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John Deere Fuel Injection Pump Repair & Installation

John Deere Fuel Injection Pump Repair & Installation

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Published by: johncouey on Nov 21, 2012
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05/07/2014

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30-10-4DieselFuelSystem---
FuelandAirRepair
BLEEDINGFUELSYSTEMFUELINJECTIONPUMP
A.CAUTION:Escapingdieselfuelunder
..
pressurecanhavesufficientforcetopen-
etratetheskin,causingseriouspersonalinjury.Beforedisconnectinglinesbesuretorelieveallpressure.Beforeapplyingpressuretothesystem,besureallconnectionsaretightandthatlines,pipesandhosesarenotdamaged.Fuelescapingfromaverysmallholecanbealmostinvisible.Useapieceofcardboardorwood,ratherthanhands,tosearchforsuspectedleaks.Ifinjuredbyescapingfuel,seeadoctoratonce.Seriousinfectionorreactioncandevelopifpropermedicaltreatmentisnotadministeredimmediate-ly.Wheneverthefuelsystemhasbeenopenedupforservice(linesdisconnectedorfiltersremoved),itwillbenecessarytobleedtheairfromsystem.Tobleedthefuelsystemon"0"engines,loosenthebleedplugonthefuelfilterbase(A,Fig.6)andoperatethehandprimeronthefuelpumpuntilmostoftheairbubblesareexpelledfromthefilter.
Pushthehandprimerback(towardengine)asfaraspossibleandtightenfilterbleedplug.Tobleedthefuelsystemon"T"and"A"engines,loosenthebleedplug(A,Fig.6).Unscrewthehandprimerknurledknobonthefuelpump,andloosenuntilitcanbepulledupbyhand.Operatethehandprimeruntil
most
oftheairbubblesareexpelledfromtheglass
bowlonthepump.
Pushhandprimerdownandtighten.Tightenbleedplug.
NOTE:
Iftheenginewillnotstart,itmaybeneces-sarytoloosenthefuelpipesattheinjection
nozzles
tobleedairfromthe
system.
Withthehandthrottlepushedallthewayin,turntheengineoverwiththestarteruntilfuelwithoutairflowsfromthe
loose
fuelpipeconnections.Tightentheconnections.TM-1106(Jan-79)Lithoin
U.S.A
4270DRemoval
Cleantheinjectionpump,pipes,andareaaroundthepumpwithcleaningsolventorasteamcleaner.IMPORTANT:Neversteamcleanorpourcoldwateronaninjectionpumpwhilethepumpisrunningorwhileitiswarm.Todosomaycauseseizureofpumpparts.
Fig.8-Removing42700FuelInjectionPump
1.SetenginetoNo.1TDCcompression(see
page
10-05-03).
2.Disconnectelectricalfuelshut-offlead.3.Disconnectspeedcontrollinkage(notshown).4.Disconnectfuelinletandreturnlines.5.Disconnecttachometerdrivecable.6.Removefuellines.Capfittingsonnozzlesandoninjectionpump.7.Removehold-downnutsandliftinjectionpumpfromengine.
Engines
-
400Series
 
