Dodge RAM TRUCK 1500 1995 Service Manual page 1201

B R GENERAL DIAGNOSIS—DIESEL ENGINE 1 4 - 1 1 9
SYSTEM DIAGNOSIS CHARTS
Refer to Engine Diagnosis in Group 9, Engine for
diagnostic charts.
FUEL INJECTION PUMP TIMING
(1) Thoroughly clean the engine and fuel system
before attempting to remove any "components. Pay
special attention to the top of the fuel injection
pump. Use compressed air to remove any water re­
maining on the fuel pump after the cleaning process.
CAUTION: DO NOT ALLOW ANY DIRT, D E B R I S , OR
PAINT CHIPS TO ENTER THE F U E L S Y S T E M WHILE
IT I S O P E N . IF FOREIGN MATERIAL OF ANY T Y P E
IS A L L O W E D INTO THE PUMP, LINES OR INJEC­
TORS DURING THIS P R O C E S S IT COULD RESULT
IN AN INJECTION PUMP OR F U E L INJECTOR MAL­
FUNCTION.
Locate top dead center (TDC) on cylinder #1.
(2) Remove the rubber access plug located in the
rear flange of the engine on the exhaust manifold
side. (Fig. 40).
Fig. 40 Rotating Engine With Barring Tool
Removing the #6 cylinder valve cover and
first barring (rotating) the engine clockwise un­
til both intake and exhaust valves are closed
will speed up locating engine TDC as described
later in step 4.
(3) Insert the barring tool number 7471B through
the access hole and into the flywheel housing (Fig.
40).
(4) While holding tension on the timing pin (to­
ward front of engine), slowly rotate the engine with
the barring tool. Hold a slight rearward (pushing)
pressure on the barring tool and rotate the tool
counter-clockwise until the timing pin drops into the
machined hole in the back of the camshaft gear.
When the pin aligns to the gear (Fig. 41), and the in­
take and exhaust valves are closed at the #6 cylinder,
the engine is at the TDC position (compression
stroke) at cylinder number 1. Place a paint mark on
the dampener to indicate TDC. Remove the pin.
This will prevent damage when barring (rotat­
ing) the engine in later steps.
The pin is located above the power steering
pump, below and to the inside of the fuel injec­
tion pump, on the rear of the cam gear housing
(Fig. 42).
MACHINED HOLE
Fig. 41 Back of Camshaft Gear
Fig. 42 Timing Pin and Location
(5) Remove #1 fuel injection line from the fuel
pump (Fig. 43).