Engine/Transmission (1998.5 - 2002) Replacing Injection Pump.A few questions.

[MFranz]

Getting ready to install a new Injection Pump from Industrial Injection. Want to make sure Ive got everything I need to do the job.

1. Do I need the barring tool to rotate the crankshaft that they show in the shop manual or is wrench and cheater bar on the alternator nut just as good. If I need the barring tool where can I get one and how much are they.

2. Do I use any kind of thread sealant on the high or low pressure fuel line fittings. If so what works best.

3. Are there any gaskets or washers that need to be replaced.

4. Whats the best procedure for bleeding the high pressure fuel lines.

5. Im planning on replacing the camshaft postion sensor since I have the pump off. That looks pretty straight forward. Any notes there.

Thanks in advance for taking the time to respond. All input is appreciated.

Mike

 

[SHobbs]

Check out http://www.nwbombers.com/membersites/kent/vp44.html. very good instructions on VP44 replacement

 

[Rebel Ram]

Baring tools are great but not absolutely necessary. You only have to get it to where you want it once for the entire job. I pull the access panel @ the trans and carefully use a prybar on the starter gear on the flex plate.

 

[ARoss]

1. Use a wrench on the alternator nut to barr the engine. Turn it anti-clockwise.

2. No thread sealant necessary.

3. No gaskets, just banjo washers.

4. You may have to crack a couple of injector lines at the head. After priming with the LP, crank the engine and watch for fuel a the cracked lines, tighten then start.

5. Never done it, can't help you there.

 

[Diesel Nut]

Use a socket on the Primary pully (dampner) from under the truck to rotate it. I think its a 14mm. Tried the alternator and wouldn't work for me. Everything else should be very strightforward. Good luck and tells us how it turns out!

 

[jwilliams3]

Get a barring tool.



http://buy1.snapon.com/catalog/item...&group_ID=1294&store=snapon-store&dir=catalog



The others ways are pretty redneck.



PS Be careful when removing pump not to drop the key into the gear case.

Also, it will take pretty good torque on the gear to get it to "POP" off of the injection pump.

You'll know when it does



When you put the new injection pump in make sure to have a mechanics mirror handy to so you can get the key into the gear perfectly.

It is very easy to damage a key and or push it out. So this part is critical.



Prior to installing a new pump make sure to use a clean rag with alcohol to clean out the shaft hole in the gear and clean the shaft off also.

This will prevent the gear from slipping on the shaft of the pump.

 

[ARoss]

Prior to installing a new pump make sure to use a clean rag with alcohol to clean out the shaft hole in the gear and clean the shaft off also.

This will prevent the gear from slipping on the shaft of the pump.

Doesn't the key in the keyway prevent that?

 

[jwilliams3]

Not really. The key is a really soft material. I suppose it could help or prevent it but that is not the keys purpose.

The key is to get the location/timing dead on for the pump.



The Common Rail pumps 03 and up have no key (but they are not timed).

 

[dieseldude]

when it comes to barring the motor you can go out and buy a specific tool but it is much cheaper to use what you have. The best way I have found is to just use the breaker bar and socket on the dampner on the lower part of the motor. turn it clockwise.

Thanks again to dieselnut motor sports for the great transmission upgrades my truck runs great!!

 

[MFranz]

Replacing Injection Pump.

Thanks for the response everybody. I've got the pump bolted on and Im in the process of reconnecting the high pressure fuel lines. That is turning out to be a little time consuming . .

A few questions.

1. After bolting on the pump I tried looking at the keyway

with a mirror from the front side where the injection pump gear nut is. I thought that I would have been able to see the keyway but I could not. So I took a piece of wire and pushed it up into the keyway thinking that it would stop

when it hit the keyway. It didn't. So I unbolted the pump and took it partly out and found the keyway still in place

so I assume that it is aligning properly and bolted it back together.

2. I was having such a hard time taking out the pump with the high pressure fuel lines in the way that I removed most of them. The challenge is to put it back together.

Any secrets there. What tools are you using to put the high pressure lines back onto the pump. I did mark the high pressure lines to ID them. but having a hard time

recalling the sequence that they should install. Its like a puzzle.

Again thanks for the replys. I would never have attempted this project without the support of TDR.

Mike

 

[MFranz]

Injection Pump.

Thanks everyone for sharing. Injection pump is in and runs great . No codes yet. Hopefully for a long time.

I do have a leak at the injection lines where they go into the injectors. I may have over torqued when installing,not sure. Has anyone had the same problem. How do you torque a nut that takes an open end wrench. The torque wrench that I have only takes sockets.

Thanks

Mike

 

[klaybus]

Thanks everyone for sharing. Injection pump is in and runs great . No codes yet. Hopefully for a long time.

I do have a leak at the injection lines where they go into the injectors. I may have over torqued when installing,not sure. Has anyone had the same problem. How do you torque a nut that takes an open end wrench. The torque wrench that I have only takes sockets.

Thanks

Mike

It's called a "Crowsfoot". It looks like the end of a open end wrench that has a square hole in it so it can attach to a torque wrench \ ratchet... . Just a taste above snug should be sufficient. Glad things went good for you. I helped my brother in law last weekend & he dropped the key into the timing cover. That added to the procedure quite a bit... .



Clay

 

[ARoss]

If you're going to use a crowsfoot, remember the torque will be set differently. Here's a link so you can calculate the correct torque.



http://www.norbar.com/torquewrenchextensioncalculator.php

 

[MACHINEST]

If you ever do it again if you look at the fuel lines,take them off in pairs of three,leaving 3 lines hooked together,much easier... .

 

[MFranz]

Crows Feet

Thanks everybody. I will be getting a set of those real soon.

Always looking for an excuse to buy more tools. Has anyone out there ever encountered a problem with a leaking fuel line at the injectors?If so what were the results?

Thanks again for sharing

Mike