Complete technical manual for John Deere PowerTech 4.5L & 6.8L Diesel Engines, with all the workshop serivce information to maintain, diagnose, and repair like professional mechanics.
CTM104 (07NOV12) (ENGLISH) – John Deere PowerTech 4.5L & 6.8L Diesel Engines – John Deere Base Engine Component Technical Manual.pdf
CTM104 (19JUN00) – John Deere PowerTech 4.5L & 6.8L Diesel Engines – John Deere Base Engine Component Technical Manual.pdf
ctm105 – Moteurs diesel 4,5 et 6,8 l (Moteur standard) – (Édition internationale) Component Technical Manual.pdf
ctm106 – 4,5-l- und 6,8-l-Dieselmotoren (Grundmotor) – (Weltweite Ausgabe) Component Technical Manual.pdf
ctm107 – Motores diésel de 4.5 l y 6.8 l (Motor básico) – (Edición mundial) Component Technical Manual.pdf
ctm116 – Motori diesel da 4,5 l e 6,8 l (Motore base) – (Edizione universale) Component Technical Manual.pdf
ctm117 – 4,5 EN 6,8 L DIESELMOTOREN (STANDAARDMOTOR) – (WERELDWIJDE UITGAVE) Component Technical Manual.pdf
ctm165 – VZNĚTOVÉ MOTORY 4.5 l A 6.8 l (ZÁKLADNÍ MOTOR) (CELOSVĚTOVÉ VYDÁNÍ) Technický manuál komponentů.pdf
ctm180 – 4.5 升和 6.8 升柴油发动机 (基本发动机) – (世界通用机型) Component Technical Manual.pdf
ctm205 – Дизельные двигатели объемом 4,5 л и 6,8 л (основной двигатель) – (Исполнение для всех стран) Component Technical Manual.pdf
ctm206 – Motores Diesel 4,5 L e 6,8 L (Motor Básico) – (Edição Mundial) Component Technical Manual.pdf
ctm426 – 4,5 L OG 6,8 L DIESELMOTORER (BASISMOTOR) (GLOBAL UDGAVE) Komponent teknisk manual (Danish).pdf
ctm427 – 4,5 L:N JA 6,8 L:N DIESELMOOTTORIT (PERUSMOOTTORI) (MAAILMANLAAJUINEN PAINOS) Komponentin tekninen käsikirja (FIN).pdf
ctm428 – 4,5 L- OG 6,8 L DIESELMOTORER (GRUNNMOTOR) (GLOBAL VERSJON) Komponent teknisk håndbok (NOR).pdf
ctm429 – 4,5 L ÉS 6,8 L DÍZEL MOTOROK (ALAP MOTOR) (EGÉSZ VILÁGON ÉRVÉNYES KIADÁS) Alkatrész műszaki kézikönyv (HU).pdf
ctm430 – SILNIKI WYSOKOPRĘŻNE 4,5 L I 6,8 L (SILNIK PODSTAWOWY) (EDYCJA OGÓLNOŚWIATOWA) Podręcznik techniczny komponentów (Polish).pdf
ctm463 – ΚΙΝΗΤΗΡΕΣ ΝΤΙΖΕΛ 4,5 L ΚΑΙ 6,8 L (ΒΑΣΙΚΟΣ ΚΙΝΗΤΗΡΑΣ) (ΔΙΕΘΝΗΣ ΕΚΔΟΣΗ) Τεχνικό εγχειρίδιο εξαρτημάτων (Greek).pdf
ctm464 – 4,5 L i 6,8 L DIZELSKI MOTORI (OSNOVNI MOTOR) (SVJETSKO IZDANJE) Tehnički priručnik za komponente (Croatian).pdf
ctm465 – 4,5 L IR 6,8 L DYZELINIAI VARIKLIAI (BAZINIS VARIKLIS) (TARPTAUTINIS LEIDINYS) Komponento techninis vadovas (Lithuanian).pdf
ctm471 – DIZELSKI MOTORJI 4,5 L IN 6,8 L (OSNOVNI MOTOR) (IZVEDBA ZA VSE CELINE IN DRŽAVE) Technická príručka komponentov (Slovenian).pdf
ctm472 – NAFTOVÉ MOTORY S OBJEMOM 4,5 L A 6,8L(ZÁKLADNÝ MOTOR) (CELOSVETOVÉ VYDANIE) Bileşen Teknik Kılavuzu (Slovak).pdf
ctm473 – 4,5 l VE 6,8 l DİZEL MOTORLAR (ANA MOTOR) (DÜNYA ÇAPINDAKİ SÜRÜM) Bileşen Teknik Kılavuzu (Turkish).pdf
ctm474 – DIZEL MOTORI OD 4,5 L I 6,8 L (OSNOVNI MOTOR) (SVETSKO IZDANJE) Komponenta Tehnički priručnik (Bosnian).pdf
ctm731 – MOTOARE DIESEL DE 4,5 L ŞI 6,8 L (MOTORUL DE BAZĂ) (EDIŢIE MONDIALĂ) Manual tehnic pentru componente (RO).pdf
CTM104 (07NOV12) (ENGLISH) – John Deere PowerTech 4.5L & 6.8L Diesel Engines – John Deere Base Engine Component Technical Manual.pdf
CTM104 (19JUN00) – John Deere PowerTech 4.5L & 6.8L Diesel Engines – John Deere Base Engine Component Technical Manual.pdf
CTM104 – John Deere PowerTech 4.5L & 6.8L Diesel Engines – John Deere Base Engine Component Technical Manual.pdf
CTM528 (Hebrew) – ג’ון דיר PowerTech 4.5L ו-6.8L מנועי דיזל אלקטרוניים 11 מפלסים רכיבים מדריך טכני.pdf
CTM704 (Arabic) – John Deere PowerTech 4.5L & 6.8L محركات الديزل الإلكترونية ذات 11 مستوى من الدليل الفني للمكونات.pdf
CTM705 (Korean) – John Deere PowerTech 4.5L 및 6.8L 디젤 엔진 전자 11 레벨 구성 요소 기술 매뉴얼.pdf
PRODUCT DETAILS:
Total Pages: 1,760 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle etc.
