John Deere PowerTech 2.4L 3.0L Engine Components Technical Manual CTM301

[Martin Welker]

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John Deere PowerTech 2.4L 3.0L Engine Components Technical Manual CTM301
Size: 3.93 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Engine
Type of Manual: Components Technical Manual
Model: John Deere PowerTech 2.4L 3.0L Engine
Part Number: CTM301
Publication Date: 2005
Number of Pages: 420 Pages

Contents:
General Information
Safety
Handle Fluids Safely—Avoid Fires
Handle Starting Fluid Safely
Prevent Bypass Starting
Service Cooling System Safely
DO NOT USE Starting Fluids
Prepare for Emergencies
Prevent Battery Explosions
Prevent Acid Burns
Handling Batteries Safely
Avoid High-Pressure Fluids
Wear Protective Clothing
Service Machines Safely
Work In Ventilated Area
Work in Clean Area
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Illuminate Work Area Safely
Use Proper Lifting Equipment
Construct Dealer-Made Tools Safely
Practice Safe Maintenance
Use Proper Tools
Dispose of Waste Properly
Live With Safety
Engine Identification
Engine Model Designation
PowerTech™ Medallion
Engine Serial Number Plate
Record Engine Serial Number
OEM Engine Option Code Label
Engine Application Chart
Fuels, Lubricants, and Coolant
Diesel Fuel
Lubricity of Diesel Fuel
Diesel Fuel Storage
Bio-Diesel Fuel
Handling And Storing Bio-Diesel Fuel
Dieselscan Fuel Analysis
Filling Fuel Tank
Minimizing the Effect of Cold Weather on Diesel Engines
Diesel Engine Break-In Oil
Diesel Engine Oil
Extended Diesel Engine Oil Service Intervals
Mixing of Lubricants
Oil Filters
OILSCAN®and COOLSCAN™
Alternative and Synthetic Lubricants
Lubricant Storage
Grease
Diesel Engine Coolant
Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives
Testing Diesel Engine Coolant
Supplemental Coolant Additives
Operating in Warm Temperature Climates
Disposing of Coolant
Repair and Adjustments
Engine Rebuild
Engine Overhaul Guidelines
Engine Repair Stand
Engine Stand Safety Precautions
Install Adapters on Engine Repair Stand
Engine Lifting Procedure
Clean Engine
Disconnect Turbocharger Oil Inlet Line
Mount Engine on Repair Stand
Engine Disassembly Sequence
Engine Assembly Sequence
Engine Break-In Guidelines
Perform Engine Break-In
Cylinder Head and Valves
Cylinder Head - Exploded View
Remove Rocker Arm Cover
Remove Cylinder Head
Disassemble and Inspect Rocker Arm Assembly
Inspect, Remove, and Install Glow Plugs and Wire Harness
Measure Valve Recess in Cylinder Head
Preliminary Cylinder Head and Valve Checks
Remove Valve Assembly
Inspect and Measure Valve Springs
Clean Valves
Inspect and Measure Valves
Grind Valves
Head Gasket Inspection and Repair Sequence
Inspect and Clean Cylinder Head
Check Cylinder Head Flatness
Knurl Valve Guides
Clean and Inspect Valve Seats
Grind Valve Seats
Install Valves
Inspect Cylinder Head Cap Screws
Inspect and Clean Exhaust Manifold
Install Cylinder Head (4-Cylinder)
Install Cylinder Head (5-Cylinder)
Install Rocker Arm Assembly
Cylinder Block, Pistons, and Rods
Connecting Rods—General Information
Preliminary Cylinder Block, Pistons, and Rod Checks
Remove Pistons and Connecting Rod Assembly
Disassemble Piston and Rod Assembly
Clean Pistons
Visually Inspect Pistons
Check Piston Ring Groove Wear
Measure Piston Pin Bore
Measure Piston Skirt
Measure Piston Height
Determine Piston-to-Cylinder Bore Clearance
Deglaze Cylinder Bores
Rebore Cylinder Bores
Inspect and Measure Connecting Rod Bearings (Rods Removed from Engine)
Inspect and Measure Connecting Rod Bearings (Rod and Crankshaft in Engine)
Inspect Rod and Cap
Inspect Piston Pins and Bushings
Measure Rod Center-to-Center Bores
Inspect and Clean Cylinder Block
Measure Cylinder Block Main Bearing Bore
Measure Camshaft Follower Machined Bore
Measure Camshaft Bushing Bores in Block
Inspect and Measure Cylinder Bore
Measure Cylinder Block Top Deck Flatness
Remove, Inspect, and Install Piston Cooling Orifices
Assemble Piston and Connecting Rod
Install Piston Rings
Install Piston and Connecting Rod Assembly
Torque-Turn Connecting Rod Cap Screws
Check Engine Rotation for Excessive Tightness
Measure Piston Protrusion - Locate TDC
Complete Final Assembly
Crankshaft, Main Bearings and Flywheel
Crankshaft and Main Bearing Failure Analysis
Inspect Vibration Damper (If Equipped)
Remove Crankshaft Pulley/Damper
