Engine Controls - Adjustments - 5.9l Diesel Dodge Pickup R2500

ENGINE MECHANICAL

Before performing any on-vehicle adjustments to fuel system, ensure engine mechanical condition is okay.

VALVE CLEARANCE

Note. Valve clearance must be adjusted with engine temperature less than 140°F (60°C).

Scheme 1

1. Engine can be rotated by removing dust cover from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 1) CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
2. Note location of timing pin. (Scheme 1) Push timing pin toward front of engine. Slowly rotate engine clockwise (viewed from front of engine) while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear and cylinder No. 1 is at TDC.
3. Remove nameplate, located above rocker lever covers. Remove rocker lever covers and gaskets. Ensure cylinder No. 1 push rods are loose and valves are closed. If cylinder No. 1 push rods are not loose or valves are not closed, disengage timing pin. Rotate engine 360 degrees. Engage timing pin.
4. With cylinder No. 1 at TDC, check valve clearance on proper valves. See STEP 1 in VALVE CLEARANCE ADJUSTING SEQUENCE table. If valve clearance is not as specified, adjust valve clearance using rocker lever adjusting screw. See VALVE CLEARANCE SPECIFICATIONS table. Tighten rocker lever adjusting screw lock nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r2500/1997-1998/remont/adjustments/#engine-controls-adjustments-59l-diesel__torque-specifications).
5. Once valve clearances are checked and adjusted on proper valves, place reference marks on vibration damper and front timing gear cover. Disengage timing pin. Rotate crankshaft clockwise 360 degrees and realign reference marks.
6. Check valve clearance on proper valves. See STEP 2 in «VALVE CLEARANCE ADJUSTING SEQUENCE»(/dodge/pickup-r2500/1997-1998/remont/adjustments/#engine-controls-adjustments-59l-diesel) table. Adjust valve clearance if not within specification. See VALVE CLEARANCE SPECIFICATIONS table. Tighten rocker lever adjusting screw lock nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r2500/1997-1998/remont/adjustments/#engine-controls-adjustments-59l-diesel__torque-specifications).
7. Using NEW gaskets, install rocker lever covers. Install and tighten rocker lever cover bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r2500/1997-1998/remont/adjustments/#engine-controls-adjustments-59l-diesel__torque-specifications). Install nameplate.

VALVE CLEARANCE ADJUSTING SEQUENCE

VALVE CLEARANCE SPECIFICATIONS (1)

Scheme 2

Scheme 3

1. Disconnect negative battery cables. Remove nameplate, located above rocker lever covers. Ensure area around fuel injection pump and fuel lines are clean. Remove cylinder No. 1 rocker lever cover and gasket.
2. Engine can be rotated by removing plug from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 1) Rotate engine clockwise (viewed from front of engine) until exhaust valve on cylinder No. 1 starts to close. CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
3. Note location of timing pin. (Scheme 1) Push timing pin toward front of engine. Using Engine Barring Tool (7471B), slowly rotate engine clockwise (viewed from front of engine) while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear. (Scheme 1) Ensure valves for cylinder No. 1 are closed. This positions cylinder No. 1 at TDC on compression stroke.
4. Ensure cylinder No. 1 push rods are loose and valves are closed. If cylinder No. 1 push rods are not loose or valves are not closed, disengage timing pin and rotate engine 360 degrees.
5. Place reference mark on vibration damper and front timing gear cover to indicate TDC position. Disengage timing pin. Mark high-pressure fuel line location for installation reference.
6. Remove high-pressure fuel line for No. 1 fuel injector at fuel injection pump while holding delivery valve on fuel injection pump with wrench. It may be necessary to also disconnect high-pressure fuel line from No. 1 fuel injector for line removal. Use care not to bend high-pressure fuel line during removal.
7. Using Socket (6840), loosen but DO NOT remove delivery valve holder on fuel injection pump for No. 1 fuel injector. (Scheme 1) Remove socket from delivery valve holder. CAUTION: When removing delivery valve holder, use care not to allow spring, fill piece and any shims to fall from delivery valve holder. Delivery valve holder may rotate with a resistance, as an "O" ring is located on outside of delivery valve holder.
8. Ensure area around delivery valve holder is clean. Unscrew delivery valve holder from fuel injection pump. Slightly tip delivery valve holder outward while holding shim(s), fill piece and spring in delivery valve holder. (Scheme 2) DO NOT allow components to fall from delivery valve holder.
9. Using magnet, remove 2-piece delivery valve assembly from fuel injection pump. (Scheme 2) Using small pick, remove delivery valve washer, located between delivery valve assembly and pumping element in fuel injection pump. Use care not to scratch surfaces in fuel injection pump during washer removal.
10. Install Adapter (6842) in fuel injection pump finger tight. Using Allen wrench, loosen set screw on adapter. (Scheme 3) Install Dial Indicator (6859) and Indicator Tip (6843) into the adapter.
11. Position dial indicator to read between 7 mm and 9 mm on small inner dial on dial indicator. Tighten set screw. NOTE: Small inner dial on dial indicator is marked in 1 mm increments. Large outer dial on dial indicator is marked in.01 mm increments. One revolution of large outer dial is equal to 1 mm. CAUTION: Timing pin must be disengaged from camshaft gear before rotating engine or timing pin will be damaged.
12. Ensure timing pin is disengaged from machined hole on camshaft gear. Using engine barring tool, rotate engine counterclockwise (viewed from front of engine) 1/4 turn or until dial indicator reading stops decreasing.
13. Zero dial indicator and note reading on small inner dial on dial indicator. Slowly rotate engine clockwise (viewed from front of engine) to TDC. Note plunger lift reading on dial indicator.
14. Note TIMING TDC specification listed on engine data plate, located on fuel injection pump side of timing gear housing. (Scheme 1) TIMING TDC specification is the number of degrees BTDC. Using TIMING TDC specification listed on engine data plate, note if plunger lift is within specification. See PLUNGER LIFT SPECIFICATIONS table.
15. If plunger lift is within spec, no adjustment of fuel injection pump timing is required. Proceed to FINAL REASSEMBLY. If plunger lift is not within specification, fuel injection pump timing must be adjusted. Proceed to ADJUSTING FUEL INJECTION PUMP TIMING.

