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-UN-23FEB89
supply pump. DO NOT allow sealant to
get into fuel system.
CD7309
IMPORTANT: ALWAYS use a backup wrench when
installing fittings and/or fuel lines onto
supply pump to avoid damage to
fittings.
S11,3010,LR -19-21SEP95
S55,3010,BR -19-28SEP95
CTM4 (28OCT95) 35-15 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=372
Fuel System/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
-UN-11JUL89
running or while the pump is warm.
Doing so may cause seizure of internal
rotating pump parts.
CD6375
the pump with cleaning solvent or a steam cleaner.
3. Disconnect fuel return line (A) and fuel supply line (B).
S11,3010,LS -19-14JUL95
35
17
CTM4 (28OCT95) 35-17 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=374
Fuel System/Remove Roto Diesel/Lucas CAV Fuel Injection Pump
-UN-23MAY95
train timing when pump is reinstalled
on engine.
CD7206
mark as accurately as possible in-line
with mark on pump flange.
S11,3010,LS1 -19-29JUN95
-UN-01NOV88
Remove the three cap screws which secure fuel injection
pump drive gear to pump shaft.
T95246
• On Pumps With Solid Drive Shaft:
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
-UN-22JUL92
NOTE: Replace 6 mm, Grade 12.9 cap screws (C) as
needed.
RG6294
(threaded in drive gear) and snugly tighten center forcing
screw (B) against end of pump shaft.
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
-UN-20DEC88
nuts (attaching fuel injection pump to engine front plate)
several turns to permit shaft separation from drive gear.
L110733
will fall to the floor when unassisted.
-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.
RG,CTM4,DX399 -19-25SEP95
S11,3010,LW -19-29JUN95
CTM4 (28OCT95) 35-20 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=377
Fuel System/Install Roto Diesel/Lucas CAV Fuel Injection Pump
-UN-01NOV88
injection (13—19˚ before top dead center). Time the
pump by aligning mark on pump flange with mark on
front plate.
T95246
removed from engine, it must be timed
when reinstalled. (See INSTALL AND
TIME CAMSHAFT AND FUEL
INJECTION PUMP in Group 16.)
S11,3010,LX -19-21SEP95
35
21
CTM4 (28OCT95) 35-21 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=378
Fuel System/Install Roto Diesel/Lucas CAV Fuel Injection Pump
-UN-23MAY95
4. Install hex nuts and washers on the three studs, but
do not tighten at this time.
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.
S11,3010,LY -19-21SEP95
35
22
CTM4 (28OCT95) 35-22 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=379
Fuel System/Install Roto Diesel/Lucas CAV Fuel Injection Pump
-UN-20DEC88
only available as an assembly. DO NOT try to
disassemble or repair valves, ALWAYS replace if
condition is questionable.
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.
-UN-11JUL89
functioning properly.
CD6375
For 3-cylinder engine, U, Y and W are used in
relation to cylinders 1, 2 and 3.
10. Connect fuel return line (A) and fuel supply line (B)
to pump.
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)
-UN-14DEC88
not have a timing mark. However, a new injection pump
will have the timing mark scribed on pump flange.
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.
-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:
S11,3010,MA -19-29JUN95
CTM4 (28OCT95) 35-24 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=381
Fuel System/Timing Roto Diesel/Lucas CAV Injection Pump (Front Plate Installed)
-UN-14DEC88
• Remove No. 1 injection nozzle.
RG4823
• Attach a dial indicator so that the indicator tip rests on
valve head. Set dial indicator at 0.00 mm (in.).
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)
10. Bleed air from system and check all connections for
leaks. (See BLEED FUEL SYSTEM in Group 115.)
35
26
RG,CTM4,DY102 -19-01NOV95
CTM4 (28OCT95) 35-26 3179, 4239, 6359, 4276, and 6414 Engines
181196
PN=383