What is the plunger lift specification for the 1989 Dodge 5.9L Cummins injection pump?

Plunger lift should be 1.4 mm. If not within specification, loosen the mounting nuts and rotate the fuel injection pump on its mounting studs to obtain correct plunger lift.

What torque values are given for injection pump timing on the 5.9L Cummins?

Lock bolt: 10 ft. lbs. (14 N.m); pump mounting nuts: 18 ft. lbs. (24 N.m); timing indicator plug: 90 INCH lbs. (10 N.m).

How do you rotate the Cummins engine to set injection pump timing?

Remove the dust cover from the transmission adapter plate and install Engine Barring Tool (3904682) in the adapter plate, then rotate the engine clockwise until the No. 1 cylinder piston is at TDC and engage the timing pin.

How is the dial indicator marked when checking Cummins pump timing?

The dial indicator is marked in millimeters; one revolution equals .50 millimeters. Do not rotate the engine until the timing pin is disengaged.

What should you do after setting the injection pump timing?

Remove the timing indicator, install the plug and tighten it to 90 INCH lbs. (10 N.m), ensure the timing pin is disengaged, and bleed the fuel lines (see FUEL LINE BLEEDING).

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1989 Dodge Cummins 5.9L Diesel Injection Pump Timing Procedure - Plunger Lift

Service manual page: checking fuel injection pump timing with dial indicator figure

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Service procedure page covering fuel injection pump timing check with a timing-indicator figure and plunger-lift steps.

AI caption December 2003 · Photo 1373 of 3537

This document is page 1 of a service procedure for checking and adjusting fuel injection pump timing on a 1989 Dodge Pickup equipped with the 5.9L 6-cylinder Cummins B Series turbo diesel engine (VIN code 8). It provides step-by-step instructions: ensuring a special washer is under the lock bolt (torqued to 10 ft. lbs. / 14 N.m), rotating the engine to No. 1 cylinder TDC using an Engine Barring Tool (part 3904682) in the transmission adapter plate, installing a timing (dial) indicator in the end of the fuel injection pump, and measuring plunger lift. Cautions note that the dial indicator is marked in millimeters (one revolution = .50 mm) and the engine must not be rotated until the timing pin is disengaged. The specified plunger lift is 1.4 mm; if out of spec, the pump is rotated on its mounting studs and the mounting nuts torqued to 18 ft. lbs. (24 N.m). The access plug is reinstalled at 90 INCH lbs. (10 N.m) before bleeding fuel lines. A figure (Fig. 2) illustrates the fuel injection pump with timing indicator, courtesy of Chrysler Motors. The page is dated December 16, 2003, and copyrighted 2001 by MRIC and Snap-on Tools Company.

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

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Frequently asked questions

What is the plunger lift specification for the 1989 Dodge 5.9L Cummins injection pump?: Plunger lift should be 1.4 mm. If not within specification, loosen the mounting nuts and rotate the fuel injection pump on its mounting studs to obtain correct plunger lift.
What torque values are given for injection pump timing on the 5.9L Cummins?: Lock bolt: 10 ft. lbs. (14 N.m); pump mounting nuts: 18 ft. lbs. (24 N.m); timing indicator plug: 90 INCH lbs. (10 N.m).
How do you rotate the Cummins engine to set injection pump timing?: Remove the dust cover from the transmission adapter plate and install Engine Barring Tool (3904682) in the adapter plate, then rotate the engine clockwise until the No. 1 cylinder piston is at TDC and engage the timing pin.
How is the dial indicator marked when checking Cummins pump timing?: The dial indicator is marked in millimeters; one revolution equals .50 millimeters. Do not rotate the engine until the timing pin is disengaged.
What should you do after setting the injection pump timing?: Remove the timing indicator, install the plug and tighten it to 90 INCH lbs. (10 N.m), ensure the timing pin is disengaged, and bleed the fuel lines (see FUEL LINE BLEEDING).