PLUNGER LIFT SPECIFICATIONS

Scheme 4

1. Remove oil fill tube and adapter elbow from front timing gear cover by rotating assembly counterclockwise (viewed from front of engine). While holding engine from rotating with engine barring tool, loosen fuel injection pump drive gear nut.
2. Install pencil-type magnet in end of shaft on fuel injection pump. Perform STEP 1. (Scheme 4) Magnet is used to prevent fuel injection pump drive gear nut and washer from falling into front timing gear cover during removal. NOTE: If pencil-type magnet is not available, place shop towel below fuel injection pump drive gear nut and front timing gear cover to prevent nut from falling into engine.
3. Remove fuel injection pump drive gear nut and washer from the shaft. DO NOT allow nut or washer to fall in front timing gear cover.
4. Install pencil-type magnet in end of shaft on fuel injection pump. Install one thrust washer, one bearing and then one thrust washer from Thrust Washer & Bearing Kit (6862) on the shaft. Ensure thrust washers and bearing are installed in correct order. Thrust washer and bearing are used to prevent fuel injection pump drive gear from rotating on the shaft when tightening fuel injection pump drive gear nut.
5. Install fuel injection pump drive gear nut on shaft, allowing clearance between thrust washers and bearing. DO NOT tighten nut at this time. Ensure timing pin is disengaged. Rotate engine clockwise (viewed from front of engine) until correct plunger lift is obtained on dial indicator.
6. Once correct plunger lift is obtained, use Puller (L-4407A) to pull fuel injection pump drive gear from tapered area on shaft of fuel injection pump. Perform STEP 2. (Scheme 4) Ensure plunger lift reading on dial indicator is still correct after pulling fuel injection pump drive gear from the shaft.
7. Rotate engine 20-30 degrees counterclockwise (viewed from front of engine) and then rotate back clockwise to TDC. This removes backlash from the gear train. CAUTION: Tapered area on shaft of fuel injection pump and fuel injection pump drive gear must be clean and dry to ensure proper seating of components. Oil or dirt may result in improper seating of components which may cause slippage of fuel injection pump drive gear.
8. Loosen, but DO NOT remove, bolts used for installing gear puller. Ensure tapered area on shaft of fuel injection pump and fuel injection pump drive gear are clean and dry.
9. Using puller, rotate fuel injection pump drive gear counterclockwise while pushing fuel injection pump drive gear on the shaft of fuel injection pump. This removes backlash between fuel injection pump drive gear and camshaft gear.
10. Hand tighten fuel injection pump drive gear nut. Remove puller from fuel injection pump drive gear. Tighten fuel injection pump drive gear nut to 11 ft. lbs. (15 N.m) to seat fuel injection pump drive gear on the shaft.
11. Install pencil-type magnet in end of shaft on fuel injection pump. Remove fuel injection pump drive gear nut, thrust washers and bearing. Install washer and fuel injection pump drive gear nut. Remove magnet.
12. While holding engine from rotating with engine barring tool, tighten fuel injection pump drive gear nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r2500/1997-1998/remont/adjustments/#engine-controls-adjustments-59l-diesel__torque-specifications).
13. Repeat steps 11) - 15) under CHECKING FUEL INJECTION PUMP TIMING to verify proper plunger lift is obtained. Readjust if necessary. If plunger lift is correct, proceed to FINAL REASSEMBLY.

