1993 DODGE TRUCK fuel pressure

14
- 102
FUEL
SYSTEM
—

•
SYMPTOM

CAUSI
ACTION

lupin*
mimes under Im4 Incorrect
injection
pump
timing
Adjust
injection
pump
timing

Restricted
or
damaged
injector
nozzle
Replace
or
repair
as
necessary

Restricted
or
blocked
fuel
injection
lines Install
fittings
proper positions

Fuel
Injection
pump malfunction
or

not adjustable
Replace
fuel
injection
pump
lew power Improper
fuel
Drain
fuel
tank, flush
system,
fill
with

proper
fuel

Empty
fuel
tank or
fuel
tank vent blocked
Fill
tank, bleed
system,
check tank vent
Control lever not going
to full throttle
position Adjust
throttle
linkage

Clogged
fuel
filter
Replace
fuel
filter

Intercooler
internally
blocked
or
leaking
Check
pressure
drop
across
intercooler.
If
pressure
drop is more than
4
in.
Hg,
clean
or replace
as
necessary.

Restricted
or
blocked
fuel
supply lines
Remove
restrictions
or
replace lines

Injection
pump overflow
fitting
switched
with
inlet
fitting
Install
fittings
in
proper positions

Leaking
injection
lines, damaged lines
or
loose
connections
Replace
damaged
lines
or
tighten

connections
as
necessary.
Bleed
fuel
system
Incorrect
injection
pump
to
engine
timing
Adjust
injection
pump
timing

Restricted or
damaged
injector
nozzle
Repair
or replace as
necessary

Clogged
or
restricted
air filter
Remove
restrictions
or
replace
filter if

necessary

Air
fuel
control
tube broken
or
leaking
Repair
or replace
as
necessary

Low
manifold pressure
Check
and repair turbocharger operation.

Check
intercooler and
air
pipes
for
blockage

Injection
sequence
does
not correspond

with
firing
order Install
fuel
injection
lines in correct
order

Low
or
uneven
engine
compression
Repair
as
necessary

Restricted or blocked
fuel
injection
lines
Remove
restrictions
or
replace lines
Incorrect
injection
pump
to
engine
timing
Check
injection
pump
to
engine
timing

Fuel
injection
pump malfunction
or

not adjustable
Replace
fuel
injection
pump J9114-253
DIESEL
FUEL
INJECTION
SYSTEM
DIAGNOSIS-CONTINUED

FUEL
SYSTEM
14-103

DIESEL FUEL
INJECTION
SYSTEM DIAGNOSIS-CONTINUED

SYMPTOM
CAUSE
ACTION

Excessive
fuel
consumption improper diesel
fuel
Use
correct
fuel
for conditions. Refer
to

owner's manual
Incorrect injection pump timing
Adjust
injection pump timing
Restricted or damaged
injector
nozzle Repair or replace as necessary

Clogged
or
restricted air
filter
Remove
restrictions or replace air
filter
if

necessary

Injection sequence does not correspond

with
firing order install
fuel
injection lines in correct order
Intercooler internally blocked
or
leaking
Check
pressure drop
across
intercooler.

If
pressure drop
is
more than
4
in. Hg,
clean or replace as necessary

Low
idle misadjusted
Adjust
idle stop screw
Malfunctioning
KSB
valve
Replace
injection pump
Incorrect injection pump to engine timing
Adjust
injection pump to engine timing
Fuel injection pump malfunction or
not adjustable
Replace
fuel
injection pump
Unabie to shut engine off Voltage to
fuel
solenoid
interrupted
or
fuel

solenoid
inoperative Correct voltage supply problem or
replace

solenoid

Either poor
performance,
black moke
or
low power Improper
fuel

Drain
fuel
tank, flush
system,
fill
with

proper
fuel
for conditions. Refer to owner's
manual

Air
in
fuel
system
Bleed
fuel
system
Intercooler internally blocked
or
leaking
Check
pressure drop
across
intercooler.

If
pressure drop is more than
4
in. Hg,
clean
or
replace
as
necessary

Restricted or blocked
fuel
injection lines
Remove
restrictions or replace lines
Incorrect injection pump timing
Adjust
injection pump timing
Restricted or damaged
injector
nozzle
Repair
or replace as necessary

Clogged
or restricted air
filter
Remove
restrictions or replace
filter
if

necessary

Air
fuel
control tube leaking or broken Repair or replace as necessary

Low
manifold pressure
Check
and repair turbocharger operation
Injection sequence does not correspond

with
firing order Install
fuel
injection lines in correct order
—
Low
or uneven engine compression
Repair as necessary
J9114-255

•

FUEL
SYSTEM
14-105 DIESEL FUEL INJECTION SYSTEM DIAGNOSIS-CONTINUED

SYMPTOM

CAUSE
ACTION

Engine
does not rev up Control lever not
going
to
full
throttle

position
Adjust
throttle
linkage

Air
in
fuel
system
Bleed
fuel
system
Intercooler internally blocked or leaking
Check
pressure drop
across
intercooler.
If pressure drop is more than 4 in. Hg,
clean or replace as necessary

Clogged
fuel
filter
Replace
fuel
filter

Restricted or blocked
fuel
supply lines
Remove
restrictions or replace lines

Wax
buildup in
fuel
filter
(cold weather only)
Inspect
fuel
heater
electrical
connector
for
damage.
Replace
fuel
filter,
use recommended diesel fuel.
Incorrect injection pump timing
Adjust
injection pump timing
Injection pump overflow
fitting
switched

with
inlet
fitting
Install fittings in proper sequence

Low
or uneven engine
compression
Repair
as
necessary
Fuel injection pump malfunction or
not adjustable
Replace
injection pump
Infection pump runs hot Overflow blocked
Clean
overflow orifice or replace
fitting

