Fuel System/Fuel Injection Pump Timing

INSTALL FUEL SUPPLY PUMP

IMPORTANT: Apply LOCTITE 242 Thread Lock and

Sealer (TY9370) to cap screw threads
and fuel line fittings when reinstalling

-UN-23FEB89
supply pump. DO NOT allow sealant to
get into fuel system.

1. Install the fuel supply pump to cylinder block using a

new gasket. Tighten cap screws (A) to 30 N·m (22 lb-ft).

CD7309
IMPORTANT: ALWAYS use a backup wrench when
installing fittings and/or fuel lines onto
supply pump to avoid damage to
fittings.

2. Remove plugs and connect fuel lines. Tighten

securely.

3. Bleed fuel system. (See BLEED THE FUEL SYSTEM

in Group 115.)

S11,3010,LR -19-21SEP95

FUEL INJECTION PUMP TIMING

Fuel injection pumps on John Deere Diesel Engines are

timed one of two ways at the factory:

—By Static Timing, which is accomplished by the

alignment of internal pump timing marks (cam
ring-to-governor weight retainer) and/or the alignment of
injection pump flange-to-front plate timing marks.

—By Dynamic Timing, which involves a sensor installed

within the No. 1 fuel line and connected to a
pulse-activated timing meter to determine precisely at
what point injection occurs. Another form of dynamic
timing employs the use of a timing light along with a
fixed reference mark on engine block and a timing mark
on crankshaft damper or pulley which aligns with fixed
reference mark when light flashes. 35
15
Both types of timing are covered in this manual.
Dynamic timing the engine is the preferred method.
However, on some applications, dynamic timing values
are not available and the engine must be static timed.

S55,3010,BR -19-28SEP95

CTM4 (28OCT95) 35-15 3179, 4239, 6359, 4276, and 6414 Engines
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PN=372
 Fuel System/Fuel Injection Pump—General Information

FUEL INJECTION PUMP—GENERAL INFORMATION

Engine will be equipped with one of the following On DB4, some DB2’s, DM4 and Roto Diesel/Lucas
pumps: CAV pumps, the pump has a retained drive shaft.
The shaft stays with the pump. DB2 pumps with
—Stanadyne DM4, JDB, DB2, DB4 or retained drive shafts are identified with a label on the
pump mounting flange that reads “TOOL REQUIRED
—Roto Diesel/Lucas CAV FOR REMOVAL—SEE OPERATOR’S MANUAL.”

On JDB and some DB2 fuel injection pumps, the Refer to the appropriate service procedures in this
pump drive shaft is a non-retained drive shaft. The group.
shaft stays in the engine.

RG,CTM4,DX397 -19-21SEP95

35
16

CTM4 (28OCT95) 35-16 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=373
 Fuel System/Remove Roto Diesel/Lucas CAV Fuel Injection Pump

REMOVE ROTO DIESEL/LUCAS CAV FUEL

INJECTION PUMP

IMPORTANT: NEVER steam clean or pour cold water

on a fuel injection pump while it is

-UN-11JUL89
running or while the pump is warm.
Doing so may cause seizure of internal
rotating pump parts.

1. Clean the fuel injection pump, lines and area around

CD6375
the pump with cleaning solvent or a steam cleaner.

2. Disconnect shut-off cable and speed control linkage, if

equipped. Disconnect electrical connection to shut-off
solenoid or throttle positioning solenoid, if equipped. Tag
electrical wires for correct reassembly.

3. Disconnect fuel return line (A) and fuel supply line (B).

NOTE: On early injection pumps the injection lines (with

banjo fittings, shown) are secured to the pump
with hex fitting assemblies called pressurizing
valves. Current injection pumps have pressurizing
valves installed in the pump head with axial
outlet fittings for easier assembly and improved
joint sealing.

IMPORTANT: On current injection pumps with axial

outlet fittings, use a back-up wrench
when removing fuel lines to prevent
possible leaks upon reassembly.

4. Disconnect fuel injection lines (C).

5. Cap or plug all open connections on pump and fuel

lines. Do not use fibrous material.

S11,3010,LS -19-14JUL95

35
17

CTM4 (28OCT95) 35-17 3179, 4239, 6359, 4276, and 6414 Engines
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PN=374
 Fuel System/Remove Roto Diesel/Lucas CAV Fuel Injection Pump

IMPORTANT: Check to make sure that timing marks

are scribed on engine front plate (A)
and injection pump flange (B). Exact
alignment of these timing marks will
assure correct injection pump-to-valve

-UN-23MAY95
train timing when pump is reinstalled
on engine.

