. Place a 1 / 2 in. drive universal joint in the tool and attach enough extensions to the joint to make it convenient to turn the tool.
  2.  



Click image to see an enlarged view

Fig. Location of the injection pump timing indicator plug

  1. Using a ratchet to turn the barring tool, turn the engine until the keyway on the fuel pump shaft is pointing approximately in the six o'clock position.
  2.  



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Fig. Check the injection pump timing with the timing gauge installed

  1. Locate TDC for cylinder No. 1 by turning the engine slowly while pushing in on the TDC pin. Stop turning the engine as soon as the pin engages with the gear timing hole. Disengage the pin after locating TDC.
  2.  



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Fig. Injection pump timing gear alignment

  1. Remove the plug from the end of the pump.
  2.  
  3. Install the special timing indicator, allowing for adequate indicator pin travel. It may be necessary to disconnect one or more fuel lines to properly install the indicator.
  4.  


NOTE
The indicator is marked in increments of 0.01mm. One revolution of the indicator needle is equal to 0.050mm.

  1. Turn the engine counterclockwise until the indicator needle stops moving. Adjust the indicator face to read zero.
  2.  
  3. Rotate the engine back to TDC and count the number of revolutions of the indicator needle. The reading shown when the engine timing pin engages is the amount of the pump's plunger lift at that point.
  4.  



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Fig. Location of the timing pin

  1. Readjust the indicator face to read zero. Loosen the pump mounting nuts and rotate the pump clockwise toward the cylinder head until the indicator reads the correct value for plunger lift (the reading in Step 7). Tighten the mounting nuts to 18 ft. lbs. (24 Nm).
  2.  



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Fig. Injection pump timing marks

  1. Remove the engine turning equipment and timing indicator. Install the timing plug and tighten to 7.5 ft. lbs. (10 Nm). Connect any fuel lines that were disconnected.
  2.  
  3. Road test the vehicle.
  4.  

1999-00 Models
  1. All timing and fuel adjustments are made by the Engine Control Module. No manual adjustments are required unless a DTC has been displayed indicating "engine sync error" or "static timing error". If this appears after installation of a new or rebuilt injection pump, the keyway has probably been installed backwards.
  2.  
  3. Refer to the illustration of timing marks. Be sure the keyway has been installed with the arrow pointing to the rear of the pump.
  4.  



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Fig. Injection pump timing-1999-2000 models

 
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