DODGE TRUCK 1993 Service Repair Manual

14 - 112
FUEL
SYSTEM

J9114-57

Fig.
21 Timing Pin—Cylinder No. 1 (16) Locate TDC position (compression stroke) for

No.
1 cylinder by slowly rotating the engine with the
barring tool while lightly pushing in on the timing
pin. Stop when the timing pin engages the index hole in the camshaft gear.
(17) Disengage the timing pin from the camshaft
gear.
Check the timing marks on the flange of the injec­
tion pump (Fig. 22). Each pump and engine have unique marks. It is not possible to exchange pumps and use the same marks for alignment.
The injection pump has a lockscrew. The lockscrew
is used to hold the injection pump shaft in place once
TDC has been located. New and rebuilt injection
pumps should be received with the shaft locked in
place by the lockscrew.
(18) Loosen the injection pump shaft lockscrew. It
is located below the injection pump mounting nut.
Remove washer from injection pump (Fig. 23). Attach
washer to injection pump with wire tag for use dur­ ing installation. (19) Tighten lockscrew.
J9114-58

Fig.
22 Injection
Pump
Timing Marks

Fig.
23 Injection
Pump
Shaft
LockScrew
and
Washer
(20) Use a T-bar puller to separate the gear from
the pump shaft. Use M8 X 1.24 MM (metric) screws
to attach T-bar to shaft. Pull the injection pump gear forward until it separates from the injection pump shaft (Fig. 24). The injection pump gear cannot be re­
moved from the engine through the oil fill opening in
the timing case cover.

CAUTION:
Do not allow the drive
gear
key-way to

drop
into the
gear
housing
cover
when removing
the
pump.

(21) Remove the injection pump mounting nuts.
(22) Remove injection pump. Clean gasket surfaces
on block and injection pump.
INSTALLATION Before installing the injection pump, be sure that

No.
1 cylinder is at No. 1 position. (1) Locate TDC position (compression stroke) for

No.
1 cylinder by slowly rotating the engine with the

•

Fig.
24 Separating
Pump
Gear from injection
Pump
Shaft
barring tool while lightly pushing in on the timing
pin. Stop when the timing pin engages the index hole
in the camshaft gear.
(2) Disengage the timing pin from the camshaft
gear. (3) Install a new injection pump gasket.
The shaft of a new or reconditioned pump is locked
in place. The key is positioned to align with the drive
gear slot when cylinder No. 1 is at TDC on the com­
pression stroke.

CAUTION:
Be
sure
that
the injection
pump
shaft
key-way
does
not
fall
into the
gear
housing
when

installing
the injection
pump.
The
key-way
must
be

removed
if it
falls
into the
gear
housing.

(4) Install the injection pump. Finger tighten the
mounting nuts. The pump must be able to move in
the slot.
(5) Remove the T-bar from the injection pump
gear.
(6) Install pump drive shaft gear retaining nut and
spring washer. The injection pump will rotate
slightly if the pump mounting nuts were installed
finger tight and the crankshaft does not move.
(7) Tighten injection pump drive shaft gear retain­
ing nut to 15-20
Nth
(11-15 ft. lbs.) torque. Do not
over tighten. This is not the final tightening
torque.
(8) If installing original injection pump, rotate
pump to align timing marks. If installing a new or
rebuilt pump without a timing mark, take up gear lash by rotating pump counterclockwise towards cyl­
inder head.
(9) Tighten injection pump mounting nuts to 24
Nnn (18 ft. lbs.) torque. If installing a new or rebuilt pump, permanently
mark the injection pump flange in line with the
mark on the gear housing (Fig. 25).
FUEL
SYSTEM
14 - 113

Fig.
25 Marking New or Rebuilt Injection
Pump
New and rebuilt injection pumps should be re­
ceived with the shaft locked in place by the lock- screw.
(10) Loosen injection pump lockscrew and install
washer under lockscrew (Fig. 26). Tighten lockscrew to 13 Nnn (10 ft. lbs.) torque.