Language: English etc…
MAIN SECTIONS
Introduction….2
Forward….2
John Deere Dealers….3
POWERTECH 4.5 L Engine….5
POWERTECH 6.8 L Engine….6
Contents….7
General Information….9
Safety….11
Handle Fluids SafelyAvoid Fires….11
Handle Starting Fluid Safely….11
Service Cooling System Safely….12
Prevent Battery Explosions….12
Prepare for Emergencies….13
Handling Batteries Safely….14
Avoid High-Pressure Fluids….15
Wear Protective Clothing….15
Service Machines Safely….16
Work In Ventilated Area….16
Work in Clean Area….17
Remove Paint Before Welding or Heating….17
Avoid Heating Near Pressurized Fluid Lines….18
Illuminate Work Area Safely….18
Use Proper Lifting Equipment….19
Construct Dealer-Made Tools Safely….19
Practice Safe Maintenance….20
Use Proper Tools….20
Dispose of Waste Properly….21
Live With Safety….21
Engine Identification….23
Engine Model Designation….23
Engine Serial Number Plate Information ….24
OEM Engine Option Code Label….25
Engine Application Charts….26
Fuels, Lubricants and Coolants….33
Diesel Fuel ….33
Lubricity of Diesel Fuel….33
Engine Break-In Oil ….34
Diesel Engine Oil ….35
Extended Diesel Engine Oil Service Intervals….35
Alternative and Synthetic Lubricants ….36
Mixing of Lubricants….36
OILSCAN, OILSCAN Plus and COOLSCAN ….37
Grease….38
Diesel Engine Coolant Recommendations….39
Engine Coolant Specifications….40
Testing Diesel Engine Coolant ….43
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes….44
Operating in Warm Temperature Climates….45
Flush and Service Cooling System….46
Disposing of Coolant….47
Repair and Adjustments….49
Engine Rebuild….53
Engine Overhaul Guidelines….53
Engine Repair Stand….53
Engine Stand Safety Precautions ….54
Install Adapters on Engine Repair Stand….55
Engine Lifting Procedure….56
Clean Engine….57
Disconnect Turbocharger Oil Inlet Line….58
Mount Engine on Repair Stand….59
Engine Mounted on Repair Stand….60
Engine Disassembly Sequence….61
Sealant Application Guidelines….63
Engine Assembly Sequence….65
Engine Break-In Guidelines ….67
Perform Engine Break-In ….68
Cylinder Head and Valves….71
Check and Adjust Valve Clearance….71
Measure Valve Lift….74
Remove Cylinder Head….76
Disassemble and Inspect Rocker Arm Shaft Assembly….83
Assemble Rocker Arm Assembly….84
Inspect, Measure, and Install Fuel Supply Pump Push RodIf Applicable….84
Inspect, Measure, and Assemble Camshaft Followers….86
Measure Valve Recess in Cylinder Head….88
Preliminary Cylinder Head and Valve Checks ….89
Remove Valve Assembly….90
Inspect and Measure Valve Springs….90
Inspect Valve Rotators….91
Clean Valves….91
Inspect and Measure Valves….92
Grind Valves….93
Head Gasket Inspection and Repair Sequence….94
Inspect and Clean Cylinder Head….95
Check Cylinder Head Flatness….96
Measure Cylinder Head Thickness….97
Clean Injection Nozzle Bores….98
Clean Valve Guides….98
Measure Valve Guides….99
Knurl Valve Guides….100
Clean and Inspect Valve Seats….100
Grind Valve Seats….101
Remove Valve Seat Inserts….103
Measure Valve Seat Bore in Cylinder Head….106
Install Valve Seat Inserts….107
Install Valves….107
Clean and Inspect Cylinder Head Cap Screws….108
Inspect and Clean Exhaust Manifold….108
Clean and Inspect Top Deck of Cylinder Block….109
Measure Cylinder Liner Standout (Height above Block)….110
Install Cylinder Head….110
Torque-Turn Method for Proper Torque….113
Install Rocker Arm Assembly….114
Inspect and Clean Ventilator Outlet Hose….114
Install Rocker Arm Cover….115
Complete Final Assembly….116
Cylinder Block, Liners, Pistons and Rods….121
Connecting RodsGeneral Information….121
Remove Pistons and Connecting Rods ….122
Remove Cylinder Liners….125
Complete Disassembly of Cylinder Block (If Required)….127
Preliminary Liner, Piston and Rod Checks ….128
Disassemble Piston and Rod Assembly ….129
Clean Pistons….130
Visually Inspect Pistons….131
Clean Cylinder Liners….132
Visually Inspect Cylinder Liners….133
Check Piston Ring Groove Wear ….135
Measure Piston Pin Bore….136
Measure Piston Skirt….136
Measure Piston Height….136
Determine Piston-to-Liner Clearance ….137
Deglaze Cylinder Liners….139
Replace Piston and Liner Sets….139
Inspect and Measure Connecting Rod Bearings (Rods Removed from Engine)….140
Inspect and Measure Connecting Rod Bearings (Rod and Crankshaft in Engine)….141
Inspect Rod and Cap….142
Inspect Piston Pins and Bushings….144
Remove Piston Pin Bushing….145
Clean and Inspect Connecting Rod Pin Bore….147
Install Piston Pin Bushing in Connecting Rod….148
Measure Rod Center-to-Center Bores….149
Inspect and Clean Cylinder Block….150
Clean Cylinder Liner O-Ring Bore….152
Measure Cylinder Block Main Bearing Bore….153
Measure Camshaft Follower Machined Bore in Block….153
Measure Camshaft Bushing Bores in Block….154
Measure Balancer Shaft Bushing ID in Block4-Cylinder Engines….155
Measure Cylinder Liners and Block Bores ….156
Measure Liner Flange Counterbore Depth in Block….156
Measure Liner Flange Thickness….157
Measure Cylinder Block Top Deck Flatness….157
Remove, Inspect, and Install Piston Cooling Orifices….158
Measure Fuel Supply Pump Push Rod Bore and Push Rod OD….159
Measure Cylinder Liner Standout (Height above Block)….160
Install Packing on Cylinder Liner and O-Rings in Block….161
Install Cylinder Liner in Block….163
Assemble Piston and Connecting Rod ….165
Install Piston Rings….166
Install Piston and Connecting Rod Assembly ….167
Torque-Turn Connecting Rod Cap Screws….171
Check Engine Rotation for Excessive Tightness….172
Measure Piston Protrusion….173
Complete Final Assembly….174
Crankshaft, Main Bearings and Flywheel….175
Crankshaft and Main Bearing Failure Analysis ….175
Inspect Vibration Damper….176
Remove Pulley or Vibration Damper and Pulley ….177
Install Pulley or Vibration Damper and Pulley ….178
Replace Front Crankshaft Oil Seal and Wear Sleeve ….179
Check Crankshaft End Play….186
Inspect Flywheel….186
Check Flywheel Face Flatness….187
Check Pilot Bearing Bore Concentricity ….187
Remove Flywheel….188
Replace Flywheel Ring Gear….189
Replace Pilot Bearing in FlywheelIf Equipped….190
Install Flywheel….191
Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions….192
Remove Crankshaft Rear Oil Seal and Wear Sleeve ….192
Clean and Inspect Crankshaft Flange….197
Install Crankshaft Rear Oil Seal and Wear Sleeve….197
Remove Flywheel Housing….200
Remove and Install Crankshaft Timing Wheel (Engines with VP44 Fuel Injection Pump) ….201
Remove Crankshaft Main Bearings ….202
Check Main Bearing Oil Clearance ….203
Remove and Install Crankshaft Gear (Crankshaft Installed in Engine)….204
Remove Crankshaft….206
Inspect Crankshaft….207
Measure Crankshaft Journals and Main Bearing ID ….208
Measure Main Thrust Journal Width and Thrust Bearing Width….209
Crankshaft Grinding Guidelines….210
Crankshaft Grinding Specifications….211
Measure Assembled ID of Main Bearing Caps ….212
Remove, Inspect, and Install Piston Cooling Orifices….213
Install Main and Thrust Bearing Inserts in Block….214
Install Crankshaft….216
Install Flywheel Housing….219
Complete Final Assembly….221
Camshaft, Balancer Shafts and Timing Gear Train….223
Measure Valve Lift….223
Remove Timing Gear Cover….225
Remove and Install Camshaft Bushing with Front Plate Installed….228
Remove and Install Camshaft Gear-Driven Auxiliary Drive….232
Measure Camshaft End Play….233
Measure Balancer Shaft End Play (4-Cylinder Engines)….233
Measure Idler Gear End Play….234
Measure Timing Gear Backlash….234
Remove Camshaft….235
Visually Inspect Camshaft….237
Measure Camshaft Thrust Plate Clearance and Thickness….238
Inspect and Measure Camshaft Bushing ID and Journal OD….239
Measure Camshaft Lobe Height….240
Remove and Install Camshaft Gear….240
Inspect Camshaft Followers….241
Inspect, Measure, and Install Fuel Supply Pump Push Rod….242
Remove Balancer ShaftsIf Equipped (4-Cylinder Engines)….243
Inspect and Measure Balancer Shaft Bushings and Journals….244
Remove and Install Balancer Shaft Bushings (4-Cylinder Engines)….245
Inspect Balancer Shaft Gears and Thrust Plates….246
Remove and Install Balancer Shaft Gears….246
Remove Cylinder Block Front Plate….247
Measure Idler Gear Bushing and Shaft….250
Remove Idler Gear Bushings….251
Install Idler Gear Bushings….252
Remove Lower and Upper Idler Shafts….253
Clean and Inspect Front Plate….253
Transfer Fuel Injection Pump Timing Mark onto Replacement Front Plate ….254
Install Idler Shaft Spring Pins (If Equipped)….255
Install Upper Idler Shaft in Front Plate….255
Install Lower Idler Shaft in Front Plate….256
Install Cylinder Block Front Plate….256
Install and Time Balancer Shafts (4-Cylinder Engines)….258
Install Camshaft….262
Clean and Inspect Timing Gear Cover….265
Install Timing Gear Cover….266
Install Crankshaft Front Wear Sleeve and Oil Seal ….268
Remove and Install Magnetic Pick-Up Sensor ….270
Replace Mechanical Tachometer Adapter….271
Complete Final Assembly….272
Lubrication System….273
General Lubrication System Information….273
Remove, Inspect, and Install Oil Filter Base….273
Remove, Inspect, and Install Oil Cooler….277
Remove, Inspect, and Install Oil Bypass Valve….281
Remove and Install Oil Pressure Regulating Valve and Seat….281
Remove and Install Oil Fill Tube….284
Remove and Install Dipstick Tube with Oil Pan Installed….285
Remove and Install Dipstick Tube with Fitting….286
Remove, Inspect and Install Oil Pump Pick-Up Tube Assembly….287
Engine Oil Pump Assembly….287
Remove Engine Oil Pump….288
Inspect and Measure Clearances….289
Complete Oil Pump Disassembly….291
Assemble Engine Oil Pump….292
Install Engine Oil Pump….293
Install Oil Pan….295
Cooling System….297
Remove Water Manifold/Thermostat Cover and Thermostat ….297
Install Water Manifold/Thermostat Cover and Thermostat ….298
Remove and Install Water Manifold/Thermostat Cover and Thermostat (6010 Series Tractors with Single Thermostat) ….300
Remove and Install Water Manifold and Thermostats (Dual Thermostats) ….303
Test Thermostat(s)….304
Remove Water Pump….305
Water Pump Assembly….306
Disassemble Water Pump….307
Inspect, Clean, and Measure Water Pump Parts….308
Assemble Water Pump….309
Install Water Pump….310
Cooling System Deaeration….311
Remove and Install Automatic (Spring) Belt Tensioner….312
Checking Belt Tensioner Spring Tension and Belt Wear….312
Manual Belt Tensioner Adjustment ….314
Inspect and Install Fan Assembly….315
Remove and Inspect Fan Drive Assembly….316
Replace Bearings in Adjustable Fan Drive Assembly….317
Install Fan Drive Assembly….320
Remove and Install Fan Drive Assembly (2254 Combine)….323
Remove and Install Coolant HeaterIf Equipped….324
Remove and Install Cold Start Advance Switch (If Equipped)….325
Air Intake and Exhaust System….327
Extending Turbocharger Life….327
Remove Turbocharger….329
Turbocharger Failure Analysis….330
Turbocharger Seven-Step Inspection….332
Perform Radial Bearing Clearance Test….339
Perform Axial Bearing End Play Test….340
Adjust Turbocharger Wastegate Actuator (If Equipped)….341
Repair Turbocharger….341
Prelube Turbocharger….342
Install Turbocharger….343
Turbocharger Break-In….344
Recommendations for Turbocharger Use….345
Remove, Inspect, and Install Exhaust Manifold….346
Remove and Install Air-to-Air Aftercooler….346
Remove and Install Air Intake Pipe….347
Remove and Install Air Heater….348
Remove and Install Starting AidIf Equipped….349
Fuel System….351
Fuel System….351
Starting and Charging Systems….353
Remove and Install Starter….353
Remove and Install Alternator….354
Theory of Operation….357
Base Engine Operation….359
Base Engine Theory of Operation….359
General Engine Operation….360
General Engine OperationContinued….361
Lubrication System Operation ….362
Cooling System Operation ….364
Head Gasket Joint Construction and Operation….366
Air Intake and Exhaust System Operation….368
Air Cleaner Operation….369
Turbocharger Operation….370
How the Turbocharger Is Lubricated….370
Diagnostics….371
Observable Diagnostics and Tests….373
About This Section of the Manual….373
Diagnosing Lubrication System Malfunctions ….373
L1 – Excessive Oil Consumption….373
Check Oil in Coolant….374
Check for Excessive Crankcase Pressure (Blow-By)….374
Turbocharger Oil Seal Leak Check….375
Pistons, Rings, Cylinder Liners Check….375
L2 – Engine Oil Pressure Low ….376
L3 – Engine Oil Pressure High ….378
Diagnosing Cooling System Malfunctions….379
C1 – Engine Coolant Temperature Above Normal ….379
C2 – Engine Coolant Temperature Below Normal ….380
C3 – Coolant in Oil or Oil in Coolant ….380
Test Engine Compression Pressure….381
Test Engine Cranking Speed….384
Dynamometer Test….385
Engine Oil Consumption….386
Check Engine Oil Pressure ….387
Check for Excessive Engine Crankcase Pressure (Blow-By) ….389
Check for Turbocharger Oil Seal Leak….390
Inspect Thermostat and Test Opening Temperature….391
Pressure Test Cooling System and Radiator Cap ….392
Check for Head Gasket Failures ….394
Check and Service Cooling System….397
Check Air Intake System….399
Measure Intake Manifold Pressure (Turbocharger Boost) ….400
Check for Intake and Exhaust Restrictions ….402
Test for Intake Air Leaks….403
Check for Exhaust Air Leaks (Turbocharged Engines)….404
Test Turbocharger Wastegate….404
Test Air Filter Restriction Indicator Switch….405
Tools and Other Materials….407
Repair Tools and Other Materials….409
Cylinder Head and Valves Essential Tools….409
Cylinder Head and Valves Service Equipment and Tools….414
Cylinder Head and Valves Other Materials….416
Cylinder Block, Liners, Pistons and Rods Essential Tools….417
Cylinder Block, Liners, Pistons and Rods Service Equipment and Tools….422
Cylinder Block, Liners, Pistons and Rods Other Materials….423
Crankshaft, Main Bearings and Flywheel Essential Tools….424
Crankshaft, Main Bearings and Flywheel Service Equipment and Tools….429
Crankshaft, Main Bearings and Flywheel Other Materials….430
Camshaft, Balancer Shafts and Timing Gear Train Essential Tools….431
Camshaft, Balancer Shafts and Timing Gear Train Service Equipment and Tools….435
Camshaft, Balancer Shafts and Timing Gear Train Other Materials….436
Lubrication System Essential Tools….437
Lubrication System Service Equipment and Tools….440
Lubrication System Other Materials….441
Cooling System Essential Tools….442
Cooling System Service Equipment and Tools….443
Cooling System Other Materials….444
Air Intake and Exhaust System Other Materials….445
Starting and Charging System Essential Tools….446
Diagnostic Service Tools….447
Diagnostic Essential Tools….447
Diagnostic Service Equipment and Tools….449
Dealer Fabricated Service Tools….451
How to Make Tools ….451
DFRG3Cylinder Liner Holding Fixture….451
DFRG5Injection Pump Front Plate Timing Mark Transfer Tool….452
Engine Oil Dipstick Tube Driver (60106910 Series Tractor Engines)….453
Specifications….455
Repair and General OEM Specifications….457
Unified Inch Bolt and Cap Screw Torque Values ….457
