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Jerry
Jerry, Master Mechanic
Category: Dodge
Satisfied Customers: 1754
Experience:  ASE Master tech, 30 years exp. troubleshooter, driveability tech
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I need to time a 5.9 cummins as I am putting the injector

Customer Question

I need to time a 5.9 cummins as I am putting the injector pump back on.during removal I could not get the timing pin to move I sprayed it several times wd40 did not help.befor I put the pump I need to get #1 cyl tdc so how is this done? I have the timing
cover off.are there any marks on the gears that need to be lined up? this is a pusher motor home thanks ray dickerson
Submitted: 2 years ago.
Category: Dodge
Expert:  -Brad- replied 2 years ago.
Here are the directions on replacing the pump.. FUEL INJECTION PUMPREMOVALDisconnect both negative battery cables at both batteries.Disconnect electrical connector at throttle position sensor on side of injection pump (if equipped with automatic transmission) Throttle Position Sensor - DieselDisconnect the electrical connector at fuel shutdown solenoid. Fuel Shutdown Solenoid LocationDisconnect the main engine wiring harness at top of injection pump and position to the side.Remove the metal intake manifold-to-intercooler connecting tube.Remove the engine oil dipstick tube mounting clamp and bolt Intake Manifold Air Heater Position dipstick tube to the sideDisconnect the two air heater cable nuts Intake Manifold Air HeaterRemove the five intake manifold bolts Intake Manifold Air Heater Discard both of the old air heater base gaskets.Remove the throttle control bracket, cables and linkage assembly from the side of pump (three bolts) Position the assembly to the side.Disconnect turbocharger wastegate line and vacuum line from air fuel control (AFC) valve at rear of injection pump Wastegate and Vacuum LinesRemove the fuel supply line at both ends (injection pump and fuel filter/water separator) Fuel Injection Pump Supply Line For procedures, refer to Fuel Injection Pump Supply Line in this group. Place a rag beneath the fitting to catch excess fuelRemove the overflow valve and fuel return line at pump Injection Pump Overflow Valve Place a rag beneath the fitting to catch excess fuelDisconnect the six (6) high-pressure fuel lines from the fuel delivery valve holders at the top of injection pump Fuel Delivery Valve Holders and Pressure Lines For procedures, refer to High-Pressure Fuel Lines in this group. Place a rag beneath the fittings to catch excess fuelDisconnect the engine oil supply line at side of pump Engine Oil Supply Line - Pump Mounting NutsRemove the oil fill tube bracket mounting bolt Oil Fill Tube, Adapter and Mounting BracketRemove oil fill tube from tube-to-gear housing adapter Oil Fill Tube, Adapter and Mounting Bracket Tube is removed by screwing counterclockwise from adapterRemove oil fill tube adapter from gear housing Oil Fill Tube, Adapter and Mounting Bracket Adapter is removed by screwing counterclockwise from gear housing.The engine is equipped with a built-in moveable timing pin. This pin is located above the power steering pump, below and to the inside of the fuel injection pump, on the rear of the cam gear housing Timing Pin and Location The pin will engage into a machined hole in the back of the camshaft gear Back of Camshaft Gear - Typical It is designed to position the engine to TDC (Top Dead Center) on the compression stroke of number 1 cylinderRemove the rubber air tube connecting the turbocharger to the air cleaner housing.The engine can be rotated with a barring tool such as Snap-On No. SP371, MTE No.(###) ###-####(Cummins Tool Division), or an equivalent.The opening for the barring tool is located in the rear flange of engine on exhaust manifold side Rotating Engine with Barring Tool - Typical Remove the rubber access plug covering this openingInsert the barring tool into the flywheel housing opening Rotating Engine with Barring Tool - TypicalWhile holding tension on the timing pin (towards front of engine), very slowly rotate the engine (counterclockwise as viewed from front) with the barring tool. Rotating the barring tool counterclockwise will rotate the crankshaft clockwise. Continue to rotate until the timing pin drops into the machined hole in the back of the camshaft gear. When the pin aligns to the gear, the engine is now at the TDC position (compression stroke) at cylinder number 1CAUTION: When installing the fuel injection pump and to achieve proper injection pump timing, the engine MUST be in the TDC position (compression stroke) at cylinder number 1. Before proceeding to the next step, and to prevent shearing of the timing pin, temporarily remove the timing pin from the back of the gear.Remove the nut and washer retaining the injection pump gear to the injection pump shaft Injection Pump Gear Washer and NutPlace a shop towel below the retainer nut in the gear housing cover opening to prevent the nut or washer from falling into the gear housingCAUTION: If the gear retainer nut or washer drops into gear housing, cover must be removed to retrieve them before engine is startedUse a T-bar type puller Separating Injection Pump Gear from Pump Shaft to separate the injection pump gear from the injection pump shaft. Attach two M8 X 1.24 MM (metric) screws through the puller and into the two threaded holes supplied in the pump gear. Pull the injection pump gear forward until it loosens from the injection pump shaft. Pull on the gear only enough to loosen it from the injection pump shaft. Pulling the gear too far may cause damage or breakage to the gear cover.Remove the two (2) injection pump-to-lower mounting bracket bolts Pump Mounting BoltsRemove the four (4) injection pump-to-gear housing mounting nuts Engine Oil Supply Line - Pump Mounting NutsRemove the injection pump from gear housing. Take care not to nick the injection pump shaft on the aluminum gear housing when removing pump.Clean the injection pump o-ring mounting surfaces on both the gear housing and pump.INSTALLATIONCAUTION: Before installing the injection pump, be sure that number 1 cylinder is at the Top Dead Center (compression stroke) position. Engage the timing pin on the rear of the gear cover Timing Pin and Location into the rear of the camshaft gear. Rotate crankshaft if necessary. Before