Fig.
26 Installing
Lockscrew
Washer

(11) Install injection pump support bracket with
mounting screws finger tight. Using following the sequence, tighten mounting screws to 24 Nnn (18 ft.
lbs.) torque.
• Tighten bracket to vacuum pump screw.
• Tighten bracket to block mounting screws. • Tighten bracket to injection pump mounting
screws.
• Tighten throttle support bracket mounting screws. (12) Tighten injection pump drive shaft gear re­
taining nut to 65 N*m (48 ft. lbs.) torque.
(13) Install oil filler assembly to gear housing.
Tighten clamp screw to 43 Nnn (32 ft. lbs.) torque.
(14) Install high pressure fuel lines. Refer to High
Pressure Lines. Tighten high pressure fuel lines to 24 Nnn (18 ft. lbs.) torque.

14 - 114
FUEL
SYSTEM

• (15) Install fuel injection pump supply line. Refer
to Fuel Injection Pump Supply Line.
(16) Connect electrical connector to fuel solenoid.
(17) Connect electrical connector to KSB solenoid.
(18) Install fuel pump vent line and capscrew.
(19) Install air fuel control tube.
(20) Install throttle bracket (Fig. 15). Tighten
mounting bolts to 24 N»m (18 ft. lbs.) torque.
(21) Install throttle linkage. When connecting the
cable to the control lever, adjust the length so the le­
ver has stop-to-stop movement. Refer to Accelerator
Pedal and Throttle Controls section of Group 14,
Fuel Systems.
(22) Install and adjust throttle position sensor. Re­
fer to Service Adjustments.
(23) Bleed air from fuel system. Refer to High
Pressure Fuel Lines in the Air Bleeding portion of
the Diesel Fuel Injection section of Group 14, Fuel Systems. (24) Adjust the low idle speed if required. Refer to
Service Adjustments near the end of this group. (25) Inspect throttle linkage to be sure that the
control lever breaks over the full throttle position.
Adjust as necessary. Refer to Accelerator Pedal and
Throttle Cable section of Group 14, Fuel Systems.

FUEL
INJECTION
PUMP
SUPPLY
LINE

REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect supply line at fuel/water separator
filter (Fig. 27).

Fig.
27
Supply
Line
to Separator
Filter
Connection
(3) Do not allow the injection pump inlet fit­
ting to move when loosening supply line. Use two wrenches when removing line. Disconnect
supply line from injection pump (Fig. 28).

INSTALLATION
(1) Install low pressure fuel supply line in reverse
order of removal.
Fig.
28
Supply
Line
to Injection
Pump
Connection

(2) Tighten the supply line connections to 24 Nnn
(24 ft. lbs.) torque.
(3) Manually bleed the system of air. Refer to
Manual Bleeding in this section.
(4) Connect negative cable to battery.

FUEL
INJECTORS

REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove throttle linkage.
(3) Remove high pressure fuel lines. Refer to High
Pressure Fuel Lines in this section. (4) Remove the fuel drain manifold. Refer to Fuel
Drain Manifold in this section. (5) Thoroughly clean the area around the injector.

CAUTION:
Use a deep
well
socket
to remove the

fuel
injector (Fig. 29).
(6) Remove injector (Cummins injector nozzle
puller tool 3823276 or an equivalent). Discard copper seal.
Fig.
29
Fuel
Injector Removal/Installation

FUEL SYSTEM
14 - 115

(7) Clean injector nozzle bore with wire brush
(Cummins tool number 3822509
or
equivalent—Fig.

30).

Fig.
30
Cleaning Cylinder Head Injector Bore INSTALLATION
(1) Install
new
copper seal
on
injector
(Fig. 31).
J9114-50
Fig.
31
Injector Seal
(2) Apply
a
coating
of
anti-seize compound
to the

threads
of the
injector holddown
nut and
between
the

top
of the nut and
injector body.

CAUTION:
Align
the tab on the
side
the injector
with the
notch
in the
cylinder
head
injector
bore

(Fig.
32).