Metric Bolt and Cap Screw Torque Values ….458
General OEM Engine Specifications….459
Engine Rebuild Specifications….459
Cylinder Head and Valves Specifications….460
Cylinder Block, Liners, Pistons and Rods Specifications….464
Crankshaft, Main Bearings and Flywheel Specifications….470
Camshaft, Balancer Shafts and Timing Gear Train Specifications….472
Lubrication System Specifications….477
Cooling System Specifications….480
Air Intake and Exhaust System Specifications….483
Starting and Charging Systems Specifications ….484
Diagnostic Specifications….485
Dynamometer Test Specifications….485
Intake Manifold Pressure (Turbocharger Boost) Specifications ….493
Effects of Altitude and Temperature on Engine Performance ….503
Engine Diagnostic Specifications….504
ctm104 – 4.5L AND 6.8L DIESEL ENGINES (BASE ENGINE) -: (WORLDWIDE EDITION)
Component Technical Manual
Table of Contents
Foreword
Identification Views
Related Manuals
Training Information
Definition of Terms
Trademarks
Section 01: General Information
Group 000: Safety
Understand Signal Words
Recognize Safety Information
Replace Safety Signs
Follow Safety Instructions
Park Machine Safely
Support Machine Properly
Use Proper Lifting Equipment
Prevent Machine Runaway
Construct Dealer-Made Tools Safely
Illuminate Work Area Safely
Work in Clean Area
Use Proper Tools
Install All Guards
Service Machines Safely
Practice Safe Maintenance
Handle Fuel Safely—Avoid Fires
Prepare for Emergencies
Handle Starting Fluid Safely
In Case of Fire
Handle Fluids Safely—Avoid Fires
Avoid Static Electricity Risk When Refueling
Protect Against Noise
Protect Against High Pressure Spray
Stay Clear of Rotating Drivelines
Avoid High-Pressure Fluids
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Wear Protective Clothing
Handling Batteries Safely
Prevent Acid Burns
Wait Before Opening High-Pressure Fuel System
Prevent Battery Explosions
Avoid Hot Exhaust
Work In Ventilated Area
Service Cooling System Safely
Service Cooling System Safely
Precautions for Welding
Live With Safety
Group 001: Engine Identification
Engine Serial Number Plate Information
OEM Engine Option Code Label
Information Relative to Emissions Regulations
Emissions Control System Certification Label
Group 002: Fuels, Lubricants, and Coolant
Storing Fuel
Diesel Fuel
Lubricity of Diesel Fuel
Handling and Storing Diesel Fuel
Supplemental Diesel Fuel Additives
BioDiesel Fuel
Testing Diesel Fuel
Minimizing the Effect of Cold Weather on Diesel Engines
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
Diesel Engine Coolant (engine without wet sleeve cylinder liners)
Operating in Warm Temperature Climates
Water Quality for Mixing with Coolant Concentrate
Testing Coolant Freeze Point
Engine Oil and Filter Service Intervals — Tier 3 and Stage IIIA — OEM Applications
Diesel Engine Oil — Tier 3 and Stage III
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
Oil Filters
Fuel Filters
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Section 02A: Repair and Adjustments (4 Cylinder Engine)
Group 010: Engine Rebuild (4045)
Check Air Intake System (4045)
Check and Service Cooling System (4045)
Check Crankcase Vent System (4045)
Check Electrical System (4045)
Check Exhaust System (4045)
Clean Engine (4045)
Engine Break-In Guidelines (4045)
Engine Overhaul Guidelines (4045)
General Tune-Up Recommendations (4045)
Engine Repair Stand (4045)
Install JT07268 Engine Mounting Adapter to D05223ST Repair Stand (4045)
Install JDG11853 Engine Mounting Adapter to D05223ST Repair Stand (4045)
Lift Straps — Installation (4045)
Lift Straps — Removal (4045)
Lifting Procedure (4045)
Mount Engine to Repair Stand Using JT07268 (4045)
Mount Engine to Repair Stand Using JDG11853 (4045)
Safety Precautions (4045)
Sealant Application Guidelines (4045)
Group 020: Cylinder Head and Valve Repair and Adjustment (4045) (Two-Valve Head Engines)
Cylinder Block Top Deck — Cleaning and Inspection (4045) (Two-Valve Head)
Cylinder Head — Cleaning and Inspection (4045) (Two-Valve Head)
Cylinder Head — Flatness Check (4045) (Two-Valve Head)
Cylinder Head — Installation (4045) (Two-Valve Head)
Cylinder Head — Removal (4045) (Two-Valve Head)
Cylinder Head — Thickness Measurement (4045) (Two-Valve Head)
Cylinder Head Gasket — Inspection (4045) (Two-Valve Head)
Fuel Injector Heat Shield — Installation (4045) (Two-Valve Head)
Fuel Injector Heat Shield — Removal (4045) (Two-Valve Head)
Fuel Injector Sleeves — Installation (4045) (Two-Valve Head)
Fuel Injector Sleeves — Removal (4045) (Two-Valve Head)
Fuel Supply Pump Push Rod — Installation (4045) (Two-Valve Head)
Fuel Supply Pump Push Rod — Measurement (4045) (Two-Valve Head)
Fuel Supply Pump Push Rod — Removal (4045) (Two-Valve Head)
Push Rod — Cleaning and Inspection (4045) (Two-Valve Head)
Push Rod — Installation (4045) (Two-Valve Head)
Push Rod — Removal (4045) (Two-Valve Head)
Rocker Arm Cover Baffle — Installation (4045) (Two-Valve Head)
Rocker Arm Cover Baffle — Removal (4045) (Two-Valve Head)
Rocker Arm Cover — Installation (4045) (Two-Valve Head)
Rocker Arm Cover — Removal (4045) (Two-Valve Head)
Rocker Arm Shaft Assembly — Tear Down (4045) (Two-Valve Head)
Rocker Arm Shaft Assembly — Inspection (4045) (Two-Valve Head)
Rocker Arm Shaft Assembly — Assemble (4045) (Two-Valve Head)
Rocker Arm Shaft Assembly — Installation (4045) (Two-Valve Head)
Rocker Arm Shaft Assembly — Removal (4045) (Two-Valve Head)
Valve — Cleaning and Visual Inspection (4045) (Two-Valve Head)
Valve — Clearance Adjustment (4045) (Two-Valve Head)
Valve — Grinding (4045) (Two-Valve Head)
Valve — Measurement (4045) (Two-Valve Head)
Valve — Recess Measurement (4045) (Two-Valve Head)
Valve Assembly — Installation (4045) (Two-Valve Head)
Valve Assembly — Removal (4045) (Two-Valve Head)
Valve Guide — Cleaning (4045) (Two-Valve Head)
Valve Guide — Measurement (4045) (Two-Valve Head)
Valve Guide — Knurling (4045) (Two-Valve Head)
Valve Keeper, Rocker Arm Insert, and Valve Rotator — Inspection (4045) (Two-Valve Head)
Valve Seat — Cleaning and Inspection (4045) (Two-Valve Head)
Valve Seat — Grinding and Measurement (4045) (Two-Valve Head)
Valve Seat Inserts — Installation (4045) (Two-Valve Head)
Valve Seat Inserts — Removal (4045) (Two-Valve Head)
Valve Spring — Inspection and Measurement (4045) (Two-Valve Head)
Group 021: Cylinder Head and Valve Repair and Adjustment (4045) (Four-Valve Head Engines)
Cylinder Block Top Deck — Cleaning and Inspection (4045) (Four-Valve Head)
Cylinder Head — Cleaning and Inspection (4045) (Four-Valve Head)
Cylinder Head — Flatness Check (4045) (Four-Valve Head)
Cylinder Head — Installation (4045) (Four-Valve Head)
Cylinder Head — Removal (4045) (Four-Valve Head)
Cylinder Head — Thickness Measurement (4045) (Four-Valve Head)
Cylinder Head Gasket — Inspection (4045) (Four-Valve Head)
Fuel Leak-Off Line Heat Shield — Installation (4045) (Four-Valve Head)
Fuel Leak-Off Line Heat Shield — Removal (4045) (Four-Valve Head)
Fuel Injector Sleeves — Installation (4045) (Four-Valve Head)
Fuel Injector Sleeves — Removal (4045) (Four-Valve Head)
Fuel Supply Pump Push Rod — Installation (4045) (Four-Valve Head)
Fuel Supply Pump Push Rod — Measurement (4045) (Four-Valve Head)
Fuel Supply Pump Push Rod — Removal (4045) (Four-Valve Head)
Push Rod — Cleaning and Inspection (4045) (Four-Valve Head)
Push Rod — Installation (4045) (Four-Valve Head)
Push Rod — Removal (4045) (Four-Valve Head)
Glow Plug — Installation (4045) (Four-Valve Head)
Glow Plug — Removal (4045) (Four-Valve Head)
Glow Plug Bore — Cleaning and Inspection (4045) (Four-Valve Head)
Rocker Arm Cover Baffle — Installation (4045) (Four-Valve Head)
Rocker Arm Cover Baffle — Removal (4045) (Four-Valve Head)
Rocker Arm Cover — Installation (4045) (Four-Valve Head)
Rocker Arm Cover — Removal (4045) (Four-Valve Head)
Rocker Arm Shaft Assembly — Tear Down (4045) (Four-Valve Head)
Rocker Arm Shaft Assembly — Inspection (4045) (Four-Valve Head)
Rocker Arm Shaft Assembly — Assemble (4045) (Four-Valve Head)
Rocker Arm Shaft Assembly — Installation (4045) (Four-Valve Head)
Rocker Arm Shaft Assembly — Removal (4045) (Four-Valve Head)
Rocker Arm Shaft Carrier Assembly — Installation (External Fuel Leak-Off System) (4045) (Four-Valve Head)
Rocker Arm Shaft Carrier Assembly — Installation (Internal Fuel Leak-Off System) (4045) (Four-Valve Head)
Rocker Arm Shaft Carrier Assembly — Removal (4045) (Four-Valve Head)
Rocker Arm Shaft Carrier — Inspection (4045) (Four-Valve Head)
Valve — Cleaning and Visual Inspection (4045) (Four-Valve Head)
Valve — Clearance Adjustment (4045) (Four-Valve Head)
Valve — Grinding (4045) (Four-Valve Head)
Valve — Measurement (4045) (Four-Valve Head)
Valve — Recess Measurement (4045) (Four-Valve Head)
Valve Assembly — Installation (4045) (Four-Valve Head)
Valve Assembly — Removal (4045) (Four-Valve Head)
Valve Guide — Cleaning (4045) (Four-Valve Head)
Valve Guide — Measurement (4045) (Four-Valve Head)
Valve Guide — Knurling (4045) (Four-Valve Head)
Valve Keeper, Valve Bridges, and Valve Rotator — Inspection (4045) (Four-Valve Head)
Valve Seat — Cleaning and Inspection (4045) (Four-Valve Head)
Valve Seat — Grinding and Measurement (4045) (Four-Valve Head)
Valve Seat Inserts — Installation (4045) (Four-Valve Head)
Valve Seat Inserts — Removal (4045) (Four-Valve Head)
Valve Spring — Inspection and Measurement (4045) (Four-Valve Head)
Group 030: Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment (4045)
Connecting Rod — Center-to-Center Bore Measurement (4045)
Connecting Rod — General Information (4045)
Connecting Rod and Cap — Inspection (4045)
Connecting Rod Bearing — Inspection and Measurement (4045)
Connecting Rod Bearing — Inspection and Measurement (Rod and Crankshaft in Engine) (4045)
Connecting Rod Cap Screw — Torque Procedure (4045)
Connecting Rod Pin Bore — Cleaning and Inspection (4045)
Connecting Rod Piston Pin Bushing — Installation (4045)
Connecting Rod Piston Pin Bushing — Removal (4045)
Cylinder Block — Inspection and Plug Installation (4045)
Cylinder Block Components — Measurement (4045)
Cylinder Block O-Ring — Installation (4045)
Cylinder Liner — Cleaning (4045)
Cylinder Liner — Installation (4045)
Cylinder Liner — Removal (4045)
Cylinder Liner — Standout Measurement (4045)
Cylinder Liner — Visual Inspection (4045)
Cylinder Liner Flange — Measurement (4045)
Cylinder Liner O-Ring Bore — Cleaning (4045)
Cylinder Liner Packing — Installation (4045)
Piston — Cleaning (4045)
Piston — Visual Inspection (4045)
Piston and Connecting Rod Assembly — Assemble (4045)
Piston and Connecting Rod Assembly — Installation (4045)
Piston and Connecting Rod Assembly — Removal (4045)
Piston and Connecting Rod Assembly — Tear Down (4045)
Piston — Height Measurement (4045)
Piston — Protrusion Measurement (4045)
Piston Pin Bore — Measurement (4045)
Piston Pin — Inspection (4045)
Piston Rings — Installation (4045)
Piston Skirt — Measurement (4045)
Piston Spray Jet — Cleaning and Inspection (4045)
Piston Spray Jet — Installation (4045)
Piston Spray Jet — Removal (4045)
Piston to Cylinder Liner — Clearance Check (4045)
Group 040: Crankshaft, Main Bearings, and Flywheel Repair and Adjustment (4045)
Crankshaft — End Play Check (4045)
Crankshaft — Grinding Specifications (4045)
Crankshaft — Inspection (4045)
Crankshaft — Installation (4045)
Crankshaft — Removal (4045)
Crankshaft Gear — Installation (4045)
Crankshaft Gear — Removal (4045)
Crankshaft Grinding — Guidelines (4045)
Crankshaft Journal and Main Bearing — Measurement (4045)
Crankshaft Main Bearing Cap — Removal (4045)
Crankshaft Main Bearing Cap — Line Bore Specification (4045)
Crankshaft Main Bearing Cap — Oil Clearance Check (4045)
Crankshaft Pulley — Removal (4045)
Crankshaft Pulley — Installation (4045)
Crankshaft Pulley — Removal (Add-On Pulley Capable) (4045)
Crankshaft Pulley — Installation (Add-On Pulley Capable) (4045)
Crankshaft Rear Oil Seal — Installation (4045)
Crankshaft Rear Oil Seal — Removal (4045)
Crankshaft Front Oil Seal — Installation (4045)
Crankshaft Front Oil Seal — Removal (4045)
Crankshaft Thrust Bearing — Inspection (4045)
Crankshaft Timing Wheel — Installation (4045)
Crankshaft Timing Wheel — Removal (4045)
Flywheel — Inspection (4045)
Flywheel — Installation (4045)
Flywheel — Removal (4045)
Flywheel Face — Flatness Check (4045)
Flywheel Housing — Installation (4045)
Flywheel Housing — Removal (4045)
Flywheel Pilot Bearing Bore — Concentricity Check (4045)
Flywheel Ring Gear — Installation (4045)
Flywheel Ring Gear — Removal (4045)
Flywheel Sleeve — Installation (4045)
Flywheel Sleeve — Removal (4045)
Group 050: Camshaft, Balancing Shaft and Timing Gear Train Repair and Adjustment (4045)
Balancer Shaft — Installation (4045)
Balancer Shaft — Measure End Play (4045)
Balancer Shaft — Removal (4045)
Balancer Shaft — Visual Inspection and Measurement (4045)
Balancer Shaft and Lower Idler Gear — Timing (4045)
Balancer Shaft Bushing — Installation (4045)
Balancer Shaft Bushing — Removal (4045)
Balancer Shaft Gear — Check and Replace Components (4045)
Balancer Shaft Thrust Plate — Measure Clearance and Thickness (4045)
Balancer Shaft Weight — Installation (4045)
Balancer Shaft Weight — Removal (4045)
Camshaft — Installation (4045)
Camshaft — Measure End Play (4045)
Camshaft — Removal (4045)
Camshaft — Visual Inspection (4045)
Camshaft and Upper Idler Gear — Timing (4045)
Camshaft Bushing — Installation (4045)
Camshaft Bushing Journal #1 — Measurement (4045)
Camshaft Bushing — Removal (4045)
Camshaft Follower — Inspection and Measurement (4045)
Camshaft Follower — Installation (4045)
Camshaft Follower — Removal (4045)
Camshaft Gear — Inspection (4045)
Camshaft Gear-Driven Auxiliary Drive — Installation (4045)
Camshaft Gear-Driven Auxiliary Drive — Removal (4045)
Camshaft Journal — Measurement (4045)
Camshaft Lobe — Lift Measurement (4045)
Camshaft Thrust Plate — Measure Clearance and Thickness (4045)
Camshaft and Fuel Injection Pump — Timing (4045)
Front Plate — Installation (4045)
Front Plate — Removal (4045)
Idler Gears — Measure End Play (4045)
Idler Gear Bushing — Removal (4045)
Idler Gear Bushing — Installation (4045)
Idler Shaft Spring Pin — Installation (4045)
Lower Idler Gear — Check and Replace Components (4045)
Lower Idler Gear — Installation (4045)
Lower Idler Gear — Removal (4045)
Lower Idler Shaft — Installation (4045)
Lower Idler Shaft — Removal (4045)
Timing Gear Cover — Installation (4045)
Timing Gear Cover — Removal (4045)
Timing Gears — Check Backlash (4045)
Upper Idler Gear — Check and Replace Components (4045)
Upper Idler Gear — Installation (4045)
Upper Idler Gear — Removal (4045)
Group 060: Lubrication System Repair and Adjustment (4045)
Open Crankcase Ventilation System — Installation (4045)
Open Crankcase Ventilation System — Removal (4045)
Closed Crankcase Ventilation System — Inspection (4045)
