2001 Dodge Pickup R2500

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Russell O’Connor’
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1 FUEL INJECTION PUMP Removal CAUTION: High-pressure fuel lines must be clamped securely and routed so they do not contact each other or any other components. DO NOT weld or switch high-pressure fuel lines. High-pressure lines are same length and proper high-pressure fuel line must be installed in specified area for proper engine operation. 1. Disconnect negative battery cables. Clean fuel lines at cylinder head and injection pump. Clean fuel injection pump and fuel lines at side of pump. Disconnect 9-pin electrical connector at Fuel Pump Control Module (FPCM). Place a rag around overflow valve to catch excess fuel. Remove overflow valve and disconnect fuel return line. See Fig. 17. Remove outlet fuel pressure test port banjo bolts and fuel supply line at side of injection pump and top of fuel filter housing. 2. Remove all high pressure fuel lines, intake air tube, accelerator pedal position sensor, air intake housing, engine oil dipstick tube, wiring clips, electrical connectors at intake heaters, and engine lifting bracket. 3. Remove hose from crackcase breather. Unscrew crankcase breather from gear cover. Remove injection pump gear-to-injection pump shaft nut and washer. 4. Engine may be rotated by removing dust plug from transmission adapter plate and installing Engine Barring Tool (Snap-On SP371 or MTE ) in transmission adapter plate. See Fig. 24. Rotate engine until keyway is at 12 o'clock position. CAUTION: Engine must be rotated until keyway is at 12 o'clock position to prevent pump/gear keyway from falling into gear housing. If gear retainer nut, washer or key drops into gear housing, cover may have to be removed to retrieve them before starting engine. 5. Using gear puller, separate injection pump gear from injection pump shaft. See Fig. 26. DO NOT pull fuel injection pump drive gear too far forward or timing gear cover may be damaged. 6. Remove 3 lower fuel injection pump-to-lower mounting bracket bolts. Loosen 2 engine bracket bolts. See Fig. 25. Remove 4 fuel injection pump-to-gear housing nuts. Remove fuel injection pump. See Fig. 27. Use care not to scratch or damage shaft of fuel injection pump during removal. Sunday, January 04, :18:51 12:18:55 PM Page Mitchell Repair Information Company, LLC.

2 Fig. 24: Rotating Engine Sunday, January 04, :18:51 PM Page Mitchell Repair Information Company, LLC.

3 Fig. 25: Removing Lower Pump Bracket & Mounting Bolts Sunday, January 04, :18:51 PM Page Mitchell Repair Information Company, LLC.

4 Fig. 26: Removing Fuel Injection Pump Drive Gear Sunday, January 04, :18:51 PM Page Mitchell Repair Information Company, LLC.

5 Fig. 27: Removing Fuel Injection Pump Courtesy of GENERAL MOTORS CORP. Installation NOTE: Before installing fuel injection pump, ensure shaft on fuel injection pump is properly positioned for proper fuel injection pump timing, cylinder No. 1 at TDC on compression stroke and timing pin is engaged in machined hole on camshaft gear. If engine is rotated while fuel injection pump is removed, timing will need to be set for proper operation. See FUEL INJECTION PUMP TIMING under FUEL SYSTEM in BASIC DIAGNOSTIC PROCEDURES - RAM PICKUP - DIESEL article. 1. Check pump mounting surfaces at pump and mounting flange for nicks, cuts or damage. Check "O" ring surfaces for nicks, cuts or damage. Clean injection pump mounting flange at gear housing. Clean front of injection pump. Install new "O" ring on pump mounting area. Apply clean engine oil to injection pump Sunday, January 04, :18:51 PM Page Mitchell Repair Information Company, LLC.

6 "O" ring only. CAUTION: Ensure fuel injection pump drive gear-to-shaft mating surfaces are clean and free of oil to provide proper seating of fuel injection pump drive gear on shaft of fuel injection pump. 2. Pump/gear keyway has an arrow and 3-digit number stamped at top edge. See Fig. 28. Position keyway into pump shaft with arrow pointed toward rear of pump. Ensure 3-digit number stamped on top of keyway is identical as 3-digit number stamped on injection pump data plate. If incorrect keyway is installed, a Diagnostic Trouble Code (DTC) may be set. 3. Position pump assembly to mounting flange on gear cover while aligning injection pump shaft through back of injection pump gear. See Fig. 27. When installing pump, ensure dowel on mounting flange must align with hole in front of pump. Ensure fuel injection pump is flat against gear housing. Install 4 fuel injection pump-to-gear housing nuts finger tight. DO NOT tighten nuts at this time. CAUTION: DO NOT tighten pump to gear cover using mounting nuts. Damage to pump or gear cover may result. Pump must be positioned flat to mounting flange before attempting to tighten mounting nuts. 4. Install fuel injection pump shaft washer and nut to pump shaft finger tight. Position lower pump bracket and install 3 bolts finger tight. Tighten fuel injection pump drive gear nut to preliminary torque of 22 ft. lbs. (30 N.m). Tighten 4 fuel injection pump nuts and 3 lower pump bracket-to-pump bolts to specification. Tighten 2 engine bracket-to-engine bolts to specification. See TORQUE SPECIFICATIONS. Final tighten injection pump shaft nut. Use barring tool to prevent engine from rotating. 5. Install crackcase breather and hose. Using new gaskets, install fuel return line and overflow valve to side of injection pump. Tighten overflow valve to specification. See TORQUE SPECIFICATIONS. Using new gaskets, install fuel supply line to side of injection pump and top of fuel filter housing. Tighten banjo bolts to specification. TORQUE SPECIFICATIONS. 6. To complete installation, reverse removal procedure. Bleed air from fuel system. See BLEEDING AIR FROM FUEL SYSTEM. Sunday, January 04, :18:51 PM Page Mitchell Repair Information Company, LLC.

7 Fig. 28: Locating Keyway Arrow & Keyway Number Sunday, January 04, :18:51 PM Page Mitchell Repair Information Company, LLC.

TSB-VP1001. Friday, May 27, 2014

TSB-VP1001. Friday, May 27, 2014 TSB-VP1001 Friday, May 27, 2014 Fuel Injection Pump Replacement CAUTION: Whenever the fuel injection pump is removed from the engine, the pump drive gear is laying loose on the camshaft drive gear. Never