Inspect Pulley and Wear Sleeve
Replace Front Crankshaft Oil Seal (Without Removing Timing Gear Cover)
Install Crankshaft Pulley/Damper
Check Crankshaft End Play
Inspect Flywheel
Check Flywheel Face Flatness
Check Pilot Bearing Bore Concentricity
Remove Flywheel
Replace Flywheel Ring Gear
Remove Flywheel Housing
Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions
Remove Crankshaft Rear Oil Seal and Housing
Clean and Inspect Crankshaft Flange
Install Crankshaft Rear Oil Seal Housing
Install Crankshaft Rear Oil Seal
Remove Crankshaft Main Bearings
Check Main Bearing Oil Clearance
Remove Crankshaft
Inspect Crankshaft
Measure Crankshaft Journals and Main Bearing ID
Crankshaft Grinding Guidelines
Crankshaft Grinding Specifications
Measure Main Thrust Journal Width and Thrust Washers
Measure Assembled ID of Main Bearing Caps
Install Main Bearings, Thrust Washers and Crankshaft
Install Flywheel Housing
Install Flywheel
Camshaft, Balancer Shafts and Timing Gear Train
Remove Timing Gear Cover
Remove Balancer Shafts (If Equipped)
Inspect and Measure Balancer Shaft Bushings and Journals
Inspect Balancer Shaft Gears and Thrust Plates
Remove, Inspect and Install Balancer Idler Gears and Shafts (If Equipped)
Measure Idler Gear Bushing and Shaft
Remove Balancer Bushings
Install Balancer Bushings
Install Balancer Shafts (If Equipped)
Remove Governor Assembly and Camshaft Drive Gear
Remove Camshaft
Inspect Camshaft
Inspect and Measure Camshaft Bushing ID and Journal OD
Remove and Install Camshaft Bushings
Measure Camshaft Lobe Height
Inspect Camshaft Followers
Install Camshaft
Time Camshaft
Install Governor Assembly
Clean and Inspect Timing Gear Cover
Install Timing Gear Cover
Lubrication System
General Lubrication System Information
Remove and Install Cold Start Advance Valve
Remove Oil Cooler
Install Oil Cooler
Remove and Install Oil Pan
Remove and Install Oil Pressure Regulating Valve
Remove, Inspect, and Install Oil Pick-up Tube Assembly
Remove and Inspect Oil Pump
Install Oil Pump
Remove and Install Oil Dipstick Tube with Oil Pan Installed
Cooling System
Remove and Install Thermostat
Replacing Fan and Alternator Belt
Remove and Install Automatic (Spring) Belt Tensioner
Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner)
Remove Coolant Pump
Inspect and Clean Coolant Pump Parts
Install Coolant Pump
Cooling System Deaeration
Inspect and Install Fan Assembly
Remove Fan Bearing Serial Number (— 0010609)
Install Fan Bearing Serial Number (— 0010609)
Remove and Install Fan Bearing Serial Number (0010609 —)
Air Intake and Exhaust System
Extending Turbocharger Life
Remove Turbocharger
Turbocharger Failure Analysis
Turbocharger Inspection
Repair Turbocharger
Prelube Turbocharger
Install Turbocharger
Remove, Inspect, and Install Exhaust Manifold
Remove, Inspect, and Install Intake Manifold
Fuel System
Remove and Install Fuel Supply Pump
Remove and Install Injection Nozzles
Remove and Inspect Injection Pump Units
Measure Fuel Control Rack Travel
Install and Synchronize Injection Pump Units
Install Electronic Governor Coupler
Install Electronic Governor
Adjust Electronic Governor Actuator Arm
Install Speed Sensor
Remove and Install Fuel Rail Check Valve
Change Main Governor Spring
Change Low Idle Bumper Spring
Remove and Install Governor Lever Assembly
Remove and Install Throttle Control Assembly
Remove and Install Full Load Stop Screw
Remove and Install Idle Bias Adjustment Screw
Remove and Install Fuel Shut-Off Solenoid
Remove and Install Aneroid
Starting and Charging Systems
Remove and Install Starter
Remove and Install Alternator
Theory of Operation
Base Engine Operation
General Engine Operation
Lubrication System Operation
Coolant System Operation
Air Intake and Exhaust System Operation
Air Cleaner Operation
Turbocharger Operation
Turbocharger Lubrication
Fuel/Governor System Operation
Fuel System Operation
Fuel Supply Pump
Fuel Filter/Water Separator Operation
Governor Operation
Electronic Governor
Integrated Fuel System (IFS) Operation
Light Load and Speed Advance Operation
Cold Start Advance Operation
Glow Plug Cold Start Aid Operation
Diagnostics
Base Engine Observable Diagnostics and Tests
About This Group of the Manual
Guideline for Acceptable Oil Consumption
L1 - Excessive Oil Consumption

L2 - Engine Oil Pressure Low
L3 - Engine Oil Pressure High
C1 - Engine Coolant Temperature Above Normal
C2 - