Dodge ram truck 3500 1996 Service Manual page 1337

BR
FUEL SYSTEM 14 - 1 0 3
R E M O V A L
AND INSTALLATION
( C o n t i n u e d )
INJECTION
PUMP
GEAR
PUMP M O U N T I N G
STUDS
PUMP M O U N T I N G
FLANGE
Fig. 98 Apply Oil to Gear Cover
J9414-5
(3) Position the pump assembly to the mounting
flange on gear cover while aligning the injection
pump shaft through the back of injection pump gear.
(4) Install the four pump mounting nuts finger
tight. Do not attempt to tighten (pull) the pump
to the gear cover using the mounting nuts.
Damage to pump or gear cover may occur. The
pump must be positioned flat to its mounting
flange before attempting to tighten mounting
nuts.
(5) Install two (vertical) pump mounting bracket
bolts finger tight.
(6) Tighten the four pump mounting nuts to 24
N-m (18 ft. lbs.) torque. Tighten the two pump
mounting bracket bolts. To prevent damage to
pump and mounting flange, tighten the pump
mounting nuts first.
(7) Install injection pump drive shaft-to-injection
pump gear retaining nut and washer. Do a prelim­
inary tightening of this nut to 10 to 15 N«m (7 to
11 ft. lbs.) torque. Do not over tighten. This is
not the final tightening torque. To prevent dam­
age to the timing pin, do not exceed this
torque.
(8) Disengage the timing pin from the rear of cam­
shaft gear by pulling i t straight back.
(9) Remove the access plug from injection pump
(Fig. 95) and remove timing pin tool from pump.
(10) Do a final tightening of the injection pump
gear-to-injection pump shaft nut. Tighten to 165 N-m
(122 ft. lbs.) torque. Use the barring tool to prevent
the engine from rotating when tightening gear.
(11) After the injection pump gear has received a
final tightening, verify injection pump timing.
(a) Rotate the engine counterclockwise with the
barring tool (clockwise as observed at the crank­
shaft from the front of vehicle). Continue rotating
engine until the timing pin aligns into hole at rear
of camshaft gear (Fig. 90). The engine is now at
TDC of number cylinder 1.
(b) With the timing pin aligned into the rear of
the camshaft gear, the timing tooth should also be
centered in the access hole on the side of the injec­
tion pump (Fig. 97). Install timing pin tool (Fig. 96)
to verify.
(c) I f the timing pin tool will not fit into the tim­
ing tooth in the pump, the pump gear nut must be
removed. Loosen the pump gear from the pump
shaft with the T-bar puller tool. With the gear loos­
ened, rotate the injection pump shaft until i t aligns
to the center of access hole on side of pump.
Tighten injection gear nut and remove barring tool.
(12) Remove the timing pin tool from the pump.
Reverse the position of this tool (Fig. 96). The slotted
part of tool * should be facing outward and will be
stored in pump in this direction. Place tool back into
pump. Install access plug and its sealing washer.
Tighten plug to 15 N-m (11 ft. lbs.) torque.
(13) Install the engine oil supply line and fuel
return line/overflow valve to pump.
(14) Install the six high-pressure fuel lines to the
top of pump. Tighten lines to 30 N-m (22 ft. lbs.)
torque.
(15) Install the low-pressure fuel supply line to
pump.
(16) Install the turbocharger wastegate line and
AFC sensing line at the pump.
(17) New or rebuilt P7100 series fuel injection
pumps must be pre-lubricated before operation.
Failure to do so may result in pre-mature gov­
ernor wear.
(a) Remove the 10 mm hex plug (oil fill plug) on
• the top of the injection pump governor (Fig. 95).
(b) Add 750 ml (25 ounces) of clean engine oil
through this opening.
(c) Install oil fill plug and tighten to 28 N-m (21
ft. lbs.) torque.
(18) Install the throttle linkage assembly to pump.
Tighten bolts to 24 N-m (18 ft. lbs.) torque.
(19) Connect electrical connector to fuel solenoid.
(20) Connect the main engine wiring harness at
top of injection pump.
(21) Install the engine oil dipstick tube mounting
clamp and bolt at the opening to the intake manifold.
(22) Install oil fill tube and tube adapter.
(23) Install oil fill tube bracket and mounting bolt.
(24) Install electrical connector to throttle position
sensor (if equipped).