Banks Power Chevy_GMC Trucks: Diesel ’93 - 96 6.5L Power Systems- Stinger System '93-early '94 (non-cat) Pickups w_ factory turbo option - Manual (Page 7)

NOTE: The engine must be COLD before starting this procedure.
NOTE: Utmost cleanliness should be exercised. Do NOT use
any rags during the adjustment procedure. The lint from the rag
can clog an injector. Lay all parts on clean newspaper during
the adjustment procedure.
Make sure both battery ground cables are disconnected.
Disconnect the wiring from the top of the fuel injection pump
cover. Note their location for reassembly.
Place a drip pan under the rear of the engine to catch fuel.
Clean the upper portion of the pump with diesel fuel or a
parts cleaning solvent. See Figures 6 and 7 . Do NOT clean the pump
while the engine is hot, as doing so may damage the pump.
Remove the fuel return line from the pump cover. Remove the
top attaching bolt and loosen 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.
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 adjustment 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 extension
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
6 ). It may be necessary to remove the front crankshaft pul-
ley 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 as indicated earlier. Clockwise increases fuel, coun-
terclockwise decreases fuel.
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 to 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
” forward,
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 sole-
noid 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 igni-
tion 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 solenoid.
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.
Reconnect batteries. Turn ignition on and, after the glow
plug light goes out, crank the engine, again in intervals of 20
to 30 seconds followed by one minute of cooling, until the
engine starts. It may not start immediately, due to fuel lost
when adjusting the injector pump. It also may be necessary
to depress the accelerator pedal somewhat.
Run engine at idle for a few minutes, to allow it to warm.
Check oil feed lines for leaks. Engine may idle erratically or
surge until air is fully purged from fuel system.
Drive vehicle. Several short bursts of acceleration are
required to completely purge the fuel system of air. The
engine may run slightly rough until the purge is complete, but
will not in any way cause damage to the engine.
If possible, drive vehicle under heavy load conditions and
monitor EGT levels. If vehicle wants to exceed 1050°F under heavy
load, the pump adjustment must be reduced (Allen screw turned
counter-clockwise). Keep track of your adjustments.
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P.N. 96299 7
PUMP ADJUSTMENT PROCEDURE