Sunday, February 16, 2014
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The six-cylinder, 5.9-liter Cummins diesel engine is most common in light to medium trucks, such as Dodge Ram pickup trucks made from 1989 to 1998. It produces a large amount of low-end torque and has better fuel economy than a larger eight-cylinder engine. The 5.9-liter Cummins engine uses a timing chain to drive the camshaft with the crankshaft, which requires a cover. The procedure for removing the timing chain cover is the same for all vehicles with a 5.9-liter Cummins engine.
Instructions
1 Disconnect the water pump and power steering pump from the engine compartment with a socket wrench. Disconnect the pulley from the crankshaft and pull the crankshaft damper from the crankshaft with a suitable puller.
2 Detach the fuel lines from the fuel pump with a socket wrench and disconnect the fuel pump. Remove the front mounting bolts for the oil pump. Disconnect the mounting bolts for the timing chain and remove the timing chain.
3 Clean the mounting surface for the timing chain cover with a shop cloth and install a new gasket to the cover. Apply a bead of RTV sealer 1/8 inch wide to the oil pan gasket.
4 Tighten the mounting bolts for the timing chain cover to 30 foot-pounds with a torque wrench. Center the gasket on the oil pan and tighten the mounting bolts for the oil pan to 17 foot-pounds.
5 Coat the seal for the crankshaft damper with lithium grease and mount the damper to the crankshaft. Press the crankshaft damper to the crankshaft with Tool C-3688 and tighten the mounting bolt for the crankshaft damper to 135 foot-pounds with a torque wrench. Install the crankshaft pulley to the crankshaft with a socket wrench.
6 Connect the fuel pump with a socket wrench and attach the fuel lines to the fuel pump. Install the water pump and power steering pump.
Friday, January 17, 2014
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Volkswagen diesel engines made since 1991 use Turbocharged Direct Injection, or TDI. The 1.9-liter version of this engine appears in various Volkswagen models made since 1995, including the Golf, Jetta, Passat and New Beetle. TDI engines have a turbocharger and inject fuel directly into the cylinder. This is a mechanical method of fuel injection, which does not use an electronic controller to determine when the injector sends fuel to the cylinder.
Instructions
1 Remove the fuel pump fuse from the fuse box under the dashboard. Start the engine, and allow it to idle until it stalls. This will relieve the pressure in the fuel system. Turn the engine off, and replace the fuel pump fuse in the fuse box.
2 Disconnect the negative battery cable with a socket wrench. Wrap a clean shop cloth around the fitting on the fuel line to the fuel rail. Remove the union nuts from the fuel line, and disconnect the fuel line from the fuel rail.
3 Remove the mounting bolts for the fuel rail with a socket wrench, and disconnect the fuel rail from the engine as an assembly. Turn the fuel injectors counterclockwise and remove them from the injector hole on the cylinder head. Remove and discard the heat shields from the injector hole.
4 Install new heat shields to the injector hole, and screw the new fuel injector into its hole. Tighten the fuel injector with a socket wrench, and install the fuel rail to the engine.
5 Connect the fuel line fuel rail, and fasten the union nuts for the fuel line with a socket wrench. Connect the negative battery cable.
Thursday, November 14, 2013
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International Harvester Corp. made a series of eight-cylinder diesel engines for use in Ford F-series pickup trucks from 1982 to 1994. These engines used indirect injection, a form of mechanical fuel injection that does not require electronic control. The 6.9-liter version of the International diesel engine was in production from 1983 to 1987. The procedure for removing the fuel injectors is generally the same for all Ford vehicles that have a 6.9-liter International diesel engine.
Instructions
1 Clean the fuel injector nozzles and the surrounding area with clean fuel oil to avoid contaminating the engine when you remove the fuel injectors. Clean the fuel line connections to the fuel injector to keep debris out of the fuel system. Blow the fuel injectors clean with an air compressor.
2 Release the clamps on the fuel lines to the fuel injectors, and disconnect the fuel lines from the fuel injectors. Remove the leak-off tees from the fuel injectors, and move them out of the way. Cover the open ends of the fuel injectors with plastic caps to keep dirt out of the fuel injectors.
3 Turn the fuel injectors counterclockwise with a socket wrench, and remove them from the injector bores. Cover the nozzle ends of the fuel injectors with plastic caps to avoid fuel contamination.
4 Extract the copper gasket from the injector bore with special tool T71P-19703-C, if the gasket is not on the fuel injector nozzle.
5 Store the fuel injectors in a holder with numbered holes. Place each fuel injector in the hole corresponding to that fuel injectors cylinder number. This ensures that you will reinstall each fuel injector into the correct injector bore.
