Engine Controls - Adjustments - 5.9l Diesel Dodge Pickup R3500

ENGINE MECHANICAL

Note. Article applies only to 12-valve engine with mechanical fuel injection. Article does not apply to 24-valve engine with electronic fuel injection.

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 5

1. Engine may be rotated by removing dust cover from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 5) 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 5) 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 bolts, 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 clockwise (viewed from front of engine) one full revolution. 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. Using feeler gauge, check valve clearance between valve stem and rocker lever. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table. VALVE CLEARANCE ADJUSTING SEQUENCE Procedure Cylinders No. Step 1 (1) Intake Valve 1, 2 & 4 Exhaust Valve 1, 3 & 5 Step 2 (2) Intake Valve 3, 5 & 6 Exhaust Valve 2, 4 & 6 (1) Adjust valve clearance with engine cold, timing pin engaged and cylinder No. 1 at TDC. (2) Rotate engine clockwise (viewed from front of engine) one full revolution from TDC on cylinder No. 1 and align reference marks. VALVE CLEARANCE SPECIFICATIONS (1) Application In. (mm) Intake Valve.010 (.25) Exhaust Valve.020 (.51) (1) Adjust valve clearance with engine temperature less than 140°F (60°C).
5. If valve clearance is within specification, go to next step. If valve clearance is not within specification, loosen rocker lever adjusting screw lock nut, and adjust valve clearance by rotating rocker lever adjusting screw. Tighten rocker lever adjusting screw lock nut to specification. See TORQUE SPECIFICATIONS. Go to next step. CAUTION: Ensure timing pin is disengaged before rotating engine.
6. Once valve clearances are checked and adjusted (if necessary) on proper valves, place reference marks on vibration damper and front timing gear cover. Disengage timing pin. Rotate engine clockwise (viewed from front of engine) one full revolution and realign reference marks.
7. Check valve clearance on proper valves. See STEP 2 in VALVE CLEARANCE ADJUSTING SEQUENCE table. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table.
8. If valve clearance is within specification, go to next step. If valve clearance is not within specification, loosen rocker lever adjusting screw lock nut, and adjust valve clearance by rotating rocker lever adjusting screw. Tighten rocker lever adjusting screw lock nut to specification. See TORQUE SPECIFICATIONS. Go to next step.
9. Using NEW gaskets, install rocker lever covers. Install and tighten rocker lever cover bolts to specification. See TORQUE SPECIFICATIONS. Install nameplate. Ensure timing pin is disengaged.

Scheme 6

Scheme 7

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 may be rotated by removing plug from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 5) 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 5) 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. 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 clockwise (viewed from front of engine) one full revolution.
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. (Scheme 5) It may be necessary to also disconnect high-pressure fuel line from No. 1 fuel injector for fuel 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 5) 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 6) DO NOT allow components to fall from delivery valve holder.
9. Using magnet, remove 2-piece delivery valve assembly from fuel injection pump. (Scheme 6)
10. Install Adapter (6842) in fuel injection pump finger tight. (Scheme 7) Using Allen wrench, loosen set screw on adapter. 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 one mm increments. Large outer dial on dial indicator is marked in.01 mm increments. One revolution of large outer dial is equal to one 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 while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear. Note plunger lift reading on dial indicator.
14. Note Cummins Parts Listing (CPL) number and TIMING TDC specification listed on engine data plate. Engine data plate is located on fuel injection pump side of timing gear housing. (Scheme 5) TIMING TDC specification is the number of degrees BTDC.
15. Using CPL number and TIMING TDC specification listed on engine data plate, note if plunger lift is within specification. See PLUNGER LIFT SPECIFICATIONS table.
16. If plunger lift is within specification, no adjustment of fuel injection pump timing is required. Proceed to FINAL REASSEMBLY under FUEL INJECTION PUMP TIMING. If plunger lift is not within specification, fuel injection pump timing must be adjusted. Proceed to ADJUSTING FUEL INJECTION PUMP TIMING.

