Fix It

Industrial Injection Diesel Performance is a supplier of fuel injection parts and turbochargers. They are located in Salt Lake City, Utah. However, they have registered dealers throughout the United States and Canada.

Prodcuts

Industrial Injection Diesel Performance offers a wide range of products including injection pumps, turbochargers, fass pumps, fuel pumps and flow injectors. These products may be used with diesel vehicles from major companies such as GM, Ford and Dodge.

Services

The company offers an exchange program for most of their products. They also offer Bosch-certified repair and performance improvement services. All their technicians are certified.

Return Policy

Industrial Injection Diesel Performance accepts return and exchanges as long as they are done within 30 days of the purchase date and the original receipt is presented. All products must be inspected before a return or exchange can be accepted.

The Cummins 5.9-liter engine has six cylinders, and it typically has a turbocharger. The most common application for this engine is in heavy Dodge trucks made after 1989. The Cummins 5.9-liter engine uses diesel fuel and has fuel injection, which requires an injection pump. This pump keeps the fuel in the fuel rail at the correct pressure until it enters the engine through an intake cylinder valve. The installation procedure for an injection pump is similar for all full-size Dodge trucks made from 2000 to 2005.

Instructions

1

Detach the cables from the negative battery terminals with a socket wrench. Disconnect the bracket for the throttle linkage and remove the throttle linkage. Remove the fuel drain manifold and detach the fuel lines from the injection pump. Disconnect the fuel air control tube and electrical connector for the fuel shutoff valve. Remove the bracket and the oil fill tube from the injection pump.

2

Cover the opening in the injection gear cover with a shop towel to keep parts out of the gear housing. Disconnect the retaining nut and washer for the injection gear with a socket wrench.

3

Turn the crankshaft clockwise by hand until the key way on the shaft of the fuel pump points straight down. Push the top dead center pin on the crankshaft as you turn the crankshaft clockwise. Stop turning the crankshaft when the pin drops into the timing hole on the crankshaft gear.

4

Loosen the lock screw on the injection pump with a socket wrench, and remove its washer. Tighten the locks screw to 22 foot-pounds with a torque wrench to lock the drive shaft in place.

5

Remove the drive gear for the injection pump from the crankshaft and unfasten the mounting nuts for the injection pump. Remove the injection pump and its gasket from the engine. Clean the mounting surfaces for the gasket with a shop towel.

6

Install the new injection pump and its gasket to the engine. Tighten its mounting nuts by hand, so that the pump can still move freely within its slots. Connect the drive gear for the injection pump to the crankshaft. Tightened the retaining nut for the drive gear to between 11 and 15 foot-pounds with a torque wrench.

7

Turn the injection pump counterclockwise to seat the drive gear for the injection pump. Tighten the mounting nuts for the injection pump to 18 foot-pounds with a torque wrench. Loosen the lock screw for the injection pump with a socket wrench, so you can install the washer. Tighten the lock screw to 13 foot-pounds and remove the top dead center pin from the timing hole.

8

Install the bracket for the injection pump and tighten the retaining bolt for the injector gear to 48 foot-pounds with a torque wrench. Replace the oil filler tube and the electrical connector for the fuel shutoff valve. Install the fuel air control tube with a socket wrench and attach the fuel lines to the injection pump. Connect the fuel drain manifold and throttle linkage. Attach the cable for the negative battery terminal.

9

Turn the bleed bolt on the fuel pipe counterclockwise with a socket wrench. Push the button on the fuel transfer pump to bleed the air from the fuel system. Tighten the bleed bolt to 72 inch-pounds with a torque wrench.

General Motors manufactured an eight-cylinder 6.5-liter diesel engine from 1992 to 2000. This engine is typically turbocharged and appears in many heavy trucks from General Motors during this period. For example, A 6.5-liter turbocharged engine is an option for the 1994 Chevrolet 3/4-ton pickup truck. This engine has fuel injection and requires a pump to keep the fuel pressurized. The procedure for installing the fuel injection pump is similar for all full-size Chevrolet trucks made from 1988 to 1998.