(3) Install injector.
(4) Tighten injector
nut to 60 N«m (44 ft. lbs.)

torque. (5) Position O-ring into groove
on
injector.
(6) Connect fuel drain manifold. Refer
to
Fuel
Drain Manifold
in
this section.
(7) Connect high pressure fuel lines. Refer
to
High
Pressure Fuel Lines
in
this section.
(8) Install throttle linkage.
(9) Connect negative cable
to
battery.
Fig.
32
Injector
Installation

(10) Bleed
air
from
the
high pressure lines. Refer
to High Pressure Lines
in the Air
Bleeding section.

FUEL/WATER SEPARATOR FILTER

REMOVAL
(1) Disconnect electrical connector from water-in-
fuel (WIF) sensor
at the
bottom
of
the separator filter (Fig.
33).

Fig.
33
Fuel/Water Separator
Filter

CAUTION:
When
removing
the
fuel/water
separator

filter,
be
sure
that
the fuel
heater
electrical
connec­
tor
is not
turned
against
the
engine.
The connector
could
be
opened
or
damaged.

(2) Remove fuel/water separator filter.
The
fuel
heater assembly should
not
move when removing
or
installing
the
fuel/water separator. (3) Remove
the
square
cut
O-ring from
the
filter
connector
at the
bottom
of the
fuel heater
(Fig. 34).

(4) Drain
the
fuel/water separator filter. Remove
the water-in-fuel sensor, O-ring
and
fuel/water drain
valve assembly from separator filter
(Fig. 34).

14
• 116
FUEL
SYSTEM

Fig.
34 WIF
Sensor,
Drain
Valve
Assembly
INSTALLATION

(1) Install new O-ring on WIF sensor.
(2) Install WIF sensor into new separator filter.
If the new fuel/water separator filter is not filled
with clean fuel before it is installed, manual air
bleeding of the fuel system may be necessary. (3) Fill separator filter with clean fuel.
(4) Apply a light film of clean unused engine oil to
the separator filter seal.
(5) Install a new square cut O-ring to the filter
connector on the bottom of the fuel heater.

CAUTION:
When installing
the
Fuel/Water separator

filter,
be
sure
that
the
fuel
heater
electrical
connec­
tor
is not
turned
against
the
engine.
The
connector could
be
damaged
or
opened.

(6) Install separator filter. Tighten separator filter
one half turn after it makes contact.
(7) Connect electrical connector to WIF sensor.

HIGH
PRESSURE
FUEL LINES
All high pressure fuel lines are of the same length
and inside diameter. Correct high pressure fuel line
usage and installation is critical to smooth engine
operation.

CAUTION:
The
high pressure
fuel
lines must
be

clamped securely
in
place
in the
holders.
The
lines
cannot contact each other
or
other components.
Do
not
attempt
to
weld high pressure
fuel
lines
or to

repair lines
that
are
damaged. Only
use the
recom­
mended lines when replacement
of
high pressure

fuel
line
is
necessary.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove throttle linkage.
(3) Remove injection pump bracket (Fig. 35).
Fig.
35 Injection
Pump
Bracket—
Typical

(4) Disconnect high pressure lines from fuel injec­

tors.
(5) Remove high pressure line holders mounting
screws.

CAUTION:
Be
sure
that
the
high pressure
fuel
lines
are installed
in the
same order
that
they
were
re­
moved.
Prevent
the
injection
pump delivery valve
holders from turning when removing
or
installing
high
pressure lines from
injection
pump (Fig.
36).

Fig.
36 Injection
Valve
Holder
(6) Disconnect high pressure lines from fuel injec­
tion pump. Remove high pressure lines.

INSTALLATION
(1) Install high pressure fuel lines in the correct
order and positioned in holders.
(2) Tighten high pressure fuel line connections.
(3) Tighten holder screws to 24 N-m (18 ft. lbs.)
torque.
(4) Install injection pump bracket. Tighten mount­
ing screws to 24 N*m (18 ft. lbs.) torque.

•

FUEL
SYSTEM
14-117
(5)
Bleed air from the fuel system. Refer to High
Pressure Fuel Lines in the Air Bleeding portion of
this section.

INJECTION
TIMING
If incorrect injection timing is suspected, injection
pump-to-engine timing or injection pump timing may
be the cause. Check injection pump timing before checking injection pump-to-engine timing.

