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Recall Notification #605 
Diesel Fuel Injection Pump
 
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Date: June, 1994 

Models: 1991- 1993 Ram Diesel

This Service Requirement Applies to Both, Original Equipment and Warranty Replacement Fuel Injection Pumps an the Following Vehicles:

Discussion:

The fuel injection pump fulcrum lever pin may break causing a loss of throttle control. To correct this condition, the fuel injection pump must be replaced.

IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery.

Details of this service action are explained in the following sections.

Service Procedure Videotape

As an additional service aid, a videotape demonstrating the service procedure will be included in the May, 1994 Master Tech program.

Parts:

Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Fuel Injection Pump Packages, PN C3906051 (Manual Transmission) and C3906052 (Automatic Transmission), to service 10% of those vehicles (minimum of 2 and maximum of 5 packages each).

Each parts package contains the following components:

  Quantity     Description
1 Pump, Diesel Fuel Injection (with 2 fuel outlet tube sealing washers)
1 Gasket, Pump Mounting
2 Washers, Fuel Filter-To-Pump Supply Line Sealing
1 Sensor, Throttle Position (TPS) -- Automatic Transmission Package Only
1 Instruction Sheet

Service Procedure:

A. Fuel Injection Pump Date Code Inspection

Fuel injection pump replacement is only necessary for pumps manufactured between March and September, 1991 (date codes 163 through 169), that have not already been repaired for this condition. Pumps having an infinity symbol on either the pump data plate or the Mopar Remanufactured Parts data tag have already been repaired and therefore, do not require replacement. Suspect pumps may have been installed either during vehicle assembly or as a replacement (remanufactured) part.

1.    Inspect the pump data plate for an infinity symbols shown in figure 1. Note: If a remanufactured pump has been installed, inspect the remanufactured parts data tag for an infinity symbol as shown in figure 1 .

   If there IS an infinity symbol present on either the data plate or tag, no further action is required.

2.    Inspect the pump data plate for date code 163, 164, 165, 166, 167, 168, or 169 (Figure 1).

Note: If a remanufactured pump has been installed, remove the top rivet and rotate the remanufactured parts data tag down to inspect the date code on the pump data plate below it.

If the date code on the data plate is NOT 163, 164, -1-65, 166, 167, 168, or 169, no further action is required.

Note: Apply a daub of RTV sealer behind the remanufactured part data tag (if equipped) to hold it in place.

Injection Pump Identification
Figure 1 - Fuel Injection Pump Data Plate and Remanufactured Parts Data Tag

B. Remove Fuel Injection Pump

1.    With the ignition key in the OFF position, disconnect the battery.

Note: To ensure customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset the electronic memory when you have completed the service procedure.

2.    Disconnect throttle linkage at the pump lever ball stud and remove the throttle linkage bracket and return springs (Figure 2).

Caution: Do not remove the pump control lever from the pump as it is indexed to the shaft during pump calibration.

figure 2

3.    Remove the air fuel control tube (Figure 3).

Caution: DO NOT bend any fuel tubes.   Figure 3

4.    Remove the low pressure supply line from the pump and the separator filter (Figure 4).

Figure 4

5.    Disconnect the fuel drain manifold and remove the hold-down clamp bolt located behind the high pressure lines (Figure 5).

6.    Label and disconnect the electrical wires to the fuel shut off valve, KSB solenoid and for automatic transmission only, the throttle position sensor.

Note. Two wires to fuel shut-off valve are interchangeable.

7.    Disconnect the six high pressure lines at the rear of the pump using an injector fuel line crowfoot such as Mac #CHBM17, Matco #WCFS17M or Snap-On #FRHM 17 (Figure 6).

Caution: Note each fuel line-to-pump outlet location to assure that the high pressure lines are installed onto the new pump properly.

Figure 5 and 6

8.    Remove the oil dipstick and the top engine cover. Remove the four bracket bolts at the top of the manifold holding the two fuel bundles (Figure 7).

9.    Disconnect the fuel tubes from the injectors using an injector fuel line socket such as Mac #COBR17, Matco #WCFM1517 or Snap-On #FRXM17. Remove the fuel line bundle for injectors 1, 2 and 3, then rotate the fuel bundle for injectors 4, 5 and 6 down to gain additional clearance at the rear of the pump (Figure 7).

