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Home >> GMC >> 1991 >> Value Van 7.4 N >> Repair and Diagnosis >> External Pages >> Different car >> Section 44 (Engine Controls - Adjustments - 5.9L Diesel) >> Adjustments >> Fuel Injection Pump Timing >> Checking Fuel Injection Pump Timing

Checking Fuel Injection Pump Timing

WARNING: This page is about a different car, the 1995 Dodge Pickup and 1995 Dodge Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable. Remove nameplate, located above rocker lever covers. Ensure area around fuel injection pump and fuel lines are clean. Remove No. 1 cylinder 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. See Figure . Rotate engine clockwise (viewed from front of engine) until exhaust valve on No. 1 cylinder starts to close.
  3. Note location of timing pin. See Figure . Push timing pin to ward front of engine. Using 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. See Figure . Ensure valves for No. 1 cylinder are closed. This positions No. 1 cylinder at TDC on compression stroke.
    CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
  4. Ensure No. 1 cylinder push rods are loose and valves are closed. If No. 1 cylinder 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 fuel line during removal.
  7. Using Socket (6840), loosen but DO NOT  remove the delivery valve holder on the fuel injection pump for the No. 1 fuel injector. See Figure . 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 a "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. See Fig 1 . DO NOT  allow components to fall from delivery valve holder.
    Fig 1: Removing & Installing Delivery Valve Holder With Components & Delivery Valve Assembly
    G94H65406Courtesy of CHRYSLER CORP.
  9. Using magnet, remove 2-piece delivery valve assembly from fuel injection pump. See Fig 1 . Using small pick, remove Copper 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. See Fig 2 . Ins tall Dial Indicator (6859) and Indicator Tip (6843) into the adapter.
    Fig 2: Installing Adapter & Dial Indicator
    G94I65407Courtesy of CHRYSLER CORP.
  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 the 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. See Figure . TIMING TDC specification is the number of degrees BTDC. Using TIMING TDC specification, note if plunger lift is within specification. See PLUNGER LIFT SPECIFICATIONS  table.
    PLUNGER LIFT SPECIFICATIONS

    Timing BTDC Specification Plunger Lift Reading
    A/T Models
    11.0 5.40 mm
    11.5 5.50 mm
    12.0 5.60 mm
    12.5 5.70 mm
    13.0 5.80 mm
    13.5 5.90 mm
    M/T Models
    11.0 4.00 mm
    11.5 4.05 mm
    12.0 4.10 mm
    12.5 4.20 mm
    13.0 4.30 mm
    13.5 4.40 mm
  15. If plunger lift is within specification, 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 below.
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