Instructions

1

Disconnect the cable from the negative terminals of both batteries with a socket wrench. Remove the cooling fan and its shroud if necessary to access the intake manifold. Disconnect the intake manifold.

2

Detach the accelerator cable from the injection pump if applicable for your vehicle. You may also need to disconnect the retainer bracket for the air conditioning hose to gain access to the injection pump. Detach the fuel lines and electrical wiring from the injection pump. Plug the fuel lines with clean cloth.

3

Remove the vent hose assembly for the depression valve from the crankcase, including the oil filler tube. Detach the grommet from the oil filler tube. Turn the crankshaft clockwise to gain access to the bolts for the injection pump through the hole for the oil filler tube.

4

Disconnect the bolts that attach the front cover for the injection pump with a socket wrench. Remove the injection pump from the crankcase and discard its gasket.

5

Mount a new gasket to the new injection pump. Insert the pin on the hub of the injection pump into the hole on the driven gear for the injection pump. Install the injection pump and connect the front cover to the injection pump. Tighten the retaining nuts to the front cover to 30 ft. lbs. with a torque wrench.

6

Fasten the injection pump to the drive gear and tighten the bolts to 20 ft. lbs. with a torque wrench. Mount the grommet to the oil filler tube and install the vent hose assembly to the crankcase.

7

Remove the plugs from the fuel lines and attach the fuel lines to the injection pump. Tighten the bolts for the fuel lines to 20 ft. lbs. with a torque wrench. Connect the electrical wiring harness for the injection pump. Connect any additional components that you removed to access the injection pump.

8

Attach the cables to the negative battery terminals with a socket wrench. Start the engine and correct any fuel leaks.

Diesel fuel injection systems are much like that of gasoline injection systems in that they are prone to some of the same types of problems. However, diesel injectors are able to withstand certain conditions that gasoline injectors cannot. Having information on the pros and cons of diesel injection performance can be beneficial to auto owners.

Performance Pros

In diesel fuel injection systems, fuel is shot directly into each cylinder of the vehicles diesel engine. For this reason diesel injectors were built to perform under extremely high temperatures. Diesel injectors also can perform at pressures much too great for gasoline injectors to handle.

Performance Cons

Diesel fuel injection performance can suffer due to the fact that diesel fuel is known for clogging injectors. It also doesnt help that diesel fuel lacks the lubrication necessary to flow freely through the injectors. Some type of additive is often needed to assist with lubrication in diesel fuel injection systems.

Performance Tips

To make sure that a diesel injection system is performing properly, a digital pyrometer can be used to reveal the temperatures of the cylinders in the diesel engine. Cylinders with lower readings indicate issues with fuel delivery performance.

Although diesel fuel injectors perform using greater pressures than gasoline injectors, they are still prone to the same issues. Diesel fuels with low sulfur are actually more likely to cause issues with fuel injectors than regular gasoline. Having information on the equipment used to test for problems with a vehicles injectors can be beneficial to automobile owners.

Significance

Fuel injectors can suffer clogging issues from deposits left behind from the diesel fuel. Heavy wear, as well as leaks, are things for which vehicle owners should check. Diesel fuel also fails to provide proper lubrication, which can cause the fuel to not flow though the injectors as smoothly as it should.

Pyrometer

One type of test equipment that can be used to check diesel fuel injectors is called a digital pyrometer. Each engine cylinders temperature is revealed when using a digital pyrometer, indicating the specific cylinder thats not up to par. Low temperatures in one cylinder often means a problem with fuel injection.

Ohmmeter

Another type of test equipment used for checking fuel injectors in diesel engines is an ohmmeter. The ohmmeter tests the resistance of glow plugs as their resistance rises according to engine temperature. Because of this, a low glow plug resistance reading means no heat is being produced from a particular cylinder. This in turn can indicate injector issues.