10.   Remove the top 2 bolts, and the bottom bolt, of the pump support bracket. Then loosen the remaining bolt (located behind the power steering pump) and swing bracket rearward (Figure 8).

Figure 7 and 8

11.   Remove the oil filler bracket bolt and unscrew filler tube from base. Unscrew filler base from gear housing cover (Figure 9).

12.   Remove pump drive gear retaining nut and washer (Figure 9).

Caution: Place towel under gear nut before removing it to make sure that nut, washer or drive key do not drop into gear housing.

13.   Pull the fuel injection pump drive gear loose from the pump drive shaft using a T-bar puller such as Cummins #ST-647, Miller #L-4407A or Snap-On #CG606- BB (Figure 10). Remove T-bar puller from gear.

Note: Use 8mm x 1.25mm screws to attach puller to pump gear.

Caution: Use care when removing pump so that the drive key does not drop into the gear housing (Figure 11).

14.   Remove the three pump-to-housing mounting nuts and remove the fuel injection pump from the mounting studs (Figure 11).

Figure 11 Figure 12

15.   Remove the special washer wired to the replacement pump and set it aside for later use. Then transfer linkage ball stud an old pump throttle lever to the replacement pump throttle lever.

16. Vehicles equipped with automatic transmission only: Remove the three Allen screws attaching the Throttle Position Sensor (TPS) and bracket assembly to the old injection pump top cover. Remove the old TPS from the bracket and save the TPS adapter, screws and bracket for installation onto the replacement injection pump (Figures 12 & 13).

Figure 13

17.   Set old pump aside to drain for a minimum of ten minutes, then plug all orifices. ALL PUMPS MUST BE RETURNED TO THE WARRANTY MATERIAL RETURN CENTER. Use the replacement pump packaging for return shipment.

C. Install Replacement Fuel Injection Pump

1.    Vehicles equipped with automatic transmission only: Remove the three top cover screws from the replacement pump and install them into the old pump (old pump Allen screws are longer and required for the TPS bracket).

Install the TPS bracket onto the replacement pump using the alien screws from the old pump. Insert the hex on the bottom of the TPS adapter into the hex in the replacement pump throttle lever, making sure to engage the adapter tang into the notched area of the bracket (Figure 13). Install the provided TPS onto the bracket making sure to insert the slotted end of the TPS adapter into the notched area of the TPS.

The TPS adapter must engage the throttle lever hex and the TPS notch with the TPS and throttle levers spring loaded to the low idle position. (TPS will be adjusted after pump installation is complete).

2.    Spray the Top Dead Center (TDC) lock pin with Mopar MP-50, PN 4549626, to assure proper operation. Push the pin in and pull it out several times until it moves freely (Figure 14).

3.    Remove plastic plug at the lower right of transmission adapter housing and use a barring tool such as Cummins #337737 1, Miller #7471 A or Snap-On #SP371 to rotate engine in a clockwise direction (as viewed when facing the front of the engine) (Figure 14).

Note: To rotate the engine in a clockwise direction, the barring tool must be rotated in a counterclockwise direction as viewed from the front of the engine.

Locate the number one cylinder Top Dead Center (TDC) position of the compression stroke by watching the key-way of the pump drive gear. Slowly rotate the engine and push in on the TDC lock pin when the drive gear key-way approaches the 6:00 position. The engine will be at TDC of the compression stroke when the lock pin engages the hole in the cam gear with the drive gear key-way at about the 5:30 position (Figures 14 & 15).

Caution: Rotate engine with a barring tool only. Do NOT use starter motor. STOP barring the engine IMMEDIATELY when the TDC lock pin "SNAPS" into the cam gear hole.

If the pump drive gear key-way passes the 4:30 position and the lock pin has not engaged the cam gear, rotate the engine counterclockwise (rotate barring tool clockwise) to the 7:00 O'clock position and repeat this step. DO NOT ENGAGE THE LOCK PIN INTO THE CAM GEAR WHILE ROTATING THE ENGINE IN THE COUNTERCLOCKWISE DIRECTION AS PUMP-TO-ENGINE TIMING WILL BE AFFECTED.

Figure 14 Figure 15

4.    Remove the barring tool, install the plastic plug into the access hole and pull the TDC lock pin out of the cam gear hole. DO NOT MOVE THE ENGINE ONCE THE NUMBER 1 TDC COMPRESSION STROKE POSITION IS SET.

Caution: Be sure to PULL TDC LOCK PIN OUT of cam gear or pin will be sheared off.

5.    Remove the old injection pump mounting gasket. Clean the sealing surface and install the provided gasket (Figure 16).

Figure 16 Figure 17

6.    Install the injection pump onto the mounting studs and finger tighten the three pump mounting nuts. The pump must be free to rotate in the slots (Figure 17). Make sure the key doesn't fall into the gear housing.

Caution.- To prevent slippage, spray the pump drive shaft and drive gear with Mopar Brake Cleaner, PN 4318037, to assure both are clean and free of all oil before installation.

Note: The shaft of the replacement pump is locked so that the key aligns with the drive gear key-way when cylinder number one is at TDC of the compression stroke.

7.    Install the pump drive gear nut and spring washer and torque to 18 ft-lbs (24 N*M). The pump may rotate slightly when tightening the pump drive nut because of the gear lash between the pump drive gear and cam gear. This movement is acceptable providing the entire pump moves within the mounting stud slots and there is no pump shaft-to-pump housing movement (Figure 18).

Caution: DO NOT OVER TIGHTEN PUMP DRIVE GEAR NUT. The replacement pump shaft is looked in position to eliminate the need to set pump-to-engine timing. This is NOT the final torque for the drive gear.

Caution: DO NOT APPLY HEAVY ROTATIONAL FORCE on pump after gear backlash is removed as this may preload the pump and affect pump-to-engine timing.

Figure 18 Figure 19

8.    Gently rotate the fuel pump against the direction of drive rotation to take up any gear lash as shown in figure 19. Evenly tighten the pump mounting stud nuts to 108 in-lbs (12 N*m), then to a final torque of 18 ft-lbs (24 N*M).

9.    Use a chisel or equivalent tool to permanently mark the injection pump mounting flange to match the existing mark on the gear housing (Figure 20).

Fig 20

10.   Unlock the fuel injection pump shaft by loosening the lock screw as shown in figure 21. Insert the special washer (previously removed from the pump) under the lock screw, then torque the lock screw to 10 ft-lbs (13 N*M).

Fig 21 and 22

11.   Tighten the pump drive gear retaining nut to a final torque of 48 ft-lbs (65 N*M) as shown in figure 22. Remove towel previously placed in drive gear area.

12.   Screw the oil filler base into the gear housing cover, then screw the filler tube into the base and tighten bracket bolt (Figure 9).

13.   Install the fuel drain manifold (banjo) fitting to the pump using the new bolt and sealing washers provided with the replacement pump and torque bolt to 24 ft- lbs (32 N*M). Install the fuel tube hold-down clamp bolt and torque to 18 ft-lbs (24 N*M) (Figure 5).

Note: The new banjo bolt provided with the replacement pump has a calibrated bleed which is matched to the replacement pump. DO NOT reuse the old bolt or sealing washers.

14.   Install the fuel supply line to the pump and torque fitting to 24 ft-lbs (32 N*M). Install the other end of the supply line to the separator filter using the new sealing washers provided. Leave this banjo bolt finger tight until after the fuel system has been purged of air (Figure 4).

15.   Install the high pressure fuel lines to the pump and torque to 22 ft-lbs (30 N*M) (Figure 6). Install the fuel lines to each injector, but DO NOT tighten the fuel lines at the injectors until the fuel system has been purged of air.

Caution: Be sure that each fuel line is installed onto the same pump outlet port position from which it was removed. Prevent the injection pump delivery valve holders from turning when installing the lines onto the pump.

Note: THOROUGHLY clean the high pressure fuel lines with Mopar Brake Parts Cleaner, PN 4318037, to make sure NO debris is present before installing the fuel lines onto the injectors or fuel pump.

16.   Coat the four bolts used to secure the fuel line support brackets with Mopar Silicone Sealer (RTV), PN 4318025, then install and torque the bolts to 18 ft-lbs (24 N*M) as shown in figure 7. Install the oil dipstick and top engine cover.

Note: Failure to apply sealant to the mounting bolts can result in an air intake leak.

17.   Install the air fuel control tube (Figure 3).

18.   Connect the electrical wires to the fuel shut off valve, KSB solenoid and for automatic transmission only, the throttle position sensor.

Note: Two wires to fuel shut-off valve are interchangeable.