Closed Crankcase Ventilation System — Installation (4045)
Closed Crankcase Ventilation System — Removal (4045)
Dipstick Tube and Dipstick — Installation (4045)
Dipstick Tube and Dipstick — Removal (4045)
Oil Cooler Assembly — Installation (4045)
Oil Cooler Assembly — Removal and Inspection (4045)
Oil Cooler Coolant Adapter — Removal (4045)
Oil Cooler Coolant Adapter — Installation (4045)
Oil Fill Adapter — Installation (4045)
Oil Fill Adapter — Removal (4045)
Oil Fill Adapter Cover Plate — Installation (4045)
Oil Fill Adapter Cover Plate — Removal (4045)
Oil Filter Bypass Valve — Installation (4045)
Oil Filter Bypass Valve — Removal (4045)
Oil Filter Header — Installation (4045)
Oil Filter Header — Removal (4045)
Oil Pan — Installation (4045)
Oil Pan — Removal (4045)
Oil Pump and Tube — Installation (4045)
Oil Pump and Tube — Removal (4045)
Oil Pick-Up Tube — Installation (4045)
Oil Pick-Up Tube — Removal (4045)
Oil Pressure Regulating Valve — Installation (Old Version) (4045)
Oil Pressure Regulating Valve — Removal (Old Version) (4045)
Oil Pressure Regulating Valve — Installation (New Version) (4045)
Oil Pressure Regulating Valve — Removal (New Version) (4045)
Open Crankcase Ventilation System — Inspection (4045)
Group 070: Cooling System Repair and Adjustment (4045)
Belt — Wear Check (4045)
Belt Tensioner — Adjustment (4045)
Belt Tensioner — Installation (4045)
Belt Tensioner — Removal (4045)
Belt Tensioner — Spring Tension Check (4045)
Cold Start Advance Switch — Servicing (4045)
Coolant Heater — Servicing (4045)
Coolant Pump Assembly — Assemble (4045)
Coolant Pump Assembly — Disassembly (4045)
Coolant Pump Assembly — Installation (4045)
Coolant Pump Assembly — Removal (4045)
Coolant Pump Inlet Adapter — Installation (4045)
Coolant Pump Inlet Adapter — Removal (4045)
Coolant Pump Pulley — Installation (4045)
Coolant Pump Pulley — Removal (4045)
Coolant Pump — Visual Inspection (4045)
Cooling System — Air Bleeding (4045)
Fan Drive Assembly — Installation (4045)
Fan Drive Assembly — Removal and Inspection (4045)
Fan Drive Idler Pulley — Installation (4045)
Fan Drive Idler Pulley — Removal (4045)
Fan Drive Pulley — Installation (4045)
Fan Drive Pulley — Removal (4045)
Fan (Fixed Speed Fan) — Inspection and Installation (4045)
Fan (Fixed Speed Fan) — Removal (4045)
Thermostat and Cover — Installation (4045)
Thermostat and Cover — Removal (4045)
Group 080: Air Intake and Exhaust System Repair and Adjustment (4045)
Air Heater — Servicing (4045)
Air Inlet and Mixing Sleeve — Installation (4045)
Air Inlet and Mixing Sleeve — Removal (4045)
EGR Cooler Assembly — Installation (4045)
EGR Cooler Assembly — Removal (4045)
EGR Cooler Coolant Inlet Tube — Installation (4045)
EGR Cooler Coolant Inlet Tube — Removal (4045)
EGR Cooler Gas Outlet Tube — Installation (4045)
EGR Cooler Gas Outlet Tube — Removal (4045)
Exhaust Manifold — Installation (4045)
Exhaust Manifold — Removal (4045)
Extending Turbocharger Life (4045)
Intake Manifold — Installation (4045)
Intake Manifold — Removal (4045)
Turbocharger — Break-In (4045)
Turbocharger — Recommendations for Use (4045)
Turbocharger — Inspection (4045)
Turbocharger — Failure Analysis (4045)
Turbocharger — Installation (4045)
Turbocharger — Removal (4045)
Turbocharger Oil Drain Line — Installation (4045)
Turbocharger Oil Drain Line — Removal (4045)
Turbocharger Oil Supply Line — Installation (4045)
Turbocharger Oil Supply Line — Removal (4045)
VGT Actuator Coolant Return Line — Installation (4045)
VGT Actuator Coolant Return Line — Removal (4045)
VGT Actuator Coolant Supply Line — Installation (4045)
VGT Actuator Coolant Supply Line — Removal (4045)
Group 090: Electronic Fuel System Repair and Adjustment (4045)
Fuel System (4045)
Group 100: OEM Starting and Charging Systems Repair and Adjustment (4045)
Alternator — Installation (4045)
Alternator — Removal (4045)
Starter Motor — Installation (4045)
Starter Motor — Removal (4045)
Section 02B: Repair and Adjustments (6 Cylinder Engine)
Group 010: Engine Rebuild (6068)
Check Air Intake System (6068)
Check and Service Cooling System (6068)
Check Crankcase Vent System (6068)
Check Electrical System (6068)
Check Exhaust System (6068)
Clean Engine (6068)
Engine Break-In Guidelines (6068)
Engine Overhaul Guidelines (6068)
General Tune-Up Recommendations (6068)
Engine Repair Stand (6068)
Install JT07268 Engine Mounting Adapter to D05223ST Repair Stand (6068)
Install JDG11853 Engine Mounting Adapter to D05223ST Repair Stand (6068)
Lift Straps — Installation (6068)
Lift Straps — Removal (6068)
Lifting Procedure (6068)
Mount Engine to Repair Stand Using JT07268 (6068)
Mount Engine to Repair Stand Using JDG11853 (6068)
Safety Precautions (6068)
Sealant Application Guidelines (6068)
Group 020: Cylinder Head and Valve Repair and Adjustment (6068) (Two-Valve Head Engines)
Cylinder Block Top Deck — Cleaning and Inspection (6068) (Two-Valve Head)
Cylinder Head — Cleaning and Inspection (6068) (Two-Valve Head)
Cylinder Head — Flatness Check (6068) (Two-Valve Head)
Cylinder Head — Installation (6068) (Two-Valve Head)
Cylinder Head — Removal (6068) (Two-Valve Head)
Cylinder Head — Thickness Measurement (6068) (Two-Valve Head)
Cylinder Head Gasket — Inspection (6068) (Two-Valve Head)
Fuel Injector Heat Shield — Installation (6068) (Two-Valve Head)
Fuel Injector Heat Shield — Removal (6068) (Two-Valve Head)
Fuel Injector Sleeves — Installation (6068) (Two-Valve Head)
Fuel Injector Sleeves — Removal (6068) (Two-Valve Head)
Fuel Supply Pump Push Rod — Installation (6068) (Two-Valve Head)
Fuel Supply Pump Push Rod — Measurement (6068) (Two-Valve Head)
Fuel Supply Pump Push Rod — Removal (6068) (Two-Valve Head)
Push Rod — Cleaning and Inspection (6068) (Two-Valve Head)
Push Rod — Installation (6068) (Two-Valve Head)
Push Rod — Removal (6068) (Two-Valve Head)
Rocker Arm Cover Baffle — Installation (6068) (Two-Valve Head)
Rocker Arm Cover Baffle — Removal (6068) (Two-Valve Head)
Rocker Arm Cover — Installation (6068) (Two-Valve Head)
Rocker Arm Cover — Removal (6068) (Two-Valve Head)
Rocker Arm Shaft Assembly — Tear Down (6068) (Two-Valve Head)
Rocker Arm Shaft Assembly — Inspection (6068) (Two-Valve Head)
Rocker Arm Shaft Assembly — Assemble (6068) (Two-Valve Head)
Rocker Arm Shaft Assembly — Installation (6068) (Two-Valve Head)
Rocker Arm Shaft Assembly — Removal (6068) (Two-Valve Head)
Valve — Cleaning and Visual Inspection (6068) (Two-Valve Head)
Valve — Clearance Adjustment (6068) (Two-Valve Head)
Valve — Grinding (6068) (Two-Valve Head)
Valve — Measurement (6068) (Two-Valve Head)
Valve — Recess Measurement (6068) (Two-Valve Head)
Valve Assembly — Installation (6068) (Two-Valve Head)
Valve Assembly — Removal (6068) (Two-Valve Head)
Valve Guide — Cleaning (6068) (Two-Valve Head)
Valve Guide — Measurement (6068) (Two-Valve Head)
Valve Guide — Knurling (6068) (Two-Valve Head)
Valve Keeper, Rocker Arm Insert, and Valve Rotator — Inspection (6068) (Two-Valve Head)
Valve Seat — Cleaning and Inspection (6068) (Two-Valve Head)
Valve Seat — Grinding and Measurement (6068) (Two-Valve Head)
Valve Seat Inserts — Installation (6068) (Two-Valve Head)
Valve Seat Inserts — Removal (6068) (Two-Valve Head)
Valve Spring — Inspection and Measurement (6068) (Two-Valve Head)
Group 021: Cylinder Head and Valve Repair and Adjustment (6068) (Four-Valve Head Engines)
Cylinder Block Top Deck — Cleaning and Inspection (6068) (Four-Valve Head)
Cylinder Head — Cleaning and Inspection (6068) (Four-Valve Head)
Cylinder Head — Flatness Check (6068) (Four-Valve Head)
Cylinder Head — Installation (6068) (Four-Valve Head)
Cylinder Head — Removal (6068) (Four-Valve Head)
Cylinder Head — Thickness Measurement (6068) (Four-Valve Head)
Cylinder Head Gasket — Inspection (6068) (Four-Valve Head)
Fuel Leak-Off Line Heat Shield — Installation (6068) (Four-Valve Head)
Fuel Leak-Off Line Heat Shield — Removal (6068) (Four-Valve Head)
Fuel Injector Sleeves — Installation (6068) (Four-Valve Head)
Fuel Injector Sleeves — Removal (6068) (Four-Valve Head)
Fuel Supply Pump Push Rod — Installation (6068) (Four-Valve Head)
Fuel Supply Pump Push Rod — Measurement (6068) (Four-Valve Head)
Fuel Supply Pump Push Rod — Removal (6068) (Four-Valve Head)
Push Rod — Cleaning and Inspection (6068) (Four-Valve Head)
Push Rod — Installation (6068) (Four-Valve Head)
Push Rod — Removal (6068) (Four-Valve Head)
Glow Plug — Installation (6068) (Four-Valve Head)
Glow Plug — Removal (6068) (Four-Valve Head)
Glow Plug Bore — Cleaning and Inspection (6068) (Four-Valve Head)
Rocker Arm Cover Baffle — Installation (6068) (Four-Valve Head)
Rocker Arm Cover Baffle — Removal (6068) (Four-Valve Head)
Rocker Arm Cover — Installation (6068) (Four-Valve Head)
Rocker Arm Cover — Removal (6068) (Four-Valve Head)
Rocker Arm Shaft and Components — Tear Down (6068) (Four-Valve Head)
Rocker Arm Shaft Assembly — Inspection (6068) (Four-Valve Head)
Rocker Arm Shaft Assembly — Assemble (6068) (Four-Valve Head)
Rocker Arm Shaft Assembly — Installation (6068) (Four-Valve Head)
Rocker Arm Shaft Assembly — Removal (6068) (Four-Valve Head)
Rocker Arm Shaft Carrier — Installation (External Fuel Leak-Off System) (6068) (Four-Valve Head)
Rocker Arm Shaft Carrier Assembly — Installation (Internal Fuel Leak-Off System) (6068) (Four-Valve Head)
Rocker Arm Shaft Carrier — Removal (6068) (Four-Valve Head)
Rocker Arm Shaft Carrier — Inspection (6068) (Four-Valve Head)
Valve — Cleaning and Visual Inspection (6068) (Four-Valve Head)
Valve — Clearance Adjustment (6068) (Four-Valve Head)
Valve — Grinding (6068) (Four-Valve Head)
Valve — Measurement (6068) (Four-Valve Head)
Valve — Recess Measurement (6068) (Four-Valve Head)
Valve Assembly — Installation (6068) (Four-Valve Head)
Valve Assembly — Removal (6068) (Four-Valve Head)
Valve Guide — Cleaning (6068) (Four-Valve Head)
Valve Guide — Measurement (6068) (Four-Valve Head)
Valve Guide — Knurling (6068) (Four-Valve Head)
Valve Keeper, Valve Bridges, and Valve Rotator — Inspection (6068) (Four-Valve Head)
Valve Seat — Cleaning and Inspection (6068) (Four-Valve Head)
Valve Seat — Grinding and Measurement (6068) (Four-Valve Head)
Valve Seat Inserts — Installation (6068) (Four-Valve Head)
Valve Seat Inserts — Removal (6068) (Four-Valve Head)
Valve Spring — Inspection and Measurement (6068) (Four-Valve Head)
Group 030: Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment (6068)
Connecting Rod — Center-to-Center Bore Measurement (6068)
Connecting Rod — General Information (6068)
Connecting Rod and Cap — Inspection (6068)
Connecting Rod Bearing — Inspection and Measurement (6068)
Connecting Rod Bearing — Inspection and Measurement (Rod and Crankshaft in Engine) (6068)
Connecting Rod Cap Screw — Torque Procedure (6068)
Connecting Rod Pin Bore — Cleaning and Inspection (6068)
Connecting Rod Piston Pin Bushing — Installation (6068)
Connecting Rod Piston Pin Bushing — Removal (6068)
Cylinder Block — Inspection and Plug Installation (6068)
Cylinder Block Components — Measurement (6068)
Cylinder Block O-Ring — Installation (6068)
Cylinder Liner — Cleaning (6068)
Cylinder Liner — Installation (6068)
Cylinder Liner — Removal (6068)
Cylinder Liner — Standout Measurement (6068)
Cylinder Liner — Visual Inspection (6068)
Cylinder Liner Flange — Measurement (6068)
Cylinder Liner O-Ring Bore — Cleaning (6068)
Cylinder Liner Packing — Installation (6068)
Piston — Cleaning (6068)
Piston — Visual Inspection (6068)
Piston and Connecting Rod Assembly — Assemble (6068)
Piston and Connecting Rod Assembly — Installation (6068)
Piston and Connecting Rod Assembly — Removal (6068)
Piston and Connecting Rod Assembly — Tear Down (6068)
Piston — Height Measurement (6068)
Piston — Protrusion Measurement (6068)
Piston Pin Bore — Measurement (6068)
Piston Pin — Inspection (6068)
Piston Rings — Installation (6068)
Piston Skirt — Measurement (6068)
Piston Spray Jet — Cleaning and Inspection (6068)
Piston Spray Jet — Installation (6068)
Piston Spray Jet — Removal (6068)
Piston to Cylinder Liner — Clearance Check (6068)
Group 040: Crankshaft, Main Bearings, and Flywheel Repair and Adjustment (6068)
Crankshaft — End Play Check (6068)
Crankshaft — Grinding Specifications (6068)
Crankshaft — Installation (6068)
Crankshaft — Inspection (6068)
Crankshaft — Removal (6068)
Crankshaft Gear — Installation (6068)
Crankshaft Gear — Removal (6068)
Crankshaft Grinding — Guidelines (6068)
Crankshaft Journal and Main Bearing — Measurement (6068)
Crankshaft Main Bearing Cap — Removal (6068)
Crankshaft Main Bearing Cap — Line Bore Specification (6068)
Crankshaft Main Bearing — Oil Clearance Check (6068)
Crankshaft Vibration Damper — Installation (6068)
Crankshaft Vibration Damper — Removal (6068)
Crankshaft Vibration Damper — Inspection (6068)
Crankshaft Vibration Damper Add-On Pulley — Installation (6068)
Crankshaft Vibration Damper Add-On Pulley — Removal (6068)
Crankshaft Rear Oil Seal — Installation (6068)
Crankshaft Rear Oil Seal — Removal (6068)
Crankshaft Front Oil Seal — Installation (6068)
Crankshaft Front Oil Seal — Removal (6068)
Crankshaft Thrust Bearing — Inspection (6068)
Crankshaft Timing Wheel — Installation (6068)
Crankshaft Timing Wheel — Removal (6068)
Flywheel — Installation (6068)
Flywheel — Inspection (6068)
Flywheel — Removal (6068)
Flywheel Face — Flatness Check (6068)
Flywheel Housing — Installation (6068)
Flywheel Housing — Removal (6068)
Flywheel Pilot Bearing Bore — Concentricity Check (6068)
Flywheel Ring Gear — Installation (6068)
Flywheel Ring Gear — Removal (6068)
Flywheel Sleeve — Installation (6068)
Flywheel Sleeve — Removal (6068)
Group 050: Camshaft and Timing Gear Train Repair and Adjustment (6068)
Camshaft — Installation (6068)
Camshaft — Measure End Play (6068)
Camshaft — Removal (6068)
Camshaft — Visual Inspection (6068)
Camshaft and Upper Idler Gear — Timing (6068)
Camshaft Bushing — Installation (6068)
Camshaft Bushing Journal #1 — Measurement (6068)
Camshaft Bushing — Removal (6068)
Camshaft Follower — Inspection and Measurement (6068)
Camshaft Follower — Installation (6068)
Camshaft Follower — Removal (6068)
Camshaft Gear — Inspection (6068)
Camshaft Gear-Driven Auxiliary Drive — Removal (6068)
Camshaft Gear-Driven Auxiliary Drive — Installation (6068)
Camshaft Journal — Measurement (6068)
Camshaft Lobe — Lift Measurement (6068)
Camshaft Thrust Plate — Measure Clearance and Thickness (6068)
Camshaft and Fuel Pump — Timing (6068)
Front Plate — Installation (6068)
Front Plate — Removal (6068)
Idler Gears — Measure End Play (6068)
Idler Gear Bushing — Removal (6068)
Idler Gear Bushing — Installation (6068)
Idler Shaft Spring Pin — Installation (6068)
Lower Idler Gear — Check and Replace Components (6068)
Lower Idler Gear — Installation (6068)
Lower Idler Gear — Removal (6068)
Timing Gear Cover — Installation (6068)
Timing Gear Cover — Removal (6068)
Timing Gears — Check Backlash (6068)
Upper Idler Gear — Check and Replace Components (6068)
Upper Idler Gear — Removal (6068)
Upper Idler Gear — Installation (6068)
Group 060: Lubrication System Repair and Adjustment (6068)
Open Crankcase Ventilation System — Installation (6068)
Open Crankcase Ventilation System — Removal (6068)
Crankcase Vent Hose — Installation (6068)
Crankcase Vent Hose — Removal (6068)
Dipstick Tube and Dipstick — Installation (6068)
Dipstick Tube and Dipstick — Removal (6068)
Oil Cooler Assembly — Installation (6068)
Oil Cooler Assembly — Removal and Inspection (6068)
Oil Fill Adapter — Removal (6068)
Oil Fill Adapter — Installation (6068)
Oil Filter Bypass Valve — Installation (6068)
Oil Filter Bypass Valve — Removal (6068)
Oil Filter Header — Installation (6068)
Oil Filter Header — Removal (6068)
Oil Pan — Installation (6068)
Oil Pan — Removal (6068)
Oil Pump and Tube — Installation (6068)
Oil Pump and Tube — Removal (6068)
Oil Pick-up Tube — Installation (6068)
Oil Pick-Up Tube — Removal (6068)
Oil Pressure Regulating Valve — Installation (Old Version) (6068)
Oil Pressure Regulating Valve — Removal (Old Version) (6068)
Oil Pressure Regulating Valve — Installation (New Version) (6068)
Oil Pressure Regulating Valve — Removal (New Version) (6068)
Open Crankcase Ventilation Hose — Inspection (6068)
Group 070: Cooling System Repair and Adjustment (6068)
Belt — Wear Check (6068)
Belt Tensioner — Adjustment (6068)
Belt Tensioner — Installation (6068)
Belt Tensioner — Removal (6068)
Belt Tensioner — Spring Tension Check (6068)
Cold Start Advance Switch — Servicing (6068)
Coolant Heater — Servicing (6068)
Coolant Pump Assembly — Assemble (6068)
Coolant Pump Assembly — Disassemble (6068)
Coolant Pump Assembly — Installation (6068)
Coolant Pump Assembly — Removal (6068)
Coolant Pump Inlet Adapter — Installation (6068)
Coolant Pump Inlet Adapter — Removal (6068)
Coolant Pump Pulley — Installation (6068)
Coolant Pump Pulley — Removal (6068)
Coolant Pump — Visual Inspection (6068)
Cooling System — Air Bleeding (6068)
Fan Drive Assembly — Installation (6068)
Fan Drive Assembly — Removal and Inspection (6068)
Fan Drive Pulley — Installation (6068)
Fan Drive Pulley — Removal (6068)
Fan (Fixed Speed Fan) — Inspection and Installation (6068)
Fan (Fixed Speed Fan) — Removal (6068)
Thermostat and Cover — Installation (6068)
Thermostat and Cover — Removal (6068)
Group 080: Air Intake and Exhaust System Repair and Adjustment (6068)
Air Heater — Servicing (6068)
Air Inlet and Mixing Sleeve — Installation (6068)
Air Inlet and Mixing Sleeve — Removal (6068)
EGR Cooler Assembly — Installation (6068)
EGR Cooler Assembly — Removal (6068)
EGR Cooler Coolant Inlet Tube — Installation (6068)
EGR Cooler Coolant Inlet Tube — Removal (6068)
EGR Cooler Gas Outlet Tube — Installation (6068)
EGR Cooler Gas Outlet Tube — Removal (6068)
Exhaust Manifold — Installation (6068)
Exhaust Manifold — Removal (6068)
Extending Turbocharger Life (6068)
Intake Manifold — Installation (6068)
Intake Manifold — Removal (6068)
Turbocharger — Break-In (6068)
Turbocharger — Recommendations for Use (6068)
Turbocharger — Inspection (6068)
Turbocharger — Failure Analysis (6068)
Turbocharger — Installation (6068)
Turbocharger — Removal (6068)
Turbocharger Oil Drain Line — Installation (6068)
Turbocharger Oil Drain Line — Removal (6068)
Turbocharger Oil Supply Line — Installation (6068)
Turbocharger Oil Supply Line — Removal (6068)
VGT Actuator Coolant Return Line — Installation (6068)
VGT Actuator Coolant Return Line — Removal (6068)
VGT Actuator Coolant Supply Line — Installation (6068)
VGT Actuator Coolant Supply Line — Removal (6068)
Group 090: Electronic Fuel System Repair and Adjustment (6068)
Fuel System (6068)
Group 100: OEM Starting and Charging Systems Repair and Adjustment (6068)
Alternator — Installation (6068)
Alternator — Removal (6068)
Starter Motor — Installation (6068)
Starter Motor — Removal (6068)
Section 03: Base Engine Theory of Operation
Group 120: Base Engine Operation
General Engine Operation
Head Gasket Joint Construction and Operation
Group 123: Cooling System
Cooling System Operation
Group 126: Lubrication System
Lubrication System Operation
Group 130: Electronic Fuel System
Electronic Fuel System Operation
Group 135: Air Intake and Exhaust System
Air Intake and Exhaust System Operation
Section 04: Diagnostics
Group 150: Observable Diagnostics and Tests
About This Section of the Manual
4.5L/6.8L — L1 — Excessive Oil Consumption
4.5L/6.8L — L2 — Engine Oil Pressure Low
4.5L/6.8L — L3 — Engine Oil Pressure High
4.5L/6.8L — L4 — Soot or Sludge in Oil
4.5L/6.8L — C1 — Engine Coolant Temperature Above Normal
4.5L/6.8L — C2 — Engine Coolant Temperature Below Normal
4.5L/6.8L — C3 — Coolant in Oil or Oil in Coolant
4.5L/6.8L — C4 — Coolant Leaking from Weep Hole
Test Engine Compression Pressure
Test Engine Cranking Speed
Engine Oil Consumption
Check Engine Oil Pressure
Check for Excessive Engine Crankcase Pressure (Blow-By) (Base Pressure)
Check for Turbocharger Oil Seal Leak
Inspect Thermostat and Test Opening Temperature
Cooling System Pressure Test
Pressure Test EGR Cooler for Air Leaks
Check for Head Gasket Failures
Check and Service Cooling System
Check Air Intake System
Measure Intake Manifold Pressure (Turbocharger Boost for Tier 3/Stage IIIA Engines)
Measure Intake Manifold Pressure (Turbocharger Boost/Power Check)
Check for Intake and Exhaust Restrictions
Test for Intake Air Leaks
Check for Exhaust Air Leaks (Turbocharged Engines)
Turbocharger Wastegate Check
Excessive Engine Vibration
Section 05: Tools and Other Materials
Group 170: Special Tools
75240
D01045AA
D01061AA
D01062AA
D01168AA
D01200AA
D01218AA
D01300AA
D05012ST-A
D05022ST
D05104ST
D05223ST
D05226ST
D15001NU
D17015BR
D17024BR
D17525CI
D17526CI
D17527CI
DFRG9
DFRG11
DFRG14
DFRG15
DFYZ49
FKM10002
JD244
JD248A
JD249
JD252
JD254A
JD286
JDE81-4
JDE83
JDE85
JDE88
JDE138
JDE41296
JDG22
JDG23
JDG451
JDG536
JDG537
JDG576
JDG675
JDG676
JDG678
JDG680
JDG698A
JDG738-2
JDG739B
JDG739-1
JDG739-3
JDG739-4
JDG739-5B
JDG739-7
JDG739-8
JDG782A
JDG791A
JDG820
JDG839
JDG886
JDG953
JDG953-1
JDG953-2
JDG954B
JDG954-1B
JDG954-2
JDG954-3
JDG954-4
JDG954-5
JDG954-6
JDG954-7
JDG954-8
JDG956
JDG963
JDG965
JDG966
JDG992-1
JDG992-2
JDG1069
JDG1145
JDG1146
JDG1341
JDG1517
JDG1517-1
JDG1517-2
JDG1520
JDG1559
JDG1571
JDG1649A
JDG1651
JDG1653
JDG1653-1
JDG1653-2
JDG1923A
JDG2047A
JDG2047AP1
JDG2074A
JDG10539A
JDG10576
JDG10631
JDG10824
JDG11064
JDG11065A
JDG11205
JDG11413
JDG11853
JDG11864
JT01674A
JT05470
JT05697A
JT07268
JT07336
JT30040B
JT30041A
JT30042
KCD10001
KJD10123
KJD10140
KJD10213
KJD10233
Group 180: Lubricants, Sealants, and Other Materials
Other Materials
Section 06: Specifications
Group 200: Repair and General OEM Specifications
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Cylinder Head and Valves Specifications (Two-Valve Head)
Cylinder Head and Valves Specifications (Four-Valve Head)
Cylinder Block, Liners, Pistons, and Rods Specifications
Crankshaft, Main Bearings, and Flywheel Specifications
Camshaft, Balancer Shafts, and Timing Gear Train Specifications
Lubrication System Specifications
Cooling System Specifications
Air Intake and Exhaust System Specifications
Starting and Charging System Specifications
John Deere PowerTech 4.5L & 6.8L Diesel Engines Base Engine Component Technical Manual (CTM104)