If timing mark is not clearly visible on

front plate, scribe a visible reference

CD7206
mark as accurately as possible in-line
with mark on pump flange.

S11,3010,LS1 -19-29JUN95

6. Remove injection pump drive gear cover (shown

removed).

• On Pumps With Three Cap Screws On Drive Hub:

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Remove the three cap screws which secure fuel injection
pump drive gear to pump shaft.

Remove the three hex nuts securing pump to engine

front plate and lift out fuel injection pump.

T95246
• On Pumps With Solid Drive Shaft:

Remove drive gear retaining nut (A) and washer from

end of pump shaft. Be careful not to let washer fall
inside timing gear cover.

RG,CTM4,DX398 -19-21SEP95

35
18

CTM4 (28OCT95) 35-18 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=375
 Fuel System/Remove Roto Diesel/Lucas CAV Fuel Injection Pump

Using JDG670A Drive Gear Puller:

1. If injection pump drive gear has two holes, JDG670A

Drive Gear Puller (A) may be attached to drive gear as
shown. Follow instructions provided with tool set.

-UN-22JUL92
NOTE: Replace 6 mm, Grade 12.9 cap screws (C) as
needed.

2. Evenly tighten the two 6 mm, Grade 12.9 cap screws

RG6294
(threaded in drive gear) and snugly tighten center forcing
screw (B) against end of pump shaft.

IMPORTANT: On engines equipped with crankshaft

gear-driven auxiliary drive options, DO
NOT remove puller from gear after
pump shaft is free from gear. The drive
gear will move inside timing gear cover
and may become disengaged from
camshaft gear causing the gear to be
one or more teeth out of time.

Once gear is free from shaft, remove

center forcing screw from puller and
tighten the two 6 mm screws into gear
on puller until gear is pulled against
timing gear cover. Leave puller
attached until injection pump is
reinstalled on engine.

3. Tighten center forcing screw until pump drive gear is

free from tapered shaft. Remove JDG670A Puller and
screws from drive gear.

4. Remove injection pump mounting studs. Remove

injection pump from mounting studs.

35
19
RG,CTM4,DT441 -19-21SEP95

CTM4 (28OCT95) 35-19 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=376
 Fuel System/Repair Roto Diesel/Lucas CAV Fuel Injection Pump

Using JDG535 (or KJD10108) Injection Pump

Removal Tool:

1. Attach JDG535 (or KJD10108) Injection Pump

Removal Tool to timing gear cover. Loosen the three

-UN-20DEC88
nuts (attaching fuel injection pump to engine front plate)
several turns to permit shaft separation from drive gear.

NOTE: If the three pump-to-front plate nuts are removed

before pump shaft is loosened from gear, pump

L110733
will fall to the floor when unassisted.

2. Turn cap screw of special tool clockwise until pump

shaft is loosened from conical seat of drive gear.

3. If pump shaft cannot be removed from conical seat of

drive gear, then use a brass drift and strike engine front
plate several blows as shown.

-UN-14DEC88
4. Remove mounting nuts and withdraw the injection
pump backward from the three studs. Place pump on a
clean flat surface.

RG4821
NOTE: When removing fuel injection pump be careful not
to lose pump shaft Woodruff Key.

5. Remove JDG535 (or KJD10108) Injection Pump

Removal Tool from timing gear cover. Remove injection
pump.

RG,CTM4,DX399 -19-25SEP95

REPAIR ROTO DIESEL/LUCAS CAV FUEL

INJECTION PUMP

IMPORTANT: DO NOT disassemble the Roto

Diesel/Lucas CAV fuel injection pump
further than necessary for installing
available service parts, not even for
cleaning.

1. Have an authorized ADS Diesel Repair Station

35 perform all injection pump testing, adjustments and
20 repairs.

S11,3010,LW -19-29JUN95

CTM4 (28OCT95) 35-20 3179, 4239, 6359, 4276, and 6414 Engines
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PN=377
 Fuel System/Install Roto Diesel/Lucas CAV Fuel Injection Pump

INSTALL ROTO DIESEL/LUCAS CAV FUEL

INJECTION PUMP

Roto Diesel/Lucas CAV Injection Pumps used on

Saran-built 3179 Engines only, are timed at beginning of

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injection (13—19˚ before top dead center). Time the
pump by aligning mark on pump flange with mark on
front plate.

IMPORTANT: If the injection pump drive gear was

T95246
removed from engine, it must be timed
when reinstalled. (See INSTALL AND
TIME CAMSHAFT AND FUEL
INJECTION PUMP in Group 16.)

• On Pumps With Three Cap Screws On Drive Hub:

1. Put a new gasket on pump housing and position

pump drive hub into drive gear. Make sure that dowel
pin in gear fits into slot in pump drive hub.

2. Secure gear onto pump hub with cap screws and

tighten to 30—35 N·m (22—25 lb-ft).

• On Pumps With Solid Drive Shaft:

NOTE: Make sure that Woodruff key is properly installed

in pump drive shaft. Key MUST fit tightly in
keyway.

3. Guide pump drive shaft into bore of drive gear.

Tighten drive gear hex nut (A) to 85 N·m (63 lb-ft).

S11,3010,LX -19-21SEP95

35
21

CTM4 (28OCT95) 35-21 3179, 4239, 6359, 4276, and 6414 Engines
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PN=378
 Fuel System/Install Roto Diesel/Lucas CAV Fuel Injection Pump

Injection pump internal timing marks must be in same

position as when pump was removed.

• On Both Pump Types:

-UN-23MAY95
4. Install hex nuts and washers on the three studs, but
do not tighten at this time.

NOTE: If the front plate was replaced, no timing mark

will be found on the new plate. (See REPLACE

CD7206
ENGINE FRONT PLATE and TRANSFER
INJECTION PUMP TIMING MARK ONTO
REPLACEMENT FRONT PLATE later in this
group.) A mark must be scribed on plate based
on engine and injection pump timing. If timing
mark can not be transferred from original front
plate, see TIMING ROTO DIESEL/LUCAS CAV
INJECTION PUMP WHEN NEW SERVICE
FRONT PLATE HAS BEEN INSTALLED later in
this group.

5. Pivot pump housing first away from cylinder block as

far as slots will allow. Then pivot it back again, but only
far enough to align timing mark on the pump flange (B)
exactly with timing mark on the cylinder block front plate
(A).

6. Tighten the three hex nuts securing the pump to the

front plate to 27 N·m (20 lb-ft).

S11,3010,LY -19-21SEP95

35
22

CTM4 (28OCT95) 35-22 3179, 4239, 6359, 4276, and 6414 Engines
181196
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 Fuel System/Install Roto Diesel/Lucas CAV Fuel Injection Pump

NOTE: On early injection pumps pressurizing valves are

-UN-20DEC88
only available as an assembly. DO NOT try to
disassemble or repair valves, ALWAYS replace if
condition is questionable.

Current injection pumps have pressurizing valves

L47251
with axial outlet fittings installed in the pump
head as an assembly. DO NOT service
pressurizing valves, have the pump serviced as
an assembly by an authorized diesel repair
station.

7. On early injection pumps with banjo fittings, inspect

pressurizing valves and replace if they are not

-UN-11JUL89
functioning properly.

NOTE: Outlets on the fuel injection pump head to which

the pressure lines connect are identified by letters
stamped on pump head.

CD6375
For 3-cylinder engine, U, Y and W are used in
relation to cylinders 1, 2 and 3.

For the 4-cylinder engine, V, U, X and W are 1—Valve Body

used in relation to cylinders 1, 3, 4 and 2. 2—Valve Spring
3—Valve Piston
For 6-cylinder engine, V, U, Z, Y, X and W are 4—Valve Seat
used in relation to cylinders 1, 5, 3, 6, 2 and 4.

8. On early injection pumps with banjo connections,

connect fuel injection lines (C) to the pump. Use new
sealing washers (one on each side of banjo) and install
pressurizing valves. Tighten valves to 34 N·m (25 lb-ft).

9. On current injection pumps with axial outlet fittings,

connect fuel injection lines to fittings. Hold fittings
stationary with a back-up wrench and tighten line
connection to 34 N·m (25 lb-ft).

10. Connect fuel return line (A) and fuel supply line (B)
to pump.

11. Connect shut-off cable (or wiring lead) and speed

control rod to pump, however equipped.

12. Install injection pump drive gear nut cover plate

using a new gasket on timing gear cover. Tighten cap 35
screws to 47 N·m (35 lb-ft).
23

13. Bleed the fuel system as outlined earlier in Group

115.

S11,3010,LZ -19-29JUN95

CTM4 (28OCT95) 35-23 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=380
 Fuel System/Timing Roto Diesel/Lucas CAV Injection Pump (Front Plate Installed)

TIMING ROTO DIESEL/LUCAS CAV

INJECTION PUMP WHEN NEW SERVICE
FRONT PLATE HAS BEEN INSTALLED
A new front plate (obtained through service parts) does

-UN-14DEC88
not have a timing mark. However, a new injection pump
will have the timing mark scribed on pump flange.

