1993 DODGE TRUCK Service Repair Manual

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.

14
- 122
FUEL
SYSTEM

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

GENERAL
INFORMATION
The low idle speed adjustment is the only adjust­
ment that can be made to the injection pump. The
fuel solenoid is the only component that can be ser­ viced on the injection pump. Refer to Service Proce­dures section for fuel solenoid service. All other
injection pump service must be performed by authorized personnel.

LOW IDLE
SPEED
Use an optical tachometer such as Snap-on No.
MT139 or MTE (Cummins tool division) No. 3377462
to read engine rpm. (1) If necessary, adjust low idle speed at the low
idle speed screw (Fig. 54). If the vehicle has an auto­
matic transmission, with the air conditioning on, set
low idle speed to 700 rpm. If the vehicle has a man­
ual transmission, with the air conditioning on, set
low idle speed to 750 rpm. (2) Loosen idle screw lock nut using Cummins tool
number 3823750 or an equivalent. Adjust idle screw
Fig.
54 Adjusting Low Idle
Speed

to obtain specified rpm. Refer to the Specification section at the end of this group for idle speeds.

SERVICE ADJUSTMENTS—DIESEL

•

FUEL
SYSTEM
14 - 123
SPECIFICATIONS

GENERAL
INFORMATION
The following specifications
are
published from
the

latest information available
at the
time
of
publica­
tion.
If
anything differs between
the
specifica­
tions found
on the
Vehicle Emission Control Information (VECI) label
and the
following spec­
ifications,
use
specifications
on
VECI label. FUEL TANK CAPACITIES
TANK:

LITERS GALLONS

Standard
83.0 22
Optional 114
30

Ramcharger
120.9
34

Nominal
refill
capacities
are
shown.
A
variation
may be
observed

from vehicle
to
vehicle
due to
manufacturing tolerances
and refill
procedures.
FUEL SOLENOID-5.9L DIESEL

J9014-182

Current Draw
2
Amps
Minimum Voltage 10 Volts
Operating Voltage 12 Volts
Resistance 6.9-7.9 Ohms
J9114-214
ENGINE SPEED—5.9L DIESEL
Full Throttle Stop Speed
(No
Load) 2925 RPM (Max)
Full Throttle Stop Speed
(No
Load)
2824
RPM (Min)

Low Idle Stop Speed (A/C On—Auto Trans) 700 RPM
Low Idle Stop Speed (A/C On—Man Trans) 750 RPM
J9114-215
FUEL SYSTEM—5*9L DIESEL
Fuel Pressure Drop Across Filter 21
kPa
(3 psi) Max
Fuel Return Line Restrictions 20.4 in. Hg. Max
Injector Operating Pressure (Pop
Off
Pressure) 3550
psi

Mechanical Lift Pump Inlet Restriction 3.75 in. Hg. Max
Mechanical Lift Pump Output (Flow) 0.75
L
(0.70 qt)
per 30
seconds Max
Mechanical Lift Pump Output (Pressure) 21-35 kPa (3-5 psi)

J9114-216

14-124
FUEL SYSTEM

TORQUE-EXCEPT DIESEL

DESCRIPTION TORQUE

Accelerator Pedal Bracket Mounting
Nuts
. 7

N
m

(55
in.
lbs.)

Coolant Temperature Sensor . . 11

N«
m (8 ft. lbs.)
Crankshaft Position Sensor Mounting Bolts . 8

N«
m
(70 in.
lbs.)

Fuel Filter Mounting Bolts . . . . 8

N-
m

(75
in.
lbs.)

Fuel Hose (Tube) Clamps . . . . 1

N-
m
(10 in.
lbs.)

IAC Motor-To-Throttle Body . . . 7

N-

m (60 in.
lbs.)

Intake Manifold Charge (60 in.

lbs.)

Air Temperature Sensor . . . . 28

N
•m
(20 ft.
lbs.)

MAP Sensor Mounting Screws. . 3

N

•m
(25
in.
lbs.)

Oxygen Sensor . 30

N
•m
(22
ft.
lbs.)

PCM 60-Way Connector Mounting Screw . 4

N
•m
(35 in.
lbs.)

Throttle Body Mounting Bolts. . . 23

N

•m (200 in. lbs.)
Throttle Position Sensor Mounting Bolts ......... . 7

N«
m
(60 in.
lbs.)

• —_ —_
FUEL
SYSTEM
14 - 125

Component

N-m ft.
lbs.
/In. lbs.
Air Fuel Control Tube 12 N-m 9 ft. lbs.
Fuel Line Clamp to Intake Manifold Mounting Screws 24 N-m 18 ft. lbs.
Fuel Line Fittings at Injector—High Pressure 24 N-m 18ft. lbs.
Fuel Line Fittings at Injection Pump—High Pressure 24 N-m 18ft. lbs.
Fuel Solenoid 43 Nm 32 ft. lbs.
Injection Pump Mounting Nuts 24 N-m 18ft. lbs.
Injection Pump Lockscrew (Locked Position) 30 Nm 22 ft. lbs.
Injection Pump Lockscrew (Unlocked Position) 13 Nm 10ft. lbs.
Injection Pump Gear Retaining Nut 65 Nm 48 ft. lbs.

*
Injection Pump Support Bracket 24 Nm 18 ft. lbs.
Injection Pump Timing Plug 10Nm
7.5 ft. lbs.
Injector Drain Screw 8 N-m 6 ft. lbs.
Injector Retainer Nut 60 Nm 44 ft. lbs.
Low Pressure Bleed Screw on Filter Head 8 Nm 6 ft. lbs.
Mechanical Lift Pump Mounting Screws 24 Nm 18ft. lbs.
Throttle Linkage Rod Lock Nuts 9 N-m 7 ft. lbs.
Throttle Control Bracket Mounting Screws 24 Nm 18 ft. lbs.
Throttle Rod to Throttle Rod Ball Stud Nut 10 Nm 7.5 ft. lbs.

*
Mounting bolts must be tightened in specified sequence. J9114-205

TORQUE—5.9L
DIESEL