PLUNGER LIFT SPECIFICATIONS (1)

Scheme 8

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 8) 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 into 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 and 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 8) 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 (viewed from front of engine) 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.
13. Repeat steps 12) through 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 (if removed). Using NEW gasket, install cylinder No. 1 rocker lever cover. Install and tighten rocker lever cover bolts to specification. See TORQUE SPECIFICATIONS. Install nameplate. Ensure timing pin is disengaged.
2. Remove dial indicator, indicator tip and adapter from fuel injection pump. Install delivery valve assembly in fuel injection pump. Ensure delivery valve assembly is installed in correct direction. (Scheme 6)
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 6) 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).
6. Install high-pressure fuel line on delivery valve holder. Tighten high-pressure fuel line nut to specification. See 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.
7. Reconnect negative battery cables. Loosen high-pressure fuel line nut at fuel injector (if not previously done) so fuel line may 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 9) 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 10) 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 10) Tighten shaft lock nut and recheck the distance.

Scheme 9

Scheme 10

ENGINE SPEED SENSOR

Note. Engine speed sensor may also be referred to as Crankshaft Position (CKP) sensor.

AIR GAP ADJUSTMENT

1. Engine speed sensor is located on front timing gear cover, just above vibration damper. (Scheme 11) Loosen engine speed sensor nuts. 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 11)
2. Ensure engine speed sensor is not aligned with notch areas on vibration damper. Tighten engine speed sensor nuts finger tight. DO NOT tighten nuts 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 nuts to specification. See TORQUE SPECIFICATIONS. Remove feeler gauge. Recheck air gap.

Scheme 11

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 12)
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 specification. (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 12) Rotate low idle speed adjusting screw to obtain correct engine idle speed. Tighten lock nut. Recheck engine idle speed.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. Before performing linkage rod adjustment, ensure low idle speed is correct. See LOW IDLE SPEED under IDLE SPEED. To check for proper linkage rod adjustment and full throttle, ensure ignition is off.
2. Fully depress accelerator pedal to full throttle and visually ensure 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. (Scheme 13) If throttle lever break-over does not exists, linkage rod adjustment is required. Go to next step.
3. Remove intercooler outlet duct from air inlet housing for access to linkage rod at fuel injection pump. Disconnect throttle cable, cruise control cable and throttle valve cable (A/T models) at fuel injection pump.
4. Loosen, but DO NOT remove bolts "A", "B" and "C" at throttle lever. Perform STEP 1. (Scheme 14)
5. Pivot throttle lever on fuel injection pump lever so distance between location "D" at rear of throttle lever and location "E" at rear of throttle cable bracket is 10.25" (260.0 mm). Perform STEP 2. (Scheme 14) Ensure fuel injection pump lever remains in closed throttle position when measuring the distance. Once proper distance is obtained, tighten bolts "A", "B" and "C" to 89 INCH lbs. (10.1 N.m).
6. To verify correct throttle break-over distance, measure distance from rear of throttle cable mounting stud at location "F" to the rear of cable mounting bracket at location "G". (Scheme 15) Measure this distance with throttle at closed throttle position and at full throttle position. Ensure fuel injection pump lever remains in closed throttle position or full throttle position when measuring the distance. Record both measurements.
7. This difference between both measurements obtained in step 6) should be within 1.26-1.42" (32.0-36.0 mm). If the difference between both measurements is within specification, go to step 11). If the difference between both measurements is not within specification, go to next step.
8. If distance between both measurements is less than specified, remove nut and ball stud from throttle lever. (Scheme 16) Move ball stud upward/rearward one notched hole on fuel injection pump lever. (Scheme 16) Each notched hole will change the measurement about.047" (1.2 mm). Go to step 10).
9. If the distance between both measurements is more than specified, remove nut and ball stud from throttle lever. (Scheme 16) Move ball stud downward/forward one notched hole on fuel injection pump lever. (Scheme 16) Each notched hole will change the measurement about.047" (1.2 mm). Go to next step.
10. Reinstall nut on ball stud. Tighten nut to 89 INCH lbs. (10.1 N.m). Recheck both measurements. Readjust if necessary. After correct measurement is obtained, repeat step 2) to ensure correct throttle lever break-over. Go to next step.
11. Reinstall throttle cable, cruise control cable and throttle valve cable (A/T models) at fuel injection pump. On A/T models and M/T models with EGR system, the throttle position sensor must be adjusted. See THROTTLE POSITION SENSOR ADJUSTMENT under THROTTLE POSITION SENSOR. On all models, reinstall intercooler outlet duct on air inlet housing