Roto Diesel/Lucas CAV injection pump timing is

established for beginning of injection—not TDC. Use the

RG4822
following procedure only when injection pump timing
mark cannot be transferred from original front plate or
when you suspect that the original timing mark was
incorrect.

IMPORTANT: To check pump internal timing, the

sealing wire and inspection cover plate
(bold arrow) must be removed from

-UN-11JUL89
side of pump. If the injection pump is
under warranty, contact an authorized
Roto Diesel/Lucas CAV repair station
about how to get the pump timed.

CD5531
1. Check pump internal timing (beginning of injection),
using following procedure:

• With injection pump removed from engine, connect a

nozzle tester to “U” outlet on pump head for 3-cylinder
engines and “V” outlet on 4 and 6-cylinder engines.

• Remove inspection cover plate from side of pump

housing.

• Pump handle on nozzle tester to obtain approximately

3000 kPa (30 bar) (430 psi) pressure.

• Rotate pump shaft in direction of normal rotation until

resistance is felt. In this position the straight edge of the
snap ring (1) that can be seen through the inspection
hole should be in line with the scribed mark adjacent to
letter:

—“F” on 3-cylinder engines.

—“A” (or “C” on some applications) on 4-cylinder
engines.
—“H” on 6-cylinder engines.
35
24 If mark and edge of snap ring are not aligned, see your
authorized Roto Diesel/Lucas CAV repair station for
service.

• Disconnect nozzle tester.

S11,3010,MA -19-29JUN95

CTM4 (28OCT95) 35-24 3179, 4239, 6359, 4276, and 6414 Engines
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 Fuel System/Timing Roto Diesel/Lucas CAV Injection Pump (Front Plate Installed)

2. Time Engine For Beginning Of Injection:

• Rotate engine until No. 1 piston is at TDC of

compression stroke.

-UN-14DEC88
• Remove No. 1 injection nozzle.

• Insert a 6466 engine valve into injection nozzle bore of

cylinder head until valve contacts top of piston.

RG4823
• Attach a dial indicator so that the indicator tip rests on
valve head. Set dial indicator at 0.00 mm (in.).

• Rotate crankshaft opposite of running direction

(clockwise, viewed from flywheel end) to bring valve 6.0
mm (0.20 in.) BTDC. This is necessary to eliminate
timing gear backlash as crankshaft is rotated in running
direction (next step).

• Slowly rotate crankshaft in normal running direction

(counterclockwise, viewed from flywheel end) until dial
indicator needle registers the specified piston stroke
dimension——No. 1 piston at beginning of injection.
Beginning of injection in degrees BTDC is equal to the
following piston stroke movement:

13˚—1.83 mm (0.072 in.) piston stroke

15˚—2.43 mm (0.095 in.) piston stroke
17˚—3.12 mm (0.123 in.) piston stroke
19˚—3.88 mm (0.153 in.) piston stroke

NOTE: Engine timing (beginning of injection) varies with

model and application. (See FUEL INJECTION
PUMP SPECIFICATIONS at the beginning of this
group.)

S11,3010,MC -19-28SEP95

35
25

CTM4 (28OCT95) 35-25 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=382
 Fuel System/Timing Roto Diesel/Lucas CAV Injection Pump (Front Plate Installed)

3. With both the engine and injection pump timed (Steps

1 and 2), install pump on engine. (See INSTALL ROTO
DIESEL/LUCAS CAV FUEL INJECTION PUMP earlier in
this group.) Leave nuts loose at this time.

4. Pivot pump toward cylinder block as far as slots will

allow. Then, slowly pivot pump away from block until
snap ring is aligned with correct letter-designated scribe
mark (inside pump) for the specific engine model and
application.

5. Tighten pump-to-front plate hex nuts to 27 N·m (20

lb-ft).

6. Scribe a mark on front plate in alignment with mark

on pump housing flange.

7. Install inspection cover plate on injection pump using

a new gasket. Tighten cap screws to 3.5 N·m (2.5 lb-ft)
(30 lb-in.).

NOTE: If pump is under warranty and approval (by the

authorized repair station) was given to remove
the original sealing wire, a new sealing wire must
be installed. Contact your authorized Roto
Diesel/Lucas CAV repair station for instructions.

8. Remove dial indicator and valve from No. 1 injection

nozzle bore. Install injection nozzle in cylinder head.

9. Complete installation of pump following instructions

previously given.

10. Bleed air from system and check all connections for
leaks. (See BLEED FUEL SYSTEM in Group 115.)

11. Start engine, run for several minutes and check

entire fuel system for leaks.

35
26
RG,CTM4,DY102 -19-01NOV95

CTM4 (28OCT95) 35-26 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=383