Dodge Diesel/Cummins Mechanic Advice Needed

I had similar problems with my old D50 (back when it was a Turbo Diesel truck). I learned very quickly that the timing is VERY sensitive (and easy to set wrong) on a diesel. Invest in a Dial Gauge to set the timing on the injector pump (you can pick one up on ebay for a couple bucks, last time I checked), which is a must any time you remove/replace or turn the IP.

I swapped the IP on my D50 and couldn't get it to start without cranking the crap out of it, tried rotating the pump and it would turn over HARD. So I spun it the other direction, it'd start after a while, but ran horrible and had no power. After about a month of that, and the local diesel mechanic (neighbor) scratching his head (because he had never worked on a Factory Turbo Diesel D50 with a VE41 pump). I finally decided to cough up the couple bucks and buy the tools to set the timing.

Turns out I had the timing so far off (from doing it "by ear"), that it was the equivalent of being 180* out on a Dist on a gas motor. I set it to factory specs with a Factory Service Manual and the Dial Gauge. It started up easily after that and had tons of power.

After that I worked at tweaking the timing at the cam and IP (I don't recommend messing with the cam on a 6BT, My engine had a timing belt with removable front covers) and toyed with the "smoke screw", star wheel, fuel pin, etc. When I was done, that motor would fire up at the tap of the key, in freezing temperatures, without firing the glow plugs.


EDIT, another thing that comes to mind. My diesel had a "fuel bleed off" problem the entire time I had it. If the truck sat untouched for more than 3 days, the fuel would drain back to the tank. Which makes it possible to introduce air to the IP and Injector Lines. Everybody I spoke with insisted it was a fuel delivery problem (lines, hoses, etc), but I had gone through the fuel system many times. The truck had brand new everything from the Fuel Tank all the way to the Filter/Heater/Water Separator.

I pulled my hair out on that one, till I looked in the Owners Manual & FSM, both mentioned that fuel would drain back to the tank if the truck sat for several days. I installed an Electric Lift Pump to prime the system, never had a problem after that.