JOHNDEEREENGINE4045TF270(SNAC02633ANDUP)ME12002

ServicingtheFuelInjectionPump

RemovingtheFuelInjectionPump is running or still warm, damage to the rotating pump components can occur.

NOTICE: Prior to removing the fuel injection pump, use the flywheel rotation tool to (both rocker arms on this cylinder are movable) turn the engine to the top dead center compression position of cylinder no. 1, and keep the engine in place with the adjustment pin (A), as for setting the valve tip clearance. See Figure 4-30.

2.If installed, remove the cutoff cable and throttle control linkage.

3.If installed, remove the electric connection to the stop solenoid or to the throttle position solenoid.

4.If installed, remove the cold-starting switch.

5.Mark the electric cables to ensure correct reassembly.

IMPORTANT:When loosening and tightening fuel feed lines on the fuel injection pump, ALWAYS use a spanner to hold the lock nut and avoid damage to the pump ports. This avoids internal pump damage.

6.Remove fuel return line (A) and fuel feed line (C). See Figure 4-31.

7.Use a 17 mm crowfoot wrench with a long socket to remove all fuel feed lines (pressure lines) (B) from the fuel injection pump. See Figure 4-31.

Figure 4-30 Adjustment Pin Opening

All Stanadyne DB2 and DB4 fuel injection pumps have a fixed drive shaft (it remains in the pump if the latter is removed from the engine).

IMPORTANT:Make a mark on the drive pinion and on the pinion of the wheel gear to mark the position of the pinions for re-assembly. The drive pinion of the fuel injection pump fits exactly on the conical drive shaft and is adjusted with a female pin or a Woodruff key. This secures it against turning it out of position on the pump shaft.

Figure 4-31 Fuel Injection Pump Fuel Lines

1.Clean the fuel injection pump, lines, and area around the pump with a solvent or steam jet. See Figure 4-31.

IMPORTANT:If the fuel injection pump is cleaned with a steam jet or cold water while it

Figure 4-32 End of Pump Shaft

8.Remove the lock nut and washer from the end of the pump shaft. Make sure that the washer does not drop into the control cover.

9.Fit drive pinion extractor (E) JDG670A (available direct from John Deere) onto the drive pinion of the fuel injection pump as shown. See Figure 4-32.

Figure 4-33 Adjustment Marks

10.Be sure that adjustment marks (F, G) on the rear side of the front panel (F) and on the injection pump flange (G) are made, clearly visible, and aligned correctly. This ensures that once the pump (or a replacement pump) has been repaired and installed, it can be adjusted correctly on the engine. If the adjustment mark is not clearly visible on the front panel, make a visible mark aligned with the mark on the pump flange. See Figure 4-33.

11.Remove the three nuts of the assembly stud bolts (D) from the fuel injection pump. See Figure 4-31.

12.Remove the fuel injection pump from the assembly stud bolts.

13.Place the pump on a clean, level surface and check the outside of the shaft and drive pinion. See “Installing the Fuel Injection Pump” below.

Figure 4-34 Adjustment Marks

1.Apply clean engine oil to a new square sealing ring.

2.Insert the ring into the groove at the front surface of the pump fastening flange.

3.Slide the fuel injection pump onto the assembly stud bolts and simultaneously insert the pump shaft into the drive pinion.

IMPORTANT:The straight pin of the shaft is easily damaged if assembled incorrectly. Do not move the pump drive pinion when inserting the pump guide pin into the key groove of the drive pinion.

4.Check the pump shaft and guide pin for correct alignment to the key groove of the pump drive pinion.

5.Place the fuel injection pump partly on the assembly stud bolts, without engaging the pump guide hub with the engine front panel.

6.Place three flat washers, lock washers and hexagon nuts on the assembly stud bolts of the pump.

7.Tighten the nuts only three rotations so that the pump does not fall off of the assembly stud bolts.

IMPORTANT:Do NOT tighten the hexagon nuts more than three full rotations on the assembly stud bolts. The guide pin of the pump drive shaft can be damaged if it is not correctly aligned with the key groove of the drive pinion, and if the nuts are tightened more than three rotations. The pump drive pinion should move forward with the pump (away from the front panel of the engine) if the flange is about 3.2 mm away from the front panel.

8.Install the pump fastening flange flush with the front panel of the engine. This makes the drive pinion flush with the front panel front side.

IMPORTANT:Do NOT use the clamping force of the assembly stud bolts of the pump to pull the pump shaft into the drive pinion.

9.Tighten the nuts of the assembly stud bolts while making sure that the guide pin of the pump shaft is correctly aligned with the key groove of the drive pinion.

14.Connect pressure lines (F) to the fuel injection pump starting with the outlet (lower right) and then counterclockwise around the pump head in the same order as the engine firing order (1–3–4–2). See Figure 4-36.

15.Using a 17 mm spanner with a long extension, tighten the fuel feed lines (pressure lines) to tightening torque 20 lb.-ft. (27 Nm).

IMPORTANT:When loosening and tightening fuel feed lines on the fuel injection pump, ALWAYS use a spanner to hold the lock nut and avoid damage to the pump ports. This avoids internal pump damage.

10.Firmly press the pump drive pinion onto the conical shaft. Fit the washer and lock nut (C) onto the end of the shaft. Tighten the lock nut to the following torque: Stanadyne DB4 lock nut: Pump drive pinion: shaft (torque) 150 lb.-ft. (203 Nm).

11.Install the cover plate, use a new O-ring if necessary. Hexagon bolts of front cover plate (torque) 4 lb.-ft. (6 Nm).

12.Align the adjustment mark on the pump flange to the adjustment mark on the front panel.

13.Tighten the three hexagon nuts to tightening torque 20 lb.-ft. (27 Nm).

16.Connect fuel feed line (D) to fuel return line (E).

17.If installed, connect the fuel cutoff cable to the throttle control linkage.

18.If installed, firmly tighten the electric connections to the stop solenoid and to the throttle position solenoid.

19.If installed, connect the cold-starting switch.

20.Bleed the fuel system, loosen fuel return line (G) and actuate the fuel pump until there is no more air in the fuel that flows out. See Figure 4-37.

21.Tighten the line.

22.Start the engine, let it run for a couple of minutes, and then check the entire fuel system for leaks.

ServicingtheFuelInjection Nozzles

RemovingtheFuelInjectionNozzles

IMPORTANT:Thoroughly remove all dirt on the cylinder head in the area around the fuel injection nozzles before you remove them. Clean with compressed air to avoid dirt entering into the cylinders. Close the hole in the cylinder head after removing each nozzle. Close the openings of the fuel lines immediately after removing them.

NOTICE: If all fuel injection nozzles have to be removed, remove the fuel leak line and nozzles as a complete unit. In order to remove separate nozzles, only remove the section of the fuel return line required.

1.Loosen the pipe nuts on each nozzle (A). See Figure 4-38.

2.Remove the fuel return lines and T-elements as a unit. See Figure 4-38.

3.Remove hexagon bolt (B) that secures the nozzle to the cylinder head. See Figure 4-39.