19.   Swing the pump support bracket into position and torque the 4 bolts to 18 ft-lbs (24 N*M) (Figure 8).

20.   Install the throttle bracket and torque bolts to 1 8 ft-lbs (24 N*M). Install throttle linkage onto pump lever ball stud and install the throttle return springs (Figure 2).

21.   Inspect the closed throttle and wide open throttle accelerator linkage travel stops. Verify that the pump throttle lever contacts the low idle speed screw in the closed throttle position. With the aid of an assistant, depress accelerator pedal to the wide open throttle position. Verify that spring loaded breakover lever has moved off the stop and is against the break-over spring (Figure 23).

If the pump stops are not as described, adjust the linkage using the "Throttle Linkage Adjustment - Diesel Engine" procedure in the service manual.

22.   Loosen the low pressure supply line banjo bolt and bleed screw at the separator filter and operate the hand lever on the lift pump until the fuel flowing from the fitting is free of air. Then torque the separator filter banjo bolt to 24 ft-lbs (32 N*M) and the bleed screw to 72 in-lbs (8 NOM) (Figure 24).

Figure 23 Figure 24

23.   Loosen all six fuel tube connections at the injectors and operate the hand lever of the lift pump until fuel is observed corning out one of the high pressure fuel lines at the injectors or until lift pump lever has been pumped a minimum of 30 seconds, whichever occurs first. (Figure 25).

24.   Reconnect battery.

25.   With the fuel tube connections still loose at all injectors and the transmission in neutral or park, crank the engine to allow entrapped air to bleed from the fuel lines (Figure 25). Tighten all injector fuel line connections.

Caution: The pressure of the fuel in the line is sufficient to penetrate the skin (59,000 kpa/8,000 psi) and cause serious bodily harm. Wear safety goggles and adequate protective clothing and do not allow contact with fuel spray when bleeding high pressure lines.

Caution: Place the transmission in neutral or park and set the parking brake before engaging starter motor.

Caution: When using the starter motor to purge air from the system, do not engage it for more than 30 seconds at a time and wait two minutes between engagements.

26. Start the engine and purge air from each injector fuel tube connection one line at a time until the engine runs smoothly (Figure 25). Tighten all injector fuel line connections to 1 8 ft-lbs (24 No M) using an injector fuel line socket such as Mae #COBR17, Matco #WCFM1517 or Snap-On #FRXM17.

Caution: Do not bleed air from the fuel system of a hot engine. Do not allow fuel to spray onto the exhaust manifold when bleeding air from the fuel system.

27.   Connect an optical tachometer to the engine such as Cummins #3377462, or Snap-On #MT139 (1992-93 models may use DRB 11). Prepare the vehicle for an idle check as follows:

Figure 25 Figure 26

28.   Vehicles equipped with automatic transmission only: Check and adjust the throttle position sensor (TPS) as follows (Figure 27):

Figure 27

Completion Reporting and Reimbursement

Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.

Use the following labor operation number and time allowance:

    Labor Operation   
Number
Time
  Allowance  
Inspect fuel injection pump 14605181 0.2 Hours
Inspect and replace fuel injection pump - manual transmission vehicles 14605182 3.2 Hours
Inspect and replace fuel injection pump - automatic transmission vehicles 14605183 3.3 Hours

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

Note: For parts reimbursement, the core allowance must be subtracted from the C3906051 and C3906052 part numbers, and the net, less core value marked up.

For core reimbursement, enter the corresponding core part number, U3906051 or U3906052, on the claim with NO MARK UP. The use of the special service labor operation numbers for cores is not permitted in the DIAL system for recalls.

Parts Return

ALL REMOVED FUEL INJECTION PUMPS MUST BE RETURNED TO THE WARRANTY MATERIAL RETURN CENTER (including dealers in Alaska and Hawaii). Drain the pump for approximately ten minutes and plug orifices. Use the replacement pump packaging and orifice plugs for return shipment.

Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions.

Vehicle Not Available

If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to:

Chrysler Corporation 429-10-04
P.O. Box 1919
Detroit, Michigan 48231-1919

Following the above procedures will expedite the processing of your claim.

If you have any questions or need assistance in completing this action, please contact your Zone Service Office.


Thanks to Bob Bergevin and Barry Drodge for supplying this Recall information.

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This page was edited on: May 3, 2004