FINAL REASSEMBLY

1. Install oil fill tube and adapter elbow on front timing gear cover. Remove dial indicator, indicator tip and adapter from fuel injection pump.
2. Install NEW delivery valve washer in fuel injection pump. Install delivery valve assembly in fuel injection pump. Ensure delivery valve assembly is installed in correct direction. (Scheme 2)
3. Lubricate threads on delivery valve holder with SAE 90W gear oil. DO NOT lubricate delivery valve washer or seating area on delivery valve holder.
4. Ensure fill piece, shim(s) and spring are properly installed in delivery valve holder. (Scheme 2) Install delivery valve holder in fuel injection pump. Use care not to allow fill piece, shim(s) or spring to fall from delivery valve holder during installation.
5. Delivery valve holder must be tightened in 2 steps. Tighten delivery valve holder to 29 ft. lbs. (39 N.m). Using one motion, tighten delivery valve holder to 85 ft. lbs. (115 N.m). Install high-pressure fuel line on delivery valve holder. Tighten high-pressure fuel line nut to spec. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r2500/1997-1998/remont/adjustments/#engine-controls-adjustments-59l-diesel__torque-specifications). WARNING: Use care when bleeding high-pressure fuel line, as fuel is under extreme pressure and could penetrate skin, causing personal injury. Wear safety goggles and protective clothing when bleeding high-pressure fuel lines.
6. Reconnect negative battery cables. Loosen high-pressure fuel line nut at fuel injector (if not previously done) so fuel line can be bled. Crank engine until steady flow of fuel is observed at fuel injector. Tighten high-pressure fuel line nut to specification. Start engine and check for fuel leaks.

SOLENOID SHAFT ADJUSTMENT

1. Turn ignition on. Pull upward and hold solenoid lever in the upward position. (Scheme 5) If solenoid is operating correctly, solenoid lever should remain in upward position with ignition on.
2. Measure distance from bottom of mounting bracket to end of lever pin. (Scheme 6) Distance should be 2.64" (67.0 mm). If distance is incorrect, loosen shaft lock nut and rotate adjustment nut until correct distance is obtained. (Scheme 6) Tighten shaft lock nut and recheck the distance.

Scheme 5

Scheme 6

ENGINE SPEED SENSOR

Note. Engine speed sensor may also be referred to as crankshaft position sensor.

AIR GAP ADJUSTMENT

1. Engine speed sensor is located on front timing gear cover, just above vibration damper. (Scheme 7) Loosen engine speed sensor bolts. CAUTION: Engine speed sensor must not be aligned with notch areas on vibration damper when adjusting engine speed sensor air gap or engine speed sensor will be damaged when engine is started. (Scheme 7)
2. Ensure engine speed sensor is not aligned with notch areas on vibration damper. Tighten engine speed sensor bolts finger tight. DO NOT tighten bolts at this time.
3. Engine speed sensor air gap should be.049-.051" (1.25-1.30 mm). Install proper thickness Brass feeler gauge between tip of engine speed sensor and vibration damper.
4. Gently push engine speed sensor downward against Brass feeler gauge. Tighten engine speed sensor bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r2500/1997-1998/remont/adjustments/#engine-controls-adjustments-59l-diesel__torque-specifications). Remove feeler gauge. Recheck air gap.

Scheme 7

HIGH IDLE SPEED

Note. DO NOT attempt to adjust high idle speed. High idle speed screw is preset and sealed at the factory.

LOW IDLE SPEED

1. Warm engine to normal operating temperature. Ensure throttle lever stop contacts low idle speed adjusting screw with accelerator pedal in idle position. (Scheme 8)
2. Using optical tachometer, check engine idle speed with A/C on and with transmission in Drive (A/T models) or Neutral (M/T models). Ensure engine idle speed is within specification. See ENGINE IDLE SPEED SPECIFICATIONS table. ENGINE IDLE SPEED SPECIFICATIONS (1) Application Engine Idle Speed A/T (2) 750-800 RPM M/T (3) 780 RPM (1) Engine idle speed may be stamped on engine data plate, located on fuel injection pump side of timing gear housing. If engine data plate specification varies from specification listed, use engine data plate specs. (2) Check with engine at normal operating temperature, transmission in Drive and A/C on. (3) Check with engine at normal operating temperature, transmission in Neutral and A/C on.
3. If engine idle speed is not within specification, loosen lock nut on low idle speed adjusting screw. (Scheme 8) Rotate low idle speed adjusting screw to obtain correct engine idle speed. Tighten lock nut. Recheck engine idle speed.

Scheme 8

LINKAGE ROD ADJUSTMENT

1. Before performing linkage rod adjustment, ensure low idle speed is correct. See LOW IDLE SPEED under IDLE SPEED. Disconnect throttle cable from ball on throttle lever. (Scheme 9)
2. Measure distance between center of ball and rear face of throttle lever bracket. (Scheme 9) Distance should be 5" (127 mm). If distance is not within specification, linkage rod must be adjusted.
3. To adjust linkage rod, attach lock-type pliers on flat areas on linkage rod. Loosen front and rear lock nuts on linkage rod. Front lock nut is nut closest to Throttle Position (TP) sensor and contains left-hand threads. Rear lock nut is the nut near rear of fuel injection pump and contains right-hand threads.
4. Rotate linkage rod until correct distance is obtained. Tighten front and rear lock nuts. Operate throttle pedal to ensure no binding exists. Ensure throttle lever stop contacts low idle speed adjusting screw with accelerator pedal in idle position.
5. Check for throttle lever break-over by fully depressing accelerator pedal and visually ensuring throttle lever break-over exists. If throttle lever break-over exists, linkage rod should stop moving and throttle lever should continue to move toward rear of the vehicle. If throttle lever break-over exists, linkage rod is properly adjusted.

Scheme 9

THROTTLE POSITION SENSOR ADJUSTMENT - A/T MODELS

1. Before performing Throttle Position (TP) sensor adjustment, ensure proper linkage rod adjustment exists. See LINKAGE ROD ADJUSTMENT under THROTTLE LINKAGE.
2. Connect digital volt-ohmmeter negative lead to ground. Use paper clip to backprobe center wire terminal on electrical connector at TP sensor. DO NOT disconnect electrical connector from TP sensor. Connect digital volt-ohmmeter positive lead on paper clip.
3. Turn ignition on. DO NOT start engine. With throttle lever stop contacting low idle speed adjusting screw (idle position), (idle position), voltage should be.8-1.2 volts.
4. Open throttle to full throttle and note voltage reading. Voltage should be 2.2-2.9 volts more than voltage obtained at idle. If voltage is incorrect, linkage rod must be adjusted.
5. To adjust linkage rod, attach lock-type pliers on flat areas on linkage rod. Loosen front and rear lock nuts on linkage rod. Front lock nut is nut closest to TPS and contains left-hand threads. Rear lock nut is the nut near rear of fuel injection pump and contains right-hand threads. NOTE: DO NOT lengthen or shorten linkage rod more than.04" (1.0 mm) from base adjustment of 5" (127 mm).
6. Rotate linkage rod until voltage is.8-1.2 volts with throttle lever stop contacting low idle speed adjusting screw (idle position). Open throttle to full throttle and note voltage reading. Voltage should be 2.2-2.9 volts more than voltage obtained at idle. Once correct voltage is obtained, tighten front and rear lock nuts on linkage rod.
7. Measure distance between center of ball and rear face of throttle lever bracket. (Scheme 9) Replace TPS sensor if proper voltage cannot be obtained with linkage rod adjusted so distance is within 4.96-5in 4.96-5.04" (126.0-128.0 mm).
8. Operate throttle and ensure no binding exists. Ensure throttle lever stop contacts low idle speed adjusting screw with accelerator pedal in idle position.
9. Check for throttle lever break-over by fully depressing accelerator pedal and visually ensuring throttle lever break-over exists. If throttle lever break-over exists, linkage rod should stop moving and throttle lever should continue to move toward rear of vehicle. If throttle lever break-over exists, linkage rod is properly adjusted. Ensure low idle speed is correct.

CONTROL ROD ADJUSTMENT

1. Disconnect line from wastegate actuator. (Scheme 10) Install dial indicator for checking control rod movement. (Scheme 10)
2. Install pressure gauge and air line on wastegate actuator. Apply 15-20 psi (1.0-1.4 kg/cm 2 ) on wastegate actuator to fully seat components and take slack out of control rod. Release air pressure and zero dial indicator.
3. Apply 19.3 psi (1.35 kg/cm 2 ) air pressure to wastegate actuator and note amount of control rod movement on dial indicator. Control rod movement should be.013-.050" (.33-1.27 mm).
4. If control rod movement is not within specification, adjust control rod length. To adjust control length, ensure air pressure is applied on wastegate actuator to release spring tension on wastegate lever mounted on the turbocharger.
5. Remove clip and control rod from wastegate lever on turbocharger. Pull control rod toward wastegate actuator (closed position). Loosen lock nut on control rod.
6. Rotate clevis on end of control rod to align clevis with clevis pin on wastegate lever. Install clevis on clevis pin. DO NOT force clevis onto clevis pin. Install clip. Tighten lock nut. Recheck control rod movement.

Scheme 10

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• VALVE CLEARANCE ADJUSTING SEQUENCE