The Cummins 5.9-litre 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-litre 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.
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.
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.
Turn the crankshaft clockwise by hand until the key way on the shaft of the fuel pump points straight down. Push the top dead centre 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.
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 driveshaft in place.
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.
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.
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 centre pin from the timing hole.
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.
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.