Banks Power Chevy_GMC Trucks: Diesel ’82 - 93 6.2L Forced Induction- Sidewinder Turbo System (late-body) - Manual (Page 18)

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Remove the fuel return line from the pump
cover. Remove the top attaching bolt and loos-
en the lower attaching bolts on the fast idle solenoid
and place the solenoid aside. Remove the pump cover
bolts and remove the cover. iMPOrTanT: Utmost care
must be used to prevent damage.
1989 AND EARLIER MODELS ONLY:
Observe the position of the metering valve
spring over the top of the guide stud. This position
must be duplicated exactly during the reassembly. see
figure 19.
Remove the allen-head guide stud and sealing washer
from the rear (outside) of the pump bowl. While rocking
the throttle lever toward the rear of the engine, lift out
the governor spring assembly. do not bend any springs
or linkages.
Rotate the engine slowly by hand, In a cLOcKWIse
dIRecTIOn OnLY, using a breaker bar, a short exten-
sion and a 15 ⁄
16
” socket on the vibration damper bolt to
bring the allen screw into view in the inspection slot
in the bottom of the pump bowl (see figure 20 ). On
some late model trucks, ie: 1986 and later, it may be
necessary to remove the front crankshaft pulley to gain
access to the vibration damper bolt. dO nOT aTTeMPT
TO ROTaTe THe engIne WITH THe sTaRTeR. using a 5 ⁄
32
”
allen wrench, rotate the screw 1 ⁄
4
turn, clockwise.
nOTe: The allen-screw turns fairly tightly, and is self-
locking. Turning the screw clockwise adds fuel. Keep
track of your adjustments.
Reassemble the governor spring assembly and guide
stud (see figure 19 ). Replace the sealing washer, avail-
able from gM, if needed. Make sure the upper exten-
sion of the metering valve spring rides atop the guide
stud. Torque down the guide stud snugly (85 inch-
pounds).
1989 AND LATER MODELS ONLY:
Late model (’89 and newer) 6.2L diesel engines
may have a plastic limit cap over the head of the guide
stud. The position of the guide stud is pre-set at the
factory, and should not be altered.
using a syringe or similar means, remove as much
diesel fuel as possible from the injector pump housing.
This will make it easier to view the allen-head adjust-
ment screw through the slot in the bottom of the pump
housing when it is rotated into position.
Rotate the engine slowly by hand, In a cLOcKWIse
dIRecTIOn OnLY, using a breaker bar, a short exten-
sion and a 15 ⁄
16
” socket on the vibration damper bolt to
bring the allen screw into view in the inspection slot in
the bottom of the pump bowl. (see fig. 21. ) On some
late model trucks it may be necessary to remove the
front crankshaft pulley to gain access to the vibration
damper bolt to turn the engine over. dO nOT aTTeMPT
TO ROTaTe THe engIne WITH THe sTaRTeR. The allen-
head screw may be hard to see — a flashlight or shop
light may help. The screw will have to be adjusted at an
angle from under the guide stud/spring assembly.
using a
5 ⁄
32
” ball-end style allen wrench, rotate the allen
screw 1 ⁄
4
turn, clockwise.
nOTe: The allen screw turns fairly tightly, and is self-
locking. Turning the screw clockwise adds fuel. Keep
track of your adjustments.
Inspect the pump cover and make sure the seal
is seated in the cover. Replace if questionable.
fill the pump bowl with clean diesel fuel. Hold the
throttle in the idle position. With the bolts removed
from the pump cover, position the cover about 1 ⁄
4
” for-
ward, toward the shaft end, and about 1 ⁄
8
” above the
pump. guide the cover downward and rearward into
position, being careful not to damage the cover seal.
Reinstall the bolts with the flat washers against the
pump cover.
Reconnect battery cables. Turn the ignition
switch to the “On” position, and touch the
pink solenoid wire to the solenoid terminal. a clicking
noise should be heard. If clicking is heard, proceed to
next step. If not heard, the linkage may be jammed in
the wide-open position. DO nOT sTarT THe engine!!
Remove the pump cover. ground the solenoid lead
(opposite hot terminal on the cover) and connect the
pink wire to the cover terminal. With the ignition switch
on, the solenoid in the cover should move the linkage.
If not, free the linkage or replace the solenoid. Reinstall
the cover.
Make sure battery cables are disconnected after
solenoid test.
Reinstall the fuel return line and fast idle sole-
noid.
Purge the air from the system as follows:
Remove and fill all filters with clean diesel
and reinstall the filters. detach all fuel supply hoses
between the lift pump (fuel pump in the side of the
engine) and the injection pump at their highest ends,
and fill them with clean diesel fuel using a small funnel.
reattach the hoses.
go to step 3 in the insTallaTiOn insTrUCTiOns &
continue.
9.
10.
5.
3.
4.
6.
7.
8.
CHeCking engine PerFOrManCe
use your pyrometer (exhaust temperature gauge) to
monitor your engine’s operation. at idle, egT (exhaust
gas temperature) will be very low, perhaps only 150°f.
as the throttle is opened for higher speeds and greater
loads, the egT will rise. The highest egT will be seen
under maximum load at full throttle, such as climbing a
steep grade with a heavily laden vehicle. Use caution
if your EGT approaches 1050°F, with 1100°F being
the ABSOLUTE MAXIMUM!
If the vehicle approaches those egT levels under these
conditions, downshift the vehicle to reduce the load,
or back off the throttle. If frequent high egT levels are
encountered, the fuel delivery of the injection pump
will have to be reduced by backing out the allen head
screw in the injection pump as indicated in the PUMP
P.n. 96292 V.2.0