Engine/Transmission (1998.5 - 2002) VP44 Removal and Replacement

[MAYoung]

I have just completed a FP/Boost/EGT gauge installation. All of it was done in anticipation of the removal and replacement of the VP44 fuel injector pump replacement. My first pump failed at 79,000 miles and was covered under warranty. The second is now at 158,000 miles. It has followed a common failure mode--lift pump failure followed by the injector pump being destroyed.



I am following Bob Wagner's posting on the replacement of the VP44 and I have found his suggested procedures to be detailed and accurate for a 1998. 5 2500. I am stopped at step 27 under removal since the support bracket was indeed broken. I hope Dodge has engineered a better solution for this part since it appears that the bracket was repaired via welding at the earlier replacement.



Some others have suggest that align the key in the 12 o'clock position with a breaker bar on the altenator pully nut. I was surprised that it turned so easily.



So far, so good. Let's hope that the part comes from DC tomorrow.

 

[nps]

So far, so good. Let's hope that the part comes from DC tomorrow.

My hopes are with you. Good luck. Are you saying that the weld broke on the support bracket?

 

[Fishin Guide]

I was a little intimidated by that keyway issue on the VP. But, even after stressing that point, I was done in under 3 hours. Pretty easy swap.



Dave

 

[Gary - K7GLD]

I was a little intimidated by that keyway issue on the VP. But, even after stressing that point, I was done in under 3 hours. Pretty easy swap.



Dave

Dave - and any other lurkers having done the same job - did you swap out the CPS while you had the VP out - or just do the pump?

 

[Fishin Guide]

Dave - and any other lurkers having done the same job - did you swap out the CPS while you had the VP out - or just do the pump?

Yep! Mucho easier at that time!!!



Dave

 

[Gary - K7GLD]

Yep! Mucho easier at that time!!!



Dave

With my luck, the old one would be better than the new replacement...



Are the CPS prone to failure? Why change them if there are no symptoms of problems? I only ask because it seems pretty common to replace them during a VP swap, but I rarely see reports of them actually failing...

 

[TGibbs]

With my luck, the old one would be better than the new replacement...



Are the CPS prone to failure? Why change them if there are no symptoms of problems? I only ask because it seems pretty common to replace them during a VP swap, but I rarely see reports of them actually failing...

Could that be because jthey VP are replaced so often along with the CPS that it never gives the CPS a chance to wear out :-laf



When I replaced mine, I thought about replacing the CPS but it was 1 o'clock in the morn by this time and I had to go to class at 7 the next morning so I kept on uh chugging!



Tristan

 

[MAYoung]

Gentlemen:



Thank you for the support.



The support bracket arrived today but not to my surprise, the 2nd bracket that mounts directly to the injector pump has also been superceded--not just the bracket that mounts on the engine block. I should have checked more carefully. Usually, when DC does a new and improved version, it will bolt right back into place. Lesson learned.



To remove the bracket for the engine block, you need to undo the four nuts that hold the power steering pump on to the vacuum pump assembly (plus one nut for a wire harness support). The pump comes right off. You will then need a T-40 "socket" to undo the block support bracket. it is a little tricky but not impossible. Support the pump out of your way with a wire.



The new block mounted bracket is now quite substantial. I hope that the secondary bracket is an easy bolt on. We will see when it arrives--hope, hope--from DC.



While waiting for the support bracket, I completed the assembly of the pump and engine. I marked the key end with white paint so that I could view the alignment with a mirror. I was careful as I could be but I still fretted over the alignment. It went right in. I was a little more surprised upon the torque down of the axel bolt as I encounterd the sudden relaxation in torque as the the nut crimped down.



I did not replace the CPS sensor. I should be much more efficient the next time.



Anyway, I did not feel comfortable with Mr. Wagner's lift pump "jumper" so I just bled the injector lines by turning on the switch to activate the lift pump. I thought I still had bubbles when the engine started. Closed everything up and the vehicle started immediately.



I won't do a true test drive until tomorrow but everything looks good so far.



Again, thanks.

 

[Gary - K7GLD]

Get back to us with your results - I may not be far behind you with my own VP-44 replacement - mine has just enough failure symptoms (codes) to be worrisome - yet the truck is running great overall. BUT, RV season is here, and this is largely a wilderness area - so I really dislike taking chances. I have the spare rebuilt VP-44 anyway, so the worse (best) that could happen, is that my vague symptoms prove to be something else, and I'll have just traded spares...