injection pump installation, it must be set (pump shaft rotated) to a certain position to attain accurate pump timing. Remove the access plug from the side of pump Injection Pump Access Plug Stored behind this access plug is a plastic timing pin tool Injection Pump Timing Pin Tool This tool is used to align the injection pump timing tooth Injection Pump Timing Tooth to the center of access holeInstalling Original Pump: If the original pump is being reinstalled, the pin tool should already be mounted with the slotted end facing outward Injection Pump Timing Pin Tool When the position of this tool has been reversed, with the slotted end facing inward, it is used as a pump timing pin tool.Installing New or Rebuilt Pump: If a new or rebuilt pump is being installed, the pump should have been shipped with the slotted end of the timing pin tool engaged to the timing tooth in the pump.To set injection pump timing on an original pump or when checking timing on a new pump, rotate the pump shaft until the timing tooth appears in the center of the plug opening Injection Pump Timing Tooth Install the slotted end of the timing pin tool over the timing tooth. The pump shaft may have to be rotated slightly to align the tool to the tooth. Do not force the slots in the tool over the timing tooth.After the tool has been temporarily installed to the timing tooth, install and loosely tighten the access plug. New pumps should have been shipped with this tool already engaged.If the original pump is being installed, check the condition of the rubber o-ring at pump mounting area.Apply clean engine oil to the injection pump mounting flange opening in gear cover housing to allow easier pump installation Apply Oil to Gear Cover Also apply engine oil to the pump o-ring seal at pump mounting area. The machined tapers on both the injection pump shaft and injection pump gear must be dry, clean and free of any dirt or oil. This will ensure proper gear-to-shaft tightening.Position the pump assembly to the mounting flange on gear cover while aligning the injection pump shaft through the back of injection pump gear.Install the four pump mounting nuts finger tight. Do not attempt to tighten (pull) the pump to the gear cover using the mounting nuts. Damage to pump or gear cover may occur. The pump must be positioned flat to its mounting flange before attempting to tighten mounting nuts.Install two (vertical) pump mounting bracket bolts finger tight.Tighten the four pump mounting nuts to 24 N·m (18 ft. lbs.) torque. Tighten the two pump mounting bracket bolts. To prevent damage to pump and mounting flange, tighten the pump mounting nuts first.Install injection pump drive shaft-to-injection pump gear retaining nut and washer. Do a preliminary tightening of this nut to 10 to 15 N·m (7 to 11 ft. lbs.) torque. Do not over tighten. This is not the final tightening torque. To prevent damage to the timing pin, do not exceed this torque.Disengage the timing pin from the rear of camshaft gear by pulling it straight back.Remove the access plug from injection pump Injection Pump Access Plug and remove timing pin tool from pump.Do a final tightening of the injection pump gear-to-injection pump shaft nut. Tighten to 165 N·m (122 ft. lbs.) torque. Use the barring tool to prevent the engine from rotating when tightening gear.After the injection pump gear has received a final tightening, verify injection pump timing.Rotate the engine counterclockwise with the barring tool (clockwise as observed at the crankshaft from the front of vehicle) Continue rotating engine until the timing pin aligns into hole at rear of camshaft gear Back of Camshaft Gear - Typical The engine is now at TDC of number cylinder 1.With the timing pin aligned into the rear of the camshaft gear, the timing tooth should also be centered in the access hole on the side of the injection pump Injection Pump Timing Tooth Install timing pin tool Injection Pump Timing Pin Tool to verify.If the timing pin tool will not fit into the timing tooth in the pump, the pump gear nut must be removed. Loosen the pump gear from the pump shaft with the T-bar puller tool. With the gear loosened, rotate the injection pump shaft until it aligns to the center of access hole on side of pump. Tighten injection gear nut and remove barring tool.Remove the timing pin tool from the pump. Reverse the position of this tool Injection Pump Timing Pin Tool The slotted part of tool should be facing outward and will be stored in pump in this direction. Place tool back into pump. Install access plug and its sealing washer. Tighten plug to 15 N·m (11 ft. lbs.) torque.Install the engine oil supply line and fuel return line/overflow valve to pump.Install the six high-pressure fuel lines to the top of pump. Tighten lines to 30 N·m (22 ft. lbs.) torque.Install the low-pressure fuel supply line to pump.Install the turbocharger wastegate line and AFC sensing line at the pump.New or rebuilt P7100 series fuel injection pumps must be pre-lubricated before operation. Failure to do so may result in pre-mature governor wear.Remove the 10 mm hex plug (oil fill plug) on the top of the injection pump governor Injection Pump Access PlugAdd 750 ml (25 ounces) of clean engine oil through this opening.Install oil fill plug and tighten to 28 N·m (21 ft. lbs.) torque.Install the throttle linkage assembly to pump. Tighten bolts to 24 N·m (18 ft. lbs.) torque.Connect electrical connector to fuel solenoid.Connect the main engine wiring harness at top of injection pump.Install the engine oil dipstick tube mounting clamp and bolt at the opening to the intake manifold.Install oil fill tube and tube adapter.Install oil fill tube bracket and mounting bolt.Install electrical connector to throttle position sensor (if equipped)Install air cleaner housing-to-turbocharger tube at air cleaner housing.Using a new gasket, install air heater assembly (five bolts)Install intake manifold-to-intercooler tube.Check and adjust throttle linkage. Refer to Throttle Position Sensor in this group.Bleed air from fuel system. Refer to the Air Bleed Procedure in this section of the group.Adjust the low idle speed if required. Refer to Idle Speed Adjustment.Inspect throttle linkage to be sure that the control lever is opening to the full open position.Some engine oil was lost when removing pump. Check and adjust engine oil level.