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John Deere Powertech 4.5L & 6.8L Diesel Engine Component Technical Manual CTM104 – PDF DOWNLOAD
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John Deere Powertech 4.5L & 6.8L Diesel Engine Component Technical Manual CTM104 – PDF DOWNLOAD
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Description
John Deere Powertech 4.5L & 6.8L Diesel Engine Component Technical Manual CTM104 – PDF DOWNLOAD
FILE DETAILS:
John Deere Powertech 4.5L & 6.8L Diesel Engine Component Technical Manual CTM104 – PDF DOWNLOAD
Language : English
Pages : 616
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere Powertech 4.5L & 6.8L Diesel Engine Component Technical Manual CTM104 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- This manual (CTM104) covers only the engine base for all PowerTech 4.5L and 6.8L engines including PowerTech ”Plus” engine model as well as PowerTech ”E” and PowerTech™ ”M” engine models. It is one of eight volumes on 4.5L and 6.8L engines. The following seven companion manuals cover fuel system and electronics repair, operation and diagnostics:
• CTM207—Mechanical Fuel Systems
• CTM170—Level 4 Electronic Fuel Systems with Bosch VP44 Pump
• CTM331—Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump
• CTM284—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump
• CTM220—Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail
• CTM320—Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail
• CTM502—Level 16 Electronic Fuel Systems with Denso High Pressure Common Rail - Other manuals will be added in the future to provide additional information on electronic fuel systems as needed.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Use this component technical manual in conjunction with the machine technical manual. An application listing in Section 01, Group 001 identifies product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components.
- Information is organized in sections and groups for the various components requiring service instruction. Section 05 summarizes all applicable essential tools, service equipment and tools, other materials needed to do the job, and service parts kits. Section 06 summarizes all specifications, wear tolerances, and torque values.
TABLE OF CONTENTS:
John Deere Powertech 4.5L & 6.8L Diesel Engine Component Technical Manual CTM104 – PDF DOWNLOAD
Contents........................................................................ 13 General Information......................................................... 15 Safety.................................................................. 17 Work In Ventilated Area............................................. 17 Recognize Safety Information........................................ 17 Work in Clean Area.................................................. 17 Dispose of Waste Properly........................................... 18 Avoid Harmful Asbestos Dust......................................... 18 Handle Fuel Safely—Avoid Fires...................................... 18 Prepare for Emergencies............................................. 19 Handle Starting Fluid Safely........................................ 19 Handle Fluids Safely—Avoid Fires.................................... 19 Avoid High-Pressure Fluids.......................................... 20 Use Proper Lifting Equipment........................................ 20 Illuminate Work Area Safely......................................... 20 Live With Safety.................................................... 21 Service Machines Safely............................................. 21 Handle Chemical Products Safely..................................... 21 Protect Against Noise............................................... 22 Remove Paint Before Welding or Heating.............................. 22 Stay Clear of Rotating Drivelines................................... 23 Service Cooling System Safely....................................... 23 Follow Safety Instructions.......................................... 24 Use Proper Tools.................................................... 24 Construct Dealer-Made Tools Safely.................................. 24 Practice Safe Maintenance........................................... 25 Understand Signal Words............................................. 25 Replace Safety Signs................................................ 26 Prevent Battery Explosions.......................................... 26 Protect Against High Pressure Spray................................. 26 Avoid Heating Near Pressurized Fluid Lines.......................... 27 Wear Protective Clothing............................................ 27 Wait Before Opening High-Pressure Fuel System....................... 27 Handle Agricultural Chemicals Safely................................ 28 Handling Batteries Safely........................................... 29 Install All Guards.................................................. 29 Avoid Hot Exhaust................................................... 30 Engine Identification and Application Charts............................ 31 Engine Serial Number Plate Information.............................. 31 OEM Engine Option Code Label........................................ 33 Information Relative to Emissions Regulations....................... 33 Fuels, Lubricants and Coolants.......................................... 35 Diesel Fuel......................................................... 35 Biodiesel Fuel...................................................... 36 Minimizing the Effect of Cold Weather on Diesel Engines............. 37 Handling and Storing Diesel Fuel.................................... 38 Lubricity of Diesel Fuel............................................ 38 Testing Diesel Fuel................................................. 38 Oil Information for Uncertified or Tier 1 Engines................... 38 Diesel Engine Oil................................................... 39 Oil Information for Tier 2 Engines.................................. 39 Diesel Engine Oil................................................... 40 Oil Information for Tier 3 Engines.................................. 40 Diesel Engine Oil................................................... 41 Diesel Engine Break-In Oil.......................................... 42 Oil Filters......................................................... 42 Grease.............................................................. 43 Alternative and Synthetic Lubricants................................ 43 Lubricant Storage................................................... 43 Mixing of Lubricants................................................ 44 Heavy Duty Diesel Engine Coolant.................................... 44 Supplemental Coolant Additives...................................... 45 Operating in Warm Temperature Climates.............................. 45 Additional Information About Diesel Engine Coolants and John Dee.... 46 Diesel Engine Coolant............................................... 47 Testing Diesel Engine Coolant....................................... 47 Drain Intervals for Diesel Engine Coolant........................... 48 Repair and Adjustments...................................................... 53 Engine Rebuild.......................................................... 55 Engine Overhaul Guidelines.......................................... 55 Engine Repair Stand................................................. 55 Engine Stand Safety Precautions..................................... 56 Install Adapters on Engine Repair Stand............................. 57 Engine Lifting Procedure............................................ 58 Clean Engine........................................................ 58 Disconnect Turbocharger Oil Inlet Line.............................. 59 Mount Engine on Repair Stand........................................ 60 Engine Mounted on Repair Stand...................................... 61 Engine Disassembly Sequence......................................... 62 Sealant Application Guidelines...................................... 65 Engine Assembly Sequence............................................ 67 Engine Break-In Guidelines.......................................... 69 Perform Engine Break-In............................................. 70 Cylinder Head and Valves (Two-Valve Head Engines)....................... 71 General Information................................................. 71 Check and Adjust Valve Clearance.................................... 71 Measure Valve Lift.................................................. 74 Remove Cylinder Head................................................ 75 Disassemble and Inspect Rocker Arm Shaft Assembly................... 78 Assemble Rocker Arm Assembly........................................ 79 Inspect, Measure, and Install Fuel Supply Pump Push Rod (If Appl.... 79 Inspect, Measure, and Assemble Camshaft Followers................... 80 Measure Valve Recess in Cylinder Head............................... 82 Preliminary Cylinder Head and Valve Checks.......................... 83 Remove Valve Assembly............................................... 84 Inspect and Measure Valve Springs................................... 85 Inspect Valve Rotators.............................................. 85 Clean Valves........................................................ 85 Inspect and Measure Valves.......................................... 86 Grind Valves........................................................ 87 Head Gasket Inspection and Repair Sequence.......................... 88 Inspect and Clean Cylinder Head..................................... 89 Check Cylinder Head Flatness........................................ 89 Measure Cylinder Head Thickness..................................... 90 Remove Fuel Injector Sleeves (2-Valve Head Engines with HPCR Fue.... 91 Remove Fuel Injector Sleeves (2-Valve Head Engines with HPCR Fue.... 92 Install Fuel Injector Sleeves (2-Valve Head Engines with HPCR Fu.... 93 Clean Valve Guides.................................................. 93 Measure Valve Guides................................................ 94 Knurl Valve Guides.................................................. 94 Clean and Inspect Valve Seats....................................... 94 Grind Valve Seats................................................... 95 Remove Valve Seat Inserts........................................... 97 Measure Valve Seat Bore in Cylinder Head............................ 99 Install Valve Seat Inserts.......................................... 99 Install Valves......................................................100 Inspect Cylinder Head Cap Screws....................................100 Inspect and Clean Exhaust Manifold..................................101 Clean and Inspect Top Deck of Cylinder Block........................101 Check Cylinder Liner Standout (Height Above Block)..................102 Install Cylinder Head...............................................102 Torque-Turn Method for Proper Torque................................105 Install Rocker Arm Assembly.........................................105 Inspect and Clean Ventilator Outlet Hose............................106 Remove, Inspect, and Install Closed Crankcase Ventilation System....107 Install Rocker Arm Cover............................................108 Complete Final Assembly.............................................110 Cylinder Head and Valves (Four-Valve Head Engines)......................113 General Information.................................................113 Check and Adjust Valve Clearance....................................113 Measure Valve Lift..................................................116 Do Not Open High-Pressure Fuel System...............................117 Remove Cylinder Head................................................117 Inspect and Measure Valve Bridges...................................126 Disassemble and Inspect Rocker Arm Shaft Assembly...................127 Assemble Rocker Arm Shaft...........................................128 Inspect, Measure, and Install Fuel Supply Pump Push Rod.............128 Inspect, Measure, and Assemble Camshaft Followers...................130 Measure Valve Recess in Cylinder Head...............................131 Preliminary Cylinder Head and Valve Checks..........................132 Remove Valve Assembly...............................................133 Inspect and Measure Valve Springs...................................134 Clean Valves........................................................134 Inspect and Measure Valves..........................................135 Grind Valves........................................................136 Head Gasket Inspection and Repair Sequence..........................137 Inspect and Clean Cylinder Head.....................................138 Check Cylinder Head Flatness........................................138 Measure Cylinder Head Thickness.....................................139 Remove Fuel Injector Sleeves (4-Valve Head Engines with HPCR Fue....140 Clean Fuel Injector Bores...........................................142 Install Fuel Injector Sleeves.......................................142 Clean Glow Plug Bores...............................................143 Clean Valve Guides..................................................143 Measure Valve Guides................................................144 Knurl Valve Guides..................................................144 Clean and Inspect Valve Seats.......................................144 Grind Valve Seats...................................................145 Remove Valve Seat Inserts...........................................145 Measure Valve Seat Bore in Cylinder Head............................147 Install Valve Seat Inserts..........................................148 Install Valves......................................................148 Inspect Cylinder Head Cap Screws....................................149 Inspect and Clean Exhaust Manifold..................................149 Clean and Inspect Top Deck of Cylinder Block........................150 Check Cylinder Liner Standout (Height Above Block) — Four-Valve ....150 Install Cylinder Head...............................................151 Torque-Turn Method for Proper Torque................................153 Install Fuel Injectors..............................................154 Install Injector Leak-Off Fittings (External fuel Leak-off syste....155 Install Glow Plugs..................................................155 Install Rocker Arm Carrier (External fuel leak-off system)..........156 Install Rocker Arm Carrier (Internal fuel leak-off system)..........157 Install Rocker Arm Shaft Assembly...................................158 Inspect and Clean Ventilator Outlet Hose............................160 Remove, Inspect, and Install Closed Crankcase Ventilation System....161 Install Rocker Arm Cover............................................162 Complete Final Assembly.............................................163 Cylinder Block, Liners, Pistons and Rods................................169 Connecting Rods—General Information.................................169 Remove Pistons and Connecting Rods..................................170 Remove Cylinder Liners..............................................173 Complete Disassembly of Cylinder Block (If Required)................175 Preliminary Liner, Piston and Rod Checks............................176 Disassemble Piston and Rod Assembly.................................176 Clean Pistons.......................................................177 Visually Inspect Pistons............................................178 Clean Cylinder Liners...............................................178 Visually Inspect Cylinder Liners....................................179 Check Piston Ring Groove Wear.......................................180 Measure Piston Pin Bore.............................................181 Measure Piston Skirt................................................181 Measure Piston Height...............................................181 Determine Piston-to-Liner Clearance.................................182 Deglaze Cylinder Liners.............................................183 Replace Piston and Liner Sets.......................................183 Inspect and Measure Connecting Rod Bearings (Rods Removed from E....184 Connecting Rod Bearings — Inspection and Measurement (Rod and Cr....184 Inspect Rod and Cap.................................................185 Inspect Piston Pins and Bushings....................................186 Remove Piston Pin Bushing...........................................187 Clean and Inspect Connecting Rod Pin Bore...........................188 Install Piston Pin Bushing in Connecting Rod........................189 Measure Rod Center-to-Center Bores..................................190 Inspect and Clean Cylinder Block....................................191 Clean Cylinder Liner O-Ring Bore....................................193 Measure Cylinder Block Main Bearing Bore............................194 Measure Camshaft Follower Machined Bore in Block....................194 Measure Camshaft Bushing Bores in Block.............................194 Measure Balancer Shaft Bushing ID in Block (4-Cylinder Engines).....195 Measure Cylinder Liners and Block Bores.............................196 Measure Liner Flange Counterbore Depth in Block.....................196 Measure Liner Flange Thickness......................................197 Measure Cylinder Block Top Deck Flatness............................197 Remove, Inspect, and Install Piston Cooling Orifices................198 Measure Fuel Supply Pump Push Rod Bore and Push Rod OD..............199 Measure and Adjust Cylinder Liner Standout (Height Above Block).....200 Install Packing on Cylinder Liner and O-Rings in Block..............201 Install Cylinder Liner in Block.....................................202 Assemble Piston and Connecting Rod..................................204 Install Piston Rings................................................205 Install Piston and Connecting Rod Assembly..........................206 Torque-Turn Connecting Rod Cap Screws...............................209 Check Engine Rotation for Excessive Tightness.......................209 Measure Piston Protrusion...........................................210 Complete Final Assembly.............................................211 Crankshaft, Main Bearings and Flywheel..................................213 Crankshaft and Main Bearing Failure Analysis........................213 Inspect Vibration Damper (6.8 L Engines)............................213 Remove Pulley or Vibration Damper and Pulley........................214 Install Pulley or Vibration Damper and Pulley.......................216 Replace Front Crankshaft Oil Seal and Wear Sleeve...................219 Check Crankshaft End Play...........................................231 Inspect Flywheel....................................................231 Check Flywheel Face Flatness........................................232 Check Pilot Bearing Bore Concentricity..............................232 Remove Flywheel.....................................................233 Replace Flywheel Ring Gear..........................................233 Replace Pilot Bearing in Flywheel (If Equipped).....................234 Replace Sleeve in Flywheel (If Equipped)............................234 Install Flywheel....................................................235 Install Flywheel Adapter on CD6068HT480 Engine......................236 Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions.......236 Remove Crankshaft Rear Oil Seal and Wear Sleeve.....................236 Clean and Inspect Crankshaft Flange.................................239 Install Crankshaft Rear Oil Seal and Wear Sleeve....................240 Remove Flywheel Housing.............................................242 Remove and Install Crankshaft Timing Wheel (If Equipped)............243 Remove Crankshaft Main Bearings.....................................244 Check Main Bearing Oil Clearance....................................245 Remove and Install Crankshaft Gear (Crankshaft Installed in Engi....245 Remove Crankshaft...................................................246 Inspect Crankshaft..................................................247 Measure Crankshaft Journals and Main Bearing ID.....................248 Measure Main Thrust Journal Width and Thrust Bearing Width..........249 Crankshaft Grinding Guidelines......................................250 Crankshaft Grinding Specifications..................................251 Measure Assembled ID of Main Bearing Caps...........................252 Install Main and Thrust Bearing Inserts in Block....................252 Install Crankshaft..................................................254 Install Flywheel Housing............................................256 Complete Final Assembly.............................................258 Camshaft, Balancer Shafts and Timing Gear Train.........................259 Remove Timing Gear Cover............................................259 Remove and Install Camshaft Bushing with Front Plate Installed......262 Remove and Install Camshaft Gear-Driven Auxiliary Drive.............265 Measure Camshaft End Play...........................................266 Measure Balancer Shaft End Play (If Equipped—4-Cylinder Engines)....266 Measure Idler Gear End Play.........................................266 Measure Timing Gear Backlash........................................267 Remove Camshaft.....................................................268 Visually Inspect Camshaft...........................................270 Measure Camshaft Thrust Plate Clearance and Thickness...............270 Inspect and Measure Camshaft Bushing ID and Journal OD..............271 Measure Camshaft Lobe Height........................................272 Inspect Camshaft Gear...............................................272 Inspect Camshaft Followers..........................................273 Inspect, Measure, and Install Fuel Supply Pump Push Rod.............274 Remove Balancer Shafts (If Equipped—4-Cylinder Engines).............275 Inspect and Measure Balancer Shaft Bushings and Journals............276 Remove and Install Balancer Shaft Bushings..........................277 Inspect Balancer Shaft Gears and Thrust Plates......................277 Remove and Install Balancer Shaft Gears.............................278 Remove Cylinder Block Front Plate...................................279 Measure Idler Gear Bushing and Shaft................................281 Remove Idler Gear Bushings..........................................282 Install Idler Gear Bushings.........................................283 Remove Lower and Upper Idler Shafts.................................284 Clean and Inspect Front Plate.......................................284 Transfer Fuel Injection Pump Timing Mark onto Replacement Front ....285 Install Idler Shaft Spring Pins (If Equipped).......................285 Install Upper Idler Shaft in Front Plate............................286 Install Lower Idler Shaft in Front Plate............................287 Install Cylinder Block Front Plate..................................287 Install and Time Balancer Shafts (If Equipped—4-Cylinder Engines....289 Install Camshaft....................................................293 Time Camshaft and Fuel Injection Pump (Non-HPCR Engines)............294 Install Upper Idler Gear (Non-HPCR Engines).........................299 Time Camshaft and Install Upper Idler Gear (4-Valve and HPCR/2-V....300 Clean and Inspect Timing Gear Cover.................................301 Timing Gear Cover Gaskets...........................................302 Install Timing Gear Cover...........................................303 Remove and Install Magnetic Pick-Up Sensor..........................306 Complete Final Assembly.............................................306 Lubrication System......................................................307 General Lubrication System Information..............................307 Remove, Inspect, and Install Oil Filter Base........................307 Remove, Inspect, and Install Oil Cooler.............................312 Remove, Inspect, and Install Oil Bypass Valve.......................316 Remove and Install Oil Filter Bypass Valve (Extended-Life Filter....316 Remove and Install Oil Pressure Regulating Valve....................317 Remove and Install Oil Fill Adapter.................................321 Remove and Install Dipstick Tube with Oil Pan Installed.............322 Remove and Install Dipstick Tube with Fitting.......................323 Remove and Install Oil Fill Tube (if equipped)......................324 Remove, Inspect, and Install Oil Pump Pick-Up Tube Assembly.........325 Engine Oil Pump Assembly............................................325 Remove Engine Oil Pump..............................................326 Inspect and Measure Clearances......................................327 Complete Oil Pump Disassembly.......................................329 Assemble Engine Oil Pump............................................330 Install Engine Oil Pump.............................................330 Install Oil Pan.....................................................332 Cooling System..........................................................335 Remove Coolant Manifold/Thermostat Cover and Thermostat.............335 Install Coolant Manifold/Thermostat Cover and Thermostat............336 Remove and Install Coolant Manifold/Thermostat Cover and Thermos....337 Remove and Install Coolant Manifold and Thermostats (Dual Thermo....339 Remove and Install Coolant Manifold, Thermostats and Side Port (....340 Remove and Install Thermostat Cover and Thermostats (Engines wit....341 Test Thermostat(s)..................................................342 Remove Coolant Pump.................................................342 Coolant Pump Assembly...............................................343 Disassemble Coolant Pump............................................344 Inspect, Clean, and Measure Coolant Pump Parts......................345 Assemble Coolant Pump...............................................346 Install Coolant Pump................................................348 Cooling System — De-aeration........................................349 Remove and Install Automatic (Spring) Belt Tensioner................350 Checking Belt Tensioner Spring Tension and Belt Wear................351 Manual Belt Tensioner Adjustment Using Belt Tension Gauge...........353 Manual Belt Tensioner Adjustment Using Belt Tension Tool (Altern....354 Inspect and Install Fan Assembly....................................356 Remove and Inspect Fan Drive Assembly...............................357 Replace Bearings in Adjustable Fan Drive Assembly...................358 Replace Bearings in Heavy-Duty, Adjustable Fan Drive Assembly.......360 Install Fan Drive Assembly..........................................362 Remove and Install Fan Drive Assembly (2254 Combine)................365 Remove and Install Coolant Heater (If Equipped).....................366 Remove and Install Cold Start Advance Switch (If Equipped)..........367 Air Intake and Exhaust System...........................................369 Extending Turbocharger Life.........................................369 Remove Turbocharger.................................................371 Turbocharger Failure Analysis.......................................373 Turbocharger Inspection.............................................375 Perform Radial Bearing Clearance Test...............................379 Adjust Turbocharger Wastegate Actuator (If Equipped)................380 Remove and Install Variable Geometry Turbocharger Actuator (4-Cy....381 Remove and Install Variable Geometry Turbocharger Actuator (6-Cy....386 Remove and Install Turbocharger Actuator Linkage (6-Cylinder Eng....387 Remove and Install Turbocharger Turbine Housing (6-Cylinder Engi....390 Repair Turbocharger.................................................391 Prelube Turbocharger................................................392 Install Turbocharger................................................392 Turbocharger Break-In...............................................395 Recommendations for Turbocharger Use................................395 Remove, Inspect, and Install Exhaust Manifold.......................396 Remove and Install Air-to-Air Aftercooler...........................397 Remove and Install EGR Exhaust Tube (Tier 3/Stage IIIA).............397 Remove and Install EGR Coolant Inlet Tube (Tier 3/Stage IIIA).......398 Remove and Install EGR Cooler (Tier 3/Stage IIIA)...................399 Remove, Inspect, and Install EGR Valve (Tier 3/Stage IIIA)..........401 Remove and Install Air Intake Pipe..................................402 Remove, Inspect, and Install Intake Manifold (Four-Valve Head)......402 Remove, Inspect, and Install Air Inlet and Mixing Sleeve (Tier 3....403 Remove, Inspect, and Install Intake Manifold (Tier 3/Stage IIIA)....403 Remove and Install Air Heater (If Equipped).........................404 Remove and Install Starting Aid (If Equipped).......................405 Fuel System.............................................................407 Fuel System.........................................................407 Starting and Charging Systems...........................................409 Remove and Install Starter..........................................409 Remove and Install Alternator.......................................410 Theory of Operation.........................................................411 Base Engine Operation...................................................413 Base Engine Theory of Operation.....................................413 General Engine Operation............................................413 General Engine Operation—Continued..................................414 Lubrication System Operation........................................416 Cooling System Operation............................................420 Head Gasket Joint Construction and Operation........................423 Air Intake and Exhaust System Operation.............................424 Air Cleaner Operation...............................................426 Turbocharger Operation..............................................427 Variable Geometry Turbocharger (VGT) Operation (Tier 3/Stage III....427 How the Turbocharger Is Lubricated..................................427 Diagnostics.................................................................429 Observable Diagnostics and Tests........................................431 About This Section of the Manual....................................431 Guideline for Acceptable Oil Consumption............................432 4.5L/6.8L - L1 - Excessive Oil Consumption..........................432 4.5L/6.8L - L1 - Excessive Oil Consumption......................432 4.5L/6.8L - L2 - Engine Oil Pressure Low............................435 4.5L/6.8L - L3 - Engine Oil Pressure High...........................436 4.5L/6.8L - C1 - Engine Coolant Temperature Above Normal............437 4.5L/6.8L - C2 - Engine Coolant Temperature Below Normal............437 4.5L/6.8L - C3 - Coolant in Oil or Oil in Coolant...................438 Test Engine Compression Pressure....................................438 Test Engine Cranking Speed..........................................443 Dynamometer Test....................................................444 Engine Oil Consumption..............................................444 Check Engine Oil Pressure...........................................445 Check for Excessive Engine Crankcase Pressure (Blow-By).............446 Check for Turbocharger Oil Seal Leak................................448 Inspect Thermostat and Test Opening Temperature.....................449 Pressure Test Cooling System and Radiator Cap.......................450 Pressure Test EGR Cooler for Air Leaks..............................450 Check for Head Gasket Failures......................................451 Check and Service Cooling System....................................453 Check Air Intake System.............................................455 Measure Intake Manifold Pressure (Turbocharger Boost for Tier 3/....455 Measure Intake Manifold Pressure (Turbocharger Boost/Power Check....456 Check for Intake and Exhaust Restrictions...........................457 Test for Intake Air Leaks...........................................458 Check for Exhaust Air Leaks (Turbocharged Engines)..................459 Test Turbocharger Wastegate.........................................459 Test Air Filter Restriction Indicator Switch........................460 Tools and Other Materials...................................................461 Repair Tools and Other Materials........................................463 Engine Rebuild Essential Tools......................................463 Engine Rebuild Service Equipment and Tools..........................464 Engine Rebuild Other Materials......................................465 Cylinder Head and Valves Essential Tools (2-Valve Head, non-HPCR....465 Cylinder Head and Valves Service Equipment and Tools (2-Valve He....470 Other Material (Two-Valve Head).....................................471 Cylinder Head and Valves Essential Tools (4-Valve and HPCR/2-Val....472 Service Equipment and Tools (4-Valve and HPCR/2-Valve Head Engin....478 Other Material (4-Valve and HPCR/2-Valve Head Engines)..............479 Cylinder Block, Liners, Pistons and Rods Essential Tools............479 Cylinder Block, Liners, Pistons and Rods Service Equipment and T....483 Cylinder Block, Liners, Pistons and Rods Other Materials............484 Crankshaft, Main Bearings, Damper and Flywheel Essential Tools......485 Crankshaft, Main Bearings and Flywheel Service Equipment and Too....490 Crankshaft, Main Bearings and Flywheel Other Materials..............491 Camshaft, Balancer Shafts and Timing Gear Train Essential Tools.....492 Camshaft, Balancer Shafts and Timing Gear Train Service Equipmen....496 Camshaft, Balancer Shafts and Timing Gear Train Other Materials.....497 Lubrication System Essential Tools..................................498 Lubrication System Service Equipment and Tools......................501 Lubrication System Other Materials..................................502 Cooling System Essential Tools......................................503 Cooling System Service Equipment and Tools..........................504 Cooling System Other Materials......................................505 Air Intake and Exhaust System Essential Tools.......................505 Air Intake and Exhaust System Other Materials.......................506 Starting and Charging System Essential Tools........................507 Diagnostic Service Tools................................................509 Diagnostic Essential Tools..........................................509 Diagnostic Service Equipment and Tools..............................511 Dealer Fabricated Service Tools.........................................513 How to Make Tools...................................................513 DFRG3—Cylinder Liner Holding Fixture................................513 DFRG5—Injection Pump Front Plate Timing Mark Transfer Tool..........514 Engine Oil Dipstick Tube Driver (6010—6910 Series Tractor Engine....514 Specifications..............................................................515 Repair and General OEM Specifications...................................517 Unified Inch Bolt and Screw Torque Values...........................517 Metric Bolt and Screw Torque Values.................................518 General OEM Engine Specifications...................................519 Engine Rebuild Specifications.......................................521 Cylinder Head and Valves Specifications (Two-Valve Head)............522 Cylinder Head and Valves Specifications (Four-Valve Head)...........525 Cylinder Block, Liners, Pistons, and Rods Specifications............528 Crankshaft, Main Bearings, and Flywheel Specifications..............533 Camshaft, Balancer Shafts and Timing Gear Train Specifications......535 Lubrication System Specifications...................................539 Cooling System Specifications.......................................541 Air Intake and Exhaust System Specifications........................544 Starting and Charging Systems Specifications........................545 Diagnostic Specifications...............................................547 Engine Diagnostic Specifications....................................547 Dynamometer Test Specifications.....................................547 Power Ratings on Dynamometer for OEM Engines (4 Cyl.)...............548 Power Ratings on Dynamometer for OEM Engines (6 Cyl.)...............558 Intake Manifold Pressure (Turbocharger Boost) Specifications........566 Intake Manifold Pressure (Turbocharger Boost) Specifications (Co....578 Intake Manifold Pressure (Turbocharger Boost) Specifications (Co....587 Intake Manifold Pressure (Turbocharger Boost) Specifications (Co....597 Effects of Altitude and Temperature on Engine Performance...........607 Page Number..................................................................... 13 Section 01.................................................................. 15 Group 000............................................................... 17 Group 001............................................................... 31 Group 002............................................................... 35 Section 02.................................................................. 53 Group 010............................................................... 55 Group 020............................................................... 71 Group 021...............................................................113 Group 030...............................................................169 Group 040...............................................................213 Group 050...............................................................259 Group 060...............................................................307 Group 070...............................................................335 Group 080...............................................................369 Group 090...............................................................407 Group 100...............................................................409 Section 03..................................................................411 Group 120...............................................................413 Section 04..................................................................429 Group 150...............................................................431 Section 05..................................................................461 Group 170...............................................................463 Group 180...............................................................509 Group 190...............................................................513 Section 06..................................................................515 Group 200...............................................................517 Group 210...............................................................547
S.S 07/03/2025
