1993 DODGE TRUCK Service Repair Manual

14
- 110
FUEL SYSTEM
SENSOR
J9114-39

Fig.
13 Fuel/Water Separator
Filter

(5) Remove the filter adapter from the fuel heater
(Fig. 14).
(6) Remove fuel heater.
(7) Remove seals from fuel heater. Clean the fuel
heater and cylinder block mating surfaces.

INSTALLATION
(1) Install new seals in fuel heater and adapter.
(2) Install fuel heater and adapter. Tighten
adapter to 32 Nrn (24 ft. lbs.) torque. (3) Apply a light film of clean engine oil to sealing
surface of WIF sensor.
(4) Install WIF sensor into new fuel/water separa­
tor filter.
(5) Fill separator filter with clean fresh fuel. •

Fig.
14
Fuel
Heater Removal/Installation (6) Apply a light film of clean engine oil to sealing
surface of separator filter.
(7) Install a new square cut O-ring to the filter
connector on the bottom of the fuel heater. (8) Install separator filter. Tighten separator filter
one half turn after it makes contact. (9) Connect electrical connector to WIF sensor and
Fuel Heater.

FUEL INJECTION PUMP

REMOVAL (1) Disconnect negative cable from battery.
(2) Disconnect throttle linkage.
(3) Remove throttle bracket (Fig. 15).

Fig.
15
Throttle
Bracket
(4) Remove injection pump supply line. Refer to
Fuel Injection Pump Supply Line.
(5) Remove high pressure fuel lines. Refer to High
Pressure Lines. (6) Disconnect electrical connector from fuel sole­
noid. (7) Disconnect electrical connector from KSB Sole­
noid.

INSTALLATION

(1) Using new seals on all fittings, assemble fuel
drain manifold in reverse order of disassembly. (2) Tighten drain manifold fitting screws at the in­
jectors to 8 N#m (6 ft. lbs.) torque. (3) Tighten drain manifold holddown clamp screws
to 24 N*m (18 ft. lbs.) torque. (4) Tighten injection pump capscrew to 32 N#m (24
ft. lbs.) torque.

FUEL HEATER
The fuel heater is located above the fuel/water sep­
arator filter (Fig. 13).

REMOVAL
(1) Thoroughly clean the area around the separa­
tor filter before service is performed.
(2) Disconnect the water-in-fuel (WIF) sensor elec­
trical connector (Fig. 13). (3) Remove the fuel/water separator filter. Refer to
Fuel/Water Separator Filter removal and installation
in this group.
(4) Disconnect electrical connector from the fuel
heater (Fig. 13).

•
(8) Remove the air control tube (Fig. 16).
(9) Remove fuel pump vent line and capscrew (Fig.

16).
Fig.
16 Fuel Solenoid, Air Control Tube,
Pump
Vent Line
The control lever is indexed to the shaft during cal­
ibration. Do not remove the control lever from in­
jection pump. (10) Remove bolt attaching the injection pump sup­
port bracket to the vacuum pump. Remove the upper and lower bolts attaching the support bracket to the
engine block. Loosen the middle bolt and pivot the
bracket towards the rear of the engine (Fig. 17).

Fig.
17 Injection
Pump
Support
Bracket
(11) Remove oil fill tube bracket mounting screw
(Fig. 18). (12) Remove oil fill tube from and adapter from
front cover.

CAUTION:
If
gear
retainer
nut or
washer drops into

gear
housing,
cover must
be
removed
to
retrieve

them before engine
is
started. FUEL
SYSTEM
14-111

Fig.
18 Oil Fill Tube and Bracket (13) Place a shop towel below the retainer nut in
the gear housing cover opening to prevent the nut or
washer from falling into the gear housing. Remove
the gear retaining nut and washer.
The engine can be rotated with a barring tool such
as Snap-On No.
SP371,
MTE No. 3377462 (Cummins
Tool Division), or an equivalent.
(14) Insert the barring tool into the flywheel hous­
ing opening. The opening is located in rear flange of
the engine, on the exhaust manifold side (Fig. 19).

Fig.
19 Rotating
Engine
with
Barring Tool
(15) Rotate engine with the barring tool until the
fuel injection pump key-way is in the position shown in Fig. 20.
The engine has a timing pin (Fig. 21). 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.

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