How do I set the engine to TDC before removing the Cummins fuel injection pump?

Remove the dust cover from the transmission adapter plate, install Engine Barring Tool (3904682) in the adapter plate, and rotate the engine clockwise until the No. 1 cylinder piston is at TDC. The key of the fuel injection pump shaft should point toward the bottom of the engine; then engage the timing pin.

What torque is specified for the fuel injection pump lock bolt?

After removing the special washer, tighten the lock bolt to 22 ft. lbs. (30 N.m). Retain the special washer for reassembly.

Why must banjo bolt locations be marked before removal?

A smaller orifice is used in the banjo bolt at the fuel pump than at the filter head, so their locations at the fuel filter and fuel pump must be marked prior to removal.

How is the fuel pump drive gear removed from the pump shaft?

Use a gear puller and two M8 x 1.25 bolts to pull the drive gear free from the fuel pump shaft, then remove the pump mounting nuts, the injection pump, and the gasket.

Can the timing marks on the pump flange be used when installing a different pump?

No. The timing marks apply to each specific engine and fuel injection pump pairing and cannot be used to exchange fuel injection pumps.

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1989 Dodge 5.9L Cummins Fuel Injection Pump Removal Procedure - Page 1

Service manual page: fuel injection pump removal steps for 5.9L Cummins diesel

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Service procedure page detailing fuel injection pump removal for a 5.9L Cummins B-series turbo diesel in a 1989 Dodge pickup.

AI caption December 2003 · Photo 1369 of 3537

This document is page 1 of a service procedure for the 5.9L 6-cylinder Cummins B Series turbo diesel (VIN code 8) as installed in a 1989 Dodge Pickup, printed from a 2001 MRIC/Snap-on Tools electronic manual system on December 15, 2003. It covers the removal portion of the fuel injection pump procedure in seven numbered steps. Key instructions include disconnecting the throttle linkage and shutoff valve wire, capping fuel lines, and removing the turbo boost line; a caution to mark the banjo bolt locations at the fuel filter and fuel pump (the pump banjo bolt has a smaller orifice) and not to remove the throttle control lever from the pump shaft; removing the fuel pump drive gear retaining nut without dropping it into the timing gear cover; positioning the engine at TDC of the No. 1 cylinder using Engine Barring Tool 3904682; engaging the timing pin carefully; noting timing mark alignment on the pump flange and gear housing (marks apply only to the original engine/pump pairing); loosening the lock bolt, tightening it to 22 ft. lbs. (30 N.m), and pulling the drive gear with a gear puller and two M8 x 1.25 bolts before removing the pump and gasket.

This document covers 1989, which may differ from this 1992 Ford Bronco.

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Frequently asked questions

How do I set the engine to TDC before removing the Cummins fuel injection pump?: Remove the dust cover from the transmission adapter plate, install Engine Barring Tool (3904682) in the adapter plate, and rotate the engine clockwise until the No. 1 cylinder piston is at TDC. The key of the fuel injection pump shaft should point toward the bottom of the engine; then engage the timing pin.
What torque is specified for the fuel injection pump lock bolt?: After removing the special washer, tighten the lock bolt to 22 ft. lbs. (30 N.m). Retain the special washer for reassembly.
Why must banjo bolt locations be marked before removal?: A smaller orifice is used in the banjo bolt at the fuel pump than at the filter head, so their locations at the fuel filter and fuel pump must be marked prior to removal.
How is the fuel pump drive gear removed from the pump shaft?: Use a gear puller and two M8 x 1.25 bolts to pull the drive gear free from the fuel pump shaft, then remove the pump mounting nuts, the injection pump, and the gasket.
Can the timing marks on the pump flange be used when installing a different pump?: No. The timing marks apply to each specific engine and fuel injection pump pairing and cannot be used to exchange fuel injection pumps.