INJECTION
PUMP
TIMING

CAUTION;
When
setting
injection
pump
timing,
re­
fer to the engine
identification
plate
attached
to the

timing
case
flange for the
correct
specification
(Fig.
37). Fig. 37
Engine
identification Plate

The engine can be rotated with a barring tool such
as Snap-On No.
SP371,
MTE No. 3377462 (Cummins
Tool Division), or an equivalent.
The engine has a timing pin (Fig. 38). The pin en­
gages a hole in the camshaft gear when cylinder No.
1
is at TDC on the compression stroke.
J9114-57

Fig. 38
Timing
Pin—Cylinder
No. 1
CAUTION:
During engine
assembly
by the manufac­

turer,
the
timing
pin is positioned to correspond
with
the compression stroke TDC position of cylin­der number one. If the
timing
pin or
gear
housing
is

removed,
the
timing
pin
location
will
not be
correct

when reinstalled.

(1)
Locate TDC position (compression stroke) for
cylinder number one by slowly rotating the engine
with the barring tool while lightly pushing in on the
timing pin. Stop when the timing pin engages the in­ dex hole in the camshaft gear. (2) Once TDC has been located, pull the timing pin
out of the camshaft gear to the normal run position.
(3) Remove plug and copper washer from the rear
of the injection pump (Fig. 39).
PLUG
J9114-63

Fig. 39
Timing Indicator
Plug
Dial gauges and dial gauge holders used to check
injection pump timing are commercially available. Snap-On dial gauge and gauge holder YA83300,
MTE (Cummins Tool Division) dial gauge 3377259 and dial gauge holder 2066 or an equivalent can be
used. Whichever dial gauge is used, note the range of
gauge and also what one revolution of needle travel
equals. On gauge shown in Fig. 40, one revolution of
the needle equals 0.50 MM.
It may be necessary to remove one or more high
pressure fuel line(s) from the pump to install the gauge (Fig. 40). If a high pressure fuel line is re­
moved, the system must be bled of air after reinstall­ ing the fuel line. Refer to High Pressure Fuel Lines
in the Air Bleeding portion of the Diesel Fuel Injec­
tion section of Group 14, Fuel Systems.
(4) Install the gauge holder and gauge in the injec­
tion pump (Fig. 40). Be sure gauge travel is at least 2.0 MM. The engine can be rotated with a barring tool such
as Snap-On No. SP371, MTE No. 3377462 (Cummins
Tool Division), or an equivalent.
(5) Insert barring tool into the flywheel housing
opening. The opening is located in the rear flange of

14
- 118
FUEL
SYSTEM

•

J9114-64

Fig. 40 Checking injection Pump Timing
the engine, on the exhaust manifold side (Fig.
41).
Fig. 41 Rotating Engine with Barring Tool

(6)
Rotate the engine in the direction opposite en­
gine rotation until the needle on the dial gauge stops
moving. Adjust the face of the gauge to read zero at
the needle.
(7) Rotate the engine (in normal direction) back to
TDC on the No. 1 cylinder compression stroke.

CAUTION:
The dial
gauge needle should move
smoothly when
the
engine
is
rotated.
If the
needle
jumps
or
bounces, replace
the injection
pump.

(8)
Taking note of dial gauge travel (number of
revolutions), rotate the engine in the normal direc­
tion until cylinder No. 1 is again at TDC on the com­
pression stroke. Use the timing pin to locate TDC.
The reading on the dial gauge when the timing pin indicates TDC is the amount of plunger lift the pump
has at that point. Refer to the specification on the
engine identification plate for the correct amount of lift. The injection pump is properly timed when the correct amount of plunger lift is obtained at TDC
(TDC pin engages hole in camshaft gear). Set timing
to
1.25
MM lift.

(9)
If the injection pump does not have the correct
lift, rotate the injection pump on the mounting studs
while noting the reading on the dial gauge. Rotate
the pump to obtain the correct amount of injection
pump plunger lift.

(10)
Tighten mounting stud nuts to
24
N*m
(18
ft.
lbs.) torque.

(11)
Remove dial gauge and holder.

(12)
If removed, install high pressure fuel lines.

