Pump, Fuel Injection: Removal: Removal

WARNING: This page is about a different car, the 2014 RAM 3500 HD and 2014 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

Fig 1: Engine Cover, Bolts & Oil Dipstick

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Disconnect and isolate both negative battery cables.
Remove the oil dipstick (2).
Remove bolts (1) and the engine cover (3).

Fig 2: Bulk Head Connector
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Cut the cable tie and position aside the bulk head connector (1).

Fig 3: EGR Bypass Valve Harness Connector & Exhaust Pressure Sensor Wire Harness Connector
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Disconnect the exhaust pressure sensor wire harness connector (2).
Disconnect the EGR cooler bypass valve wire harness connector (1).

Fig 4: Crankcase Pressure Sensor Wire Harness Connector & Clamp
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Disconnect the crankcase pressure sensor 2 wire harness connector (1).

Fig 5: Identifying Crankcase Pressure Sensor And Components
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Disconnect the crankcase pressure sensor 1 wire harness connectors (7).

Fig 6: Injector Harness Connectors
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Disconnect both fuel injector wire harness connectors (1).

Fig 7: CCV Tube, Crankcase Pressure Sensor Connector, CCV Oil Drains & Close Crankcase Ventilation (CCV) Cover
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Remove the CCV oil drains hoses (3) from cylinder head cover.
Remove the fuel tube silencer.

Fig 8: Intake Tube & Connecting Hose
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Loosen clamps (4) and remove the Charge Air Cooler (CAC) tube (3) (above injection pump).
Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .

Fig 9: Identifying Banjo Bolt & Fuel Control Actuator Electrical Connector
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Thoroughly clean rear of injection pump, and attachment points for its fuel lines. Also clean the opposite ends of these same lines at their attachment points.
Disconnect quick-connect fitting by pressing on button (1).
CAUTION:
Whenever a fuel line fitting is connected to a secondary fitting, always use a back-up wrench on the secondary fitting. Do not allow the secondary fitting to rotate.
Remove banjo bolt (2).
Disconnect FCA (Fuel Control Actuator) wire harness connector (3).

Fig 10: Fuel Injection Pump Components - Rear View
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Remove line clamp (5).

Fig 11: Fuel Rail Components
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Remove the high pressure pump-to-fuel rail fuel tube (5).

Fig 12: Pump Drive Gear Access Cover
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Remove fuel pump drive gear access cover with a 3/8" drive ratchet. Access cover (2) is threaded to timing gear cover.
Remove fuel pump drive gear mounting nut and washer.

Fig 13: Removing Pump Drive Gear
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Attach C3428B, or (special tool #L-4407A, Puller, Gear) (or equivalent) gear puller (1) to pump drive gear with 2 bolts, and separate gear from pump (a keyway is not used on this particular injection pump). Leave drive gear hanging loose within timing gear cover.

Fig 14: Fuel Injection Pump & Mounting Components
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Remove three injection pump mounting nuts (6), and remove pump from engine.