 

[MAYoung]

Gentlemen:



The truck is now fully operational as of late this afternoon. It turns out that the largest challenge was the installation of the updated support bracket. I incorrectly assumed that it would bolt on in similar fashion to the old style bracket---wrong!



The block bracket bolted on to the same space as before but I had no drawings or guildlines as to how it should fit. It turns out that I had the bracket reversed (not upsidedown). I also discovered that the secondary bracket which actually bolts to injector pump now bolts on the "bottom," rather than the rear section of the pump.



I was so frustrated with the new bracket that I took the old one to be re-welded at Orangevale Diesel. While I was waiting for the welding, I noticed a 24-valve engine sitting on the floor with a newer style bracket. The mystery of the support bracket suddenly resolved itself.



Here are some key points for replacing the support bracket---



1) Bolt the secondary bracket that bolts directly to the pump before you install the pump. You master mechanics may have a method for installing this item after the pump is installed but I cannot see how it is done. (The older bracket could be installed after injector pump install. )



2) You will need 4 bigger and longer bolts to bolt on the new bracket. Make sure that you line them up before you begin. They are both 10mm bolts with 1. 50 threads. Two are about 1 inch long while the bolts going into the injector pump are about 40mm long. Check with DC for confirmation of bolt sizes. They will want a small forture for the two smaller bolts---$15. 00 each. You can get grade 8 equivalents at Ace Hardware for about $1. 00 each. (The three 8mm bolts no longer work with the new bracket. )



3) You will have to remove the power steering pump to do all of the bracket upgrades. Removing some of the nuts requires patience but I suggest using a 15mm 3/8" socket with and adapter to a 1/4" ratchet. Worked great for the tight space on the inside nuts.



The engine started right up. The check engine light activated while "bumping" the lift pump to prime the system. I now have a modest code reader to remove the check engine light.



It is nice to have the old engine back--quick starting, lots of power. The failing injector pump was getting to be a true hazard since it was increasingly becoming prone to stalling and hard starting.



Hope this helps someone else's VP44 project. I really appreciate Mr. Wagner and his original posting. My spouse would not have let me keep the truck if I had to pay fully dealer price, parts and labor.



Regards,



Mark Young Oo.

 

[Gary - K7GLD]

IF all the "old" VP-44 brackets were as rugged as the 1-piece stamped steel one on my truck, I sure can't understand how/why they can break!



Mine was secured to the rear underside of the VP with a pair of miserable star head (I forget the proper term!) bolts that were just 1 size larger than I had a bit for - so I filed a flat on opposite sides of the heads, and used visegrips to remove them and reinstall on the new replacement VP-44 I did Sunday.



But IF the pump itself is properly secured to the front of the engine, and the rear support is also bolted securely, what is it that breaks that brace?



Like you, I'm glad for the secure feeling of having that new VP in there for the RV towing season - but my old pump seemed to be functioning perfectly - just giving me the P0216.



I'll certainly hang on to it for a while, just in case other issues eventually arise that point to other problems instead of the pump itself. But so far, so good!

 

[benhall]

Mark,



Where are those directions located at?



Ben

 

[MAYoung]

To benhall:



Do a forum Search under user name "EdK". He has a copy attached under the thread "injector pump procedure". Their are other posting of this attachment but I cannot get it by simply searching Bob Wagner.



Good luck.

 

[MAYoung]

To Gary:



I am like you---why would a rear bracket break when the axel at the front of the injector pump is torqued down to 125 ft lbs! One would think that the front mounting alone would be substantial enough to hold the pump securely in place. Mr. Wagner was very specific and responded with all caps that the bracket must be repaired or replaced. The alternative, he suggests, is a trashed pump.



I am, however, not an engineer. Perhaps it is the torque forces applied to the pump by drive gears... ... ?????



Regards,



M Young

 

[MAYoung]

As an aside--I know that a number of individuals invest a great deal of time and effort into getting their truck just right. My truck, however, simply gets to go back to work. Within 6 hours of the repair being finished, the truck took a large load to the dump, turned around and picked up a 1,100# load of lumber and then went to pick up a horse trailer sans horses. Then a quick run to Costco since it has far greater load carrying capacity than anything we own. For such good service, it gets to go back and do the same thing tomorrow. (It was, however, washed tonight. )



My "better half" really does not like the diesel or the 5 speed manual shift although she will drive it when all else fails. She never seems to fail to volunteer the 2500 when its capabilities are needed. I guess I should not complain about the maintenance--it is doing something nearly every day of the week.