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Fuel Injection Pump: Installation

WARNING: This page is about a different car, the 1995 Dodge Pickup and 1995 Dodge Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. If installing original fuel injection pump, pump shaft must be properly positioned by engaging injector pump timing pin to provide proper fuel injection pump timing. New or rebuilt fuel injection pumps should be shipped with pump shaft properly positioned and injector pump timing pin engaged.
  2. To position pump shaft, remove access plug from side of fuel injection pump. See Fig 1. The injector pump timing pin is located in bore under access plug. Remove injector pump timing pin.
  3. Rotate fuel injection pump shaft until pump timing tooth is visible in center of access plug bore on injection pump. Install injector pump timing pin in bore until slotted end of pin engages with pump timing tooth. See Fig 1. Temporarily install access plug.
    NOTE: It may be necessary to slightly rotate fuel injection pump shaft when engaging injector pump timing pin. DO NOT force slot on injector pump timing pin onto pump timing tooth.
  4. If installing original fuel injection pump, check condition of "O" ring on front of fuel injection pump. Replace "O" ring (if necessary).
  5. Ensure injection pump drive gear-to-shaft mating surfaces are clean and free of oil. Install new "O" ring on front of fuel injection pump if necessary.
  6. Install fuel injection pump on mounting studs on rear of gear housing. Ensure fuel injection pump is flat against gear housing. DO NOT tighten mounting nut if pump is not fully engaged to gear housing. Install fuel injection pump-to-gear housing nuts finger tight. DO NOT torque nuts at this time.
    CAUTION: Ensure fuel injection pump-to-gear housing nuts are tightened to specification before tightening fuel injection pump-to-lower mounting bracket bolts. Nuts and bolts must be tightened in proper sequence to prevent damage to fuel injection pump or gear housing.
  7. Install fuel injection pump-to-lower mounting bracket bolts finger tight. Tighten fuel injection pump-to-gear housing nuts to specification. See TORQUE SPECIFICATIONS . Tighten fuel injection pump-to-lower mounting bracket bolts.
  8. Install pencil-type magnet in end of shaft on fuel injection pump. Install washer and fuel injection pump drive gear nut. Remove magnet.
  9. Tighten fuel injection pump drive gear nut to preliminary torque of 11 ft. lbs. (15 N.m). DO NOT overtighten nut, as injector pump timing pin may be damaged. This is not the final tightening torque.
  10. Disengage timing pin from camshaft gear. Remove access plug and injector pump timing pin from side of fuel injection pump. See Figure. While preventing engine from rotating, tighten injection pump drive gear nut to final torque of 144 ft. lbs. (195 N.m) .
  11. Injection pump timing must now be checked. Ensure timing pin is disengaged from camshaft gear. Rotate engine clockwise (viewed from front of engine) to TDC. Ensure timing pin engages in machined hole on camshaft gear.
  12. Ensure pump timing tooth is centered in access plug opening on fuel injection pump. Insert injector pump timing pin with slot facing inward. Ensure injector pump timing pin slot engages with timing tooth. See Figure.
  13. If injector pump timing pin engages with pump timing tooth, proceed to step 16). If injector pump timing pin will not engage, remove fuel injection pump drive gear nut and washer.
  14. Using puller, pull fuel injection pump drive gear from tapered area on shaft of fuel injection pump. Rotate fuel injection pump shaft until pump timing tooth is centered in access plug opening on fuel injection pump. Ensure injector pump timing pin engages with pump timing tooth.
  15. Install washer and fuel injection pump drive gear nut. Tighten fuel injection pump drive gear nut to preliminary torque of 11 ft. lbs. (15 N.m). Disengage timing pin from camshaft gear and remove injector pump timing pin from injection pump bore. Tighten injection pump drive gear nut to final torque specification while holding engine from rotating. See TORQUE SPECIFICATIONS . Proceed to next step.
  16. Install injector pump timing pin in the disengaged position (slot facing outward). See Figure. Install sealing washer and access plug. Tighten access plug to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification.
    CAUTION: New or rebuilt fuel injection pumps must be pre-lubricated before operating to prevent premature governor wear.
  17. If installing new or rebuilt fuel injection pump, remove oil fill plug from top of fuel injection pump governor. See Figure. Add 25 ounces (.74 liters) of clean engine oil to fuel injection pump. Install and tighten oil fill plug to specification. See TORQUE SPECIFICATIONS .
  18. On all fuel injection pumps, install and bleed fuel lines. See FUEL LINE BLEEDING under FUEL SYSTEM. Check Throttle Position Sensor (TPS) adjustment. See THROTTLE POSITION SENSOR (TPS) in ADJUSTMENTS - 5.9L DIESEL article in the ENGINE PERFORMANCE section. Adjust engine oil level (if necessary).
Fig 1: AFC, Oil Fill Plug, Access Plug & Pump Timing Pin Installation Position ID
G94H65455Courtesy of CHRYSLER CORP.
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