J9114-254

14
- 106
FUEL SYSTEi

DIESEL FUEL
INJECTION-SERVICE
PROCEDURES

INDEX

page

Air Bleed Procedure
106

Air Fuel Control Tube
107

Air Intake Heater
107
Engine
Speed
Sensor
108

Fuel Drain Manifold
109

Fuel Heater
. 110

Fuel
Injection
Pump
110

Fuel
Injection
Pump Supply Line
114

Fuel
Injectors
114

AIR BLEED PROCEDURE
A certain amount
of air
becomes trapped
in the

fuel system when fuel system components
are
ser­
viced
or
replaced. Bleed
the
system after fuel system service according
to the
following procedures.

WARNING:
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.

MANUAL BLEEDING
Some
air
enters
the
fuel system when
the
filters
or

injection pump supply line
are
changed. This small
amount
of air is
vented automatically from
the
injec­
tion pump through
the
fuel drain manifold. This
is if

the filter
was
changed according
to
instructions.
The system will have
to be
bleed manually
if:

•
The
fuel filter
is not
filled before installation

•
Injection pump
is
replaced

•
High pressure fuel line connections
are
loosened
or
lines replaced

•
Initial engine start-up
or
start-up after
an ex­

tended period
of no
engine operation. (1) Open
the low
pressure bleed screw
(Fig. 1).
(2) Operate
the
hand lever
on the
mechanical lift
pump until
the
fuel exiting
the low
pressure bleed screw
is
free
of air.
If
the
manual lever feels
as if it is not
pumping,
ro­

tate (crank)
the
engine approximately
90
degrees. Continue pumping until
air is
removed. (3) Tighten
low
pressure bleed screw
to 8 N»m (6

ft.
lbs.)
torque.

CAUTION:
The
manual lever must
be
returned
to

the lock position
(up) after
priming.

INJECTION
PUMP

WARNING:
THE
ENGINE
MAY
START WHEN
CRANKING
TO
BLEED
AIR
FROM
THE
INJECTION
page

Fuel/Water Separator
Filter
................
115

High
Pressure Fuel Lines
116
Injection
Timing
117

KSB
Solenoid
118

Mechanical
Lift
Pump
119

Powertrain Control Module (PCM)
108

Throttle
Position
Sensor
(TPS)
119
Water-ln-Fuel
Sensor
121
Fig.
1
Low
Pressure
Bleed Screw

PUMP.
PLACE
THE
TRANSMISSION
IN
NEUTRAL

OR
PARK
AND SET
PARKING BRAKE BEFORE
EN­

GAGING
THE
STARTER MOTOR.
CAUTION:
Do
not
engage
the
starter
motor
for
more
than
30
seconds
at a
time.
Allow
two
minutes
be­

tween cranking intervals.

Crank
the
engine
for 30
seconds
at a
time
to
allow
air trapped
in the
injection pump
to
vent
out the

drain manifold. Observe
the
previous WARNING
and

CAUTION.
HIGH PRESSURE FUEL LINES

WARNING:
THE
INJECTION PUMP SUPPLIES HIGH
PRESSURE
FUEL
OF
APPROXIMATELY
59,000
KPA

(8,000
PSI) TO
EACH INDIVIDUAL INJECTOR
THROUGH
THE
HIGH
PRESSURE
LINES. FUEL
UN­
DER
THIS AMOUNT
OF
PRESSURE
CAN
PENE­
TRATE
THE
SKIN
AND
CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES
AND
ADEQUATE PRO­
TECTIVE CLOTHING
AND
AVOID CONTACT
WITH

FUEL SPRAY WHEN BLEEDING HIGH
PRESSURE
FUEL LINES.

•
FUEL SYSTEM 14 - 107
WARNING;
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.

Bleed air from one injector at time. (1) Loosen the high pressure fuel line fitting at the
injector (Fig. 2).

Fig.
2
Bleeding
High Pressure Fuel Lines

(2) Crank the engine until all air is bleed from the

line.
Do not operate the starter motor for longer
than 30 seconds. Wait two minutes between cranking intervals.
(3) Start the engine and bleed one injector at a
time until the engine runs smoothly.

AIR
FUEL CONTROL TUBE
REMOWAL
(1) Disconnect tube from fuel injection pump (Fig.

3). Fig.
3 Air
Fuel
Control Tube Removal/Installation
(2) Disconnect tube from intake manifold.
(3) Remove tube. Discard seals.
INSTALLATION

(1) Connect tube to intake manifold. Tighten fit­
ting to 8 Nnn (6 ft. lbs.) torque. (2) Connect tube to injection pump using new

seals.
Tighten fitting screw to 12 Nnn (9 ft. lbs.)
torque.

AIR INTAKE HEATER
(1) Disconnect negative cable from battery.
(2) Disconnect the throttle rod from the throttle le­
ver on the injection pump. (3) Disconnect electrical connections air intake
heaters (Fig. 4).

Fig.
4 Air Intake Heaters—Typical
(4) Remove the throttle bracket (Fig. 5).

Fig.
5
Throttle
Bracket—Typical
(5) Loosen clamps securing air the crossover tube
hose to the turbo-charger.
(6) Remove air crossover tube mounting screws.
(7) Remove air crossover tube.
(8) Remove air intake heater.
(9) Clean air intake heater-to-intake manifold
mating surfaces.

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).

•

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