(13)
Install plug tod washer into injection pump.
Tighten plug to
10
Nnn
(7
ft. lbs.) torque.
(14)
If high pressure fuel lines were removed,
bleed air from the fuel system. Refer to High Pres­ sure Fuel Lines in the Air Bleeding section.
INJECTION PVMP*>TO*ENGINE TIMING
(1)
With the gear housing cover off, be sure that
the crankshaft gear and camshaft gear are correctly
timed. Correct as necessary. Refer to Group
9,
En­
gines.
The engine can be rotated with a barring tool such
as Snap-On No.
SP371,
MTE No.
3377462
(Cummins
Tool Division), or an equivalent. The engine has a timing pin (Fig.
38).
The pin en­
gages a hole in the camshaft gear when cylinder No.
1
is at TDC on the compression stroke.

CAUTION;
During engine assembly
by the
manufac­

turer, the timing pin is
positioned
to
correspond
with the
compression stroke TDC position
of
cylin­
der number one.
If the timing pin or
gear housing
is
removed,
the timing pin
location
will
not be
correct

when reinstalled.

(2)
Locate TDC position (compression stroke) for

No.
1 cylinder by slowly rotating the engine with the
barring tool while lightly pushing in on the timing
pin. Stop when the timing pin engages the index hole in the camshaft gear.

(3)
Once TDC has been located, pull the timing pin
out of the camshaft gear to the normal run position.

(4)
With the gear housing cover off, inspect the
alignment of the timing marks on the camshaft gear
and injection pump gear. The letter E on the injec­
tion pump gear should be aligned with the mark on
the camshaft gear (Fig.
42).
(5)
If necessary check and adjust injection pump
timing. Refer to Injection Pump Timing.

KSB
SOLENOID

REMOVAL The KSB Solenoid is not serviceable. It must be re­
placed as a complete unit.

•
Fig. 42 Injection
Pump-to-Engine
Timing
(1) Disconnect electrical connector from KSB sole­
noid (Fig. 43).
(2) Remove KSB solenoid.
Air does not have to be Med from the fuel in­
jection pump and fuel system after replacing the KSB solenoid.
Fig. 43 KSB Solenoid—Removal/installation INSTALLATION
(1) Install the KSB solenoid in the injection pump.
Tighten the solenoid to 43 N*m (32 ft. lbs) torque. (2) Connect harness connector to KSB solenoid.

MECHANICAL
LIFT
PUMP
The lift pump is attached to the drivers side of the
engine block towards the rear of the engine (Fig. 44).
REMOVAL (1) Disconnect negative battery cable at battery.
(2) Disconnect low pressure fuel lines from pump
(Fig. 44).
(3) Remove lift pump mounting screws.
(4) Clean mating surfaces on lift pump and engine
block.
FUEL
SYSTEM
14 - 119

Fig.
44 Lift
Pump
Removal/Installation INSTALLATION
(1) Install lift pump with new gasket. Tighten
mounting screws to 24 N#m (18 ft. lbs.) torque.
(2) Install low pressure fuel lines.
(3) Manually bleed the system of air. Refer to
Manual Bleeding in this section. (4) Connect battery cable to battery.

THROTTLE
POSITION
SENSOR
(TPS) The TPS is used on vehicles equipped with an au­
tomatic transmission only. The TPS is adjustable and
must be adjusted after installation.
REMOVAL (1) Remove the electrical connector from the TPS
(Fig. 45).

Fig.
45
Throttle
Position
Sensor

(2) Remove the two TPS mounting screws. Do not
remove the TPS mounting bracket screws from the injection pump. Lift the TPS straight up for removal. (3) If the nylon adapter (Fig. 46) has remained on
the TPS mounting bracket after removal of TPS, it
must also be removed. To remove adapter, slightly

14-120
FUEL
SYSTEM

• move the throttle lever (by hand) from the idle posi­
tion and lift adapter for removal. Fig. 46
Nylon
Adaptor—TPS to Injector Pump

INSTALLATION

The bottom of the nylon adapter (on the TPS) has a
hex head. The hex head on this adapter fits into a
hex opening in the injection pump throttle shaft (Fig.

47).

