Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Injection Pump

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Removal & Installation




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

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cables
     
    Throttle linkage and bracket
     
    Fuel drain manifold
     
    Injection pump supply line
     
    High pressure lines
     
    Fuel air control tube
     
    Fuel shut off valve connector
     
    Pump support bracket
     
    Oil fill tube and adapter
     

  4.  
  5. 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.
  6.  
  7. Turn the engine until the keyway on the fuel pump shaft is pointing approximately in the 6 o'clock position.
  8.  
  9. Locate Top Dead Center (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.
  10.  
  11. 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.
  12.  
  13. Press the pump drive gear from the driveshaft.
    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.

  14.  
  15. Remove the 3 mounting nuts and remove the injection pump from the vehicle.
  16.  
  17. Remove the gasket and clean the mounting surface.
  18.  

To install:


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.

  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). 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.  
  7. 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.
  8.  
  9. Loosen the lockscrew and install the special washer under the lockscrew; tighten to 13 ft. lbs. (18 Nm). Disengage the TDC pin.
  10.  
  11. Install or connect the following:

    Pump support bracket. Tighten the pump drive gear nut to 48 ft. lbs. (65 Nm).
     
    Oil fill tube and adapter
     
    Fuel shut off valve connector
     
    Fuel air control tube
     
    High pressure lines
     
    Injection pump supply line
     
    Fuel drain manifold
     
    Throttle linkage and bracket
     
    Negative battery cables
     

  12.  
  13. Bleed air from the system.
  14.  
  15. Start the engine and check for leaks.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cables
     
    Intake air tube
     
    Drive belt
     
    Pump wiring harness
     
    Injection pump supply line
     
    Fuel lines
     
    Drive gear access cover
     
    Drive gear mounting nut
     

  4.  
  5. Using a gear puller, remove the drive gear and leave it hanging within the timing gear cover.
  6.  
  7. Remove 3 pump mounting nuts and remove the pump.

    Click image to see an enlarged view

    Fig. Exploded view of diesel injection pump-2004-05 models

    Exploded view of diesel injection pump-2004-05 models
  8.  

To install:

  1. Install a new O-ring coated with clean engine oil into the machined groove at the pump mounting area.
  2.  
  3. Install the pump to the mounting flange on the gear housing while aligning the pump shaft through the back of the pump gear.
  4.  
  5. Install the 3 pump mounting nuts and finger-tighten.
  6.  
  7. Install the shaft washer and nut and tighten by hand.
  8.  
  9. Tighten the pump mounting nuts to 18 ft. lbs. (25 Nm).
  10.  
  11. Tighten the pump shaft nut to 77 ft. lbs. (105 Nm).
  12.  
  13. Install the drive gear cover and tighten to 71 INCH lbs. (8 Nm).
  14.  
  15. Install or connect the following:

    Fuel lines
     
    Injection pump supply line
     
    Pump wiring harness
     
    Drive belt
     
    Intake air tube
     
    Negative battery cables
     

  16.  
  17. Bleed air from the system.
  18.  
  19. Start the engine and check for leaks.
  20.  

 
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