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Fuel Injection Pump: Removal

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. Disconnect negative battery cables. Disconnect necessary electrical connections at fuel injection pump. Disconnect intercooler outlet duct from air inlet housing. See Figure.
  2. Remove clamp and position oil dipstick tube aside. Disconnect air intake heater electrical connectors. Air intake heater is installed between air inlet housing and intake manifold cover. Remove bolts, air inlet housing, air intake heater and gaskets.
  3. Remove throttle lever bracket with control cables from side of fuel injection pump. Remove turbocharger wastegate line and vacuum line from Air Flow Control (AFC) valve located on top of fuel injection pump. See Fig 3.
  4. Remove fuel injection pump supply line at both ends. Remove overflow valve and fuel return line from fuel injection pump. Overflow valve holds fuel return line on fuel injection pump. Overflow valve and fuel return line are located on cylinder block side of fuel injection pump, near front of fuel injection pump.
  5. Remove high-pressure (injector) lines from fuel injection pump. Hold delivery valve on fuel injection pump with wrench while removing high-pressure fuel line.
  6. Disconnect oil supply line from side of fuel injection pump. Remove oil fill tube and adapter elbow from front timing gear cover by rotating assembly counterclockwise (viewed from front of engine).
  7. Disconnect air inlet tube from turbocharger and air filter housing. Engine can be rotated by removing dust plug from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. See Fig 1.
    Fig 1: Rotating Engine & Engaging Timing Pin
    G94F65453Courtesy of CHRYSLER CORP.
  8. Note location of timing pin, located on back of timing gear case, just above vacuum pump and power steering pump. See Fig 1. While applying pressure on timing pin (toward front of engine), slowly rotate engine clockwise using Engine Barring Tool. Rotate engine until timing pin engages machined hole on camshaft gear. This positions cylinder No. 1 at TDC on compression stroke.
    CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
  9. While holding engine from rotating with engine barring tool, loosen fuel injection pump drive gear nut. To prevent nut from falling inside timing cover, use a pencil-type magnet on end of pump shaft. See Fig 2.
    NOTE: If pencil-type magnet is not available, place shop towel below fuel injection pump drive gear nut and front timing gear cover to prevent nut from falling into engine.
  10. Remove fuel injection pump drive gear nut and washer from pump shaft. DO NOT allow nut or washer to fall in front timing gear cover. Using Puller (L-4407A), pull fuel injection pump drive gear just enough to break loose from tapered area on pump shaft. DO NOT pull gear too far or front timing gear cover may be damaged. See Fig 3.
  11. Remove remaining fuel injection pump mounting bolts. Remove fuel injection pump. Use care not to scratch or damage on shaft of fuel injection pump during removal.
Fig 2: Removing & Installing Fuel Injection Pump Drive Gear Nut & Washer
G94G65454Courtesy of CHRYSLER CORP.
Fig 3: Removing Fuel Injection Pump Drive Gear
G95I27019Courtesy of CHRYSLER CORP.
NOTE: Before installing new or original fuel injection pump, ensure engine is at TDC and injection pump shaft is in proper position.
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