(1) Install the nylon adapter to the TPS mounting
bracket. The tang on the nylon adapter (Fig. 48) should be within the notch area on the TPS mount­
ing bracket (Fig. 48). If adapter will not drop into
hex opening on injector pump, open the throttle slightly. This will cause the throttle shaft to rotate
and allow the adapter to be positioned.

CAUTION:
Do not allow the tang on the nylon
adapter to be outside of notch area on TPS mount­
ing
bracket (Fig. 48).
Damage
to adapter and im­
proper TPS operation
will
occur.

Fig.
47
Throttle
Position
Sensor
Installation

The hex drive on the TPS nylon adapter should be
flush with the top of the throttle lever hex opening or just above it.
TPS
MOUNTING

BRACKET

TANG
NYLON
ADAPTOR

Fig. 48 Positioning
Nylon
Adapter (2) Position the TPS to nylon adapter. Refer to the
previous CAUTION.
(3) The TPS is spring loaded. After positioning the
TPS on the adapter, be certain to rotate the TPS in a clockwise direction to allow installation of its two
mounting screws.
(4) Install and tighten both TPS mounting screws.
If the TPS bracket mounting screws were removed,
tighten them to 7 N»m (60 in. lbs.) torque.
(5) Connect the electrical connector to the TPS.
(6) Adjust the TPS. Refer to the following Adjust­
ment procedure.

ADJUSTMENT

CAUTION:
Before adjusting the TPS, the
throttle
linkage
must
be checked for correct adjustment.
The
throttle
lever
must
contact the low idle
speed
screw.
The
throttle
lever
must
reach breakover
when the
throttle
is wide
open.
Refer to the
Accel­
erator Pedal and
Throttle
Cable
section
of
Group
14,
Fuel
Systems.

A digital voltmeter (Fig. 49) or the DRB II scan
tool is needed to adjust the throttle position sensor. (1) Turn the ignition key to the On position.
(2) Connect the negative probe of the voltmeter to
a good ground source such as the negative post of the
battery.
(3) Probe the throttle position sensor output wire
at the TPS electrical connector. The center wire on
the connector is the output circuit.

•

FUEL
SYSTEM
14 - 121

Fig.
49
Throttle
Position
Sensor
(TPS) Testing (4) With the fuel injection pump throttle lever con­
tacting the low idle speed screw (Fig. 50), TPS output should be 1 volt or slightly above. If not, the TPS
must be adjusted.
(5) The TPS nylon adapter (Fig. 51) is machined to
accept a 10 MM open end wrench. To adjust, gently
rotate the nylon adapter with a 10 MM open end
wrench to until correct voltage is obtained.

J9114-261

Fig.
50
Throttle
Lever
Contacting Low Idle
Speed Screw
(6)
Open throttle to the wide open position. The
spring load breakover lever should have moved off
the stop and rest against the breakover spring (Fig.
52).
If not, the throttle actuation rod must be ad­
justed before adjusting TPS. Refer to Accelerator Pedal and Throttle Cable section of Group 14, Fuel Systems.
(7) With throttle held in wide open position, check
TPS output voltage. It should be 2.25 to 2.75 volts
higher than the output voltage is at closed throttle position. If not, gently rotate nylon adapter to obtain
correct voltage.
Fig.
51 Adjusting
Throttle
Position
Sensor
Fig.
52 Correct Breakover
Spring
Position

WATER-IN-FUEL
SENSOR
REMOVAL
(1) Remove fuel/water separator filter. Refer to Fu­
el/Water Separator Filter Removal.
(2) Remove the square cut O-ring from the filter
connector at the bottom of the fuel heater (Fig. 53). (3) Drain the fuel/water separator filter. Remove
the water-in-fuel sensor, O-ring and fuel/water drain
valve assembly from separator filter (Fig. 53).

INSTALLATION
(1) Apply a light film of clean engine oil to sealing
surface of WIF sensor. (2) Install WIF sensor into new fuel/water separa­
tor filter.
(3) Fill separator filter with clean fresh fuel.
(4) Apply a light film of clean engine oil to sealing
surface of separator filter.
(5) Install a new square cut O-ring to the filter
connector on the bottom of the fuel heater.