FuelandAirRepair
DieselFuelSystem
30-10-5
Repair
Forinjectionpumprepairinformationandspecifica-tions,refertoSM-2045-"TestingandServicingFuelInjectionPumpsandNozzles".
Installation
Inspectinjectionpumpmountingholeincylinderblock.If1.0.ofthemountingholehasasharpedge,beveltheedgeslightlywithemerycloth.Removeallmetalchipsanddust.
VerifythatengineissettoNo.1TDCcompression.Ifnot,settoNo.1TDCcompression.Placethrustspringovertangonpumpdriveshaft.
Installinjectionpumpincylinderblock,makingsurethattangonpumpdriveshaftengagesslotinoilpumpdrivegear.Pumpshouldsitsquarelyandsolidlyonmountingpadwhenaslightdownwardpressureisapplied.
Installmountingnutswithwashersbutdonottight-en.
A-Weight
RetainerTimingLineB-TimingWindowC-CamTimingLine
Fig.9-lnjectionPumpTimingLines
TM-1106(Jan-79)LithoinU.S.A.
Turnpumptoaligntimingmarks(Fig.9).Tightenmountingnutssecurely.Rotateenginebackward1/4revolution.Turnengineindirectionorrotationuntilinjectionpumptimingmarkslineup.Theflywheeltimingmarksshouldnowbealigned.Ifnot,removeandreinstallinjectionpump.IMPORTANT:Thenormalbacklashofgearsisenoughtothrowtheinjectionpumptimingoffbyseveraldegrees,resultinginpoorengineperfor-mance.Therefore,itisveryimportantthatthetimingofthepumpberecheckedafterinstallation.Installfuelines.Tightenfittingsatinjectionnozzlesto20ft-Ibs(27Nm)(2.7kgm).Tightenhollowscrewsatinjectionpumpto35ft-Ibs(47Nm)(4.7kgm).
Connectelectricalfuelshut-offlead.Connectfuelinletandreturnlines.Tightenfittingsto20ft-Ibs(27Nm)(2.7kgm).
Connectspeedcontrollinkage.Donotremovetimingwindoworconnecttachome-terdrivecable.Bleedfuelsystem(seepage30-10-04).Adjustautomaticspeedadvance.RefertoSection230,Group10.
Engines
-
400Series
 
30-10-6DieselFuelSystem
FuelandAirRepair
FUELINJECTIONPUMP-Continued6404D;6466DRemoval
Cleantheinjection
pump,
pipes,andareaaroundthepumpwithcleaningsolventorasteamcleaner.IMPORTANT:Neversteamcleanorpourcoldwateronaninjectionpumpwhilethepumpisrunningorwhileitiswarm.Todosomaycauseseizureofpumpparts.Usethefollowingmethodtoremovethefuelinjec-tionpump:
1.PositionengineatTDC,withNo.1pistononthecompressionstroke.(Seepage10-05-04.)
NOTE:ObtainingTOG(No.
1
pistononcompres-sionstroke)isnotrequiredforremovingtheinjectionpump.However,itisrequiredwheninstallingbackontheengine.Iftheengineistobedisassembledorrotatedafterthepumphasbeenremoved,disregardthisstepandproceedtoStep2.
A-Pump
GearB-CapScrew
Fig.10-lnjectionPumpRemovalSteps
2.Removethetimingholecover(Fig.10).Rotatetheengineuntiltimingmarkongovernorweightre-tainer(B,Fig.11)isinlinewithtimingmarkoncamring(A).
TM-1106(Jan-79)LithoinU.S.A.
A-CamRingB-WeightRetainer
Fig.11-lnjectionPumpTimingMarks
3.Removefuelpump(page30-10-1).4.Disconnectthespeedcontrollinkage.5.Disconnectinjectionpumpinletandpump-to-nozzlefuelpipes.6.Disconnectelectricalshut-oftlead.7.Disconnectfuelreturnpipe.8.Cleanareaaroundtiminggearcoverandremovecover.Removethethreecapscrews(B,Fig.10)frompumpdrivegear(A).9.Removemountingboltnuts.Thepumpmountingflangeon64660engineissecuredwithfournuts,whereasthe64040engineusesthree.
Removepump.Besuretocapallinjectionpumpandfuelpipeopeningstoprevententryofcontami-nants.RepairForinjectionpumprepairinformationandspecifica-tions,refertoTM-1064"FuelInjectionEquipment-RoosaMaster".
InstallationCheckenginetimingtomakesurethatNo.1pistonisatTDConthecompressionstroke.Iftheenginewasrotatedaftertheinjectionpumpwasremoved,cranktheengineuntilNo.1pistonisstartingthecompres-sionstroke.Installtimingpinincylinderblock.
Engines
-
400Series

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