Scheme 17

Scheme 18

Scheme 19

1. Before performing Throttle Position (TP) sensor adjustment, fully depress accelerator pedal to full throttle and visually ensure 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. (Scheme 13)
2. If throttle lever break-over exists, go to next step. If throttle lever break-over does not exist, linkage rod adjustment is required. See LINKAGE ROD ADJUSTMENT under THROTTLE LINKAGE. Once correct throttle lever break-over exists, go to next step.
3. Verify TP sensor linkage distance from center of ball to the rear face of cable mounting bracket is 5.0" (127 mm) before proceeding with TP sensor adjustment. (Scheme 17)
4. Ensure low idle speed is within specification. See LOW IDLE SPEED under IDLE SPEED. Shut engine off.
5. Connect scan tool to data link connector. Data link connector is located below driver's side of instrument panel. (Scheme 18) Access SENSOR display on scan tool. NOTE: TP voltage may also be referred to as TPS voltage.
6. Turn ignition on with engine off. DO NOT start engine. With throttle at idle position, note TP voltage on scan tool. TP voltage should be.8-1.2 volts at idle position. Open throttle to full throttle and note TP voltage. TP voltage should be 2.2-2.9 volts more than TP voltage obtained at idle position.
7. If TP voltage is correct, turn ignition off. Remove scan tool. If TP voltage is incorrect, linkage rod must be adjusted. Go to next step.
8. Remove intercooler outlet duct from air inlet housing for access to linkage rod at fuel injection pump. Loosen nut "A" (right-hand thread) and nut "B" (left-hand thread) on linkage rod while holding adjusting nut on linkage rod. (Scheme 19)
9. Rotate adjusting nut to change length of linkage rod to obtain TP voltage of.8-1.2 volts with linkage rod in the idle position. Open throttle to full throttle and note TP voltage. TP voltage should be 2.2-2.9 volts more than TP voltage obtained at idle position. NOTE: DO NOT lengthen or shorten linkage rod more than.04" (1.0 mm) from base adjustment of 5" (127 mm) from center of ball to the rear face of cable mounting bracket. (Scheme 17) Replace TP sensor if proper voltage cannot be obtained with linkage rod length of 4.94-5.02" (125.6-127.6 mm).
10. Once correct voltage is obtained, tighten nuts "A" and "B" on linkage rod. Ensure linkage rod slightly rotates without binding at ball at each end of linkage rod. If binding exists, loosen either nut "A" or "B" until binding is eliminated. Retighten nut.
11. Operate throttle and check for any binding. Ensure throttle lever stop contacts low idle speed adjusting screw with throttle in idle position. (Scheme 12) Ensure low idle speed is still correct. See LOW IDLE SPEED under IDLE SPEED. Reinstall intercooler outlet duct. Turn ignition off. Remove scan tool.

CONTROL ROD ADJUSTMENT

Note. Line at wastegate actuator may contain tamper-proof clamp. These clamps may be replaced with a worm gear clamp.

1. Disconnect line from wastegate actuator. (Scheme 20) Install dial indicator for checking control rod movement. (Scheme 20)
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 28 psi (1.96 kg/cm 2 ) air pressure to wastegate actuator and note amount of control rod movement on dial indicator. Control rod movement should be.013-.052" (.33-1.32 mm).
4. If control rod movement is within specification, go to next step. 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 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. On correct control rod movement is obtained, go to next step.
7. Release test equipment. Reinstall line on wastegate actuator using a worm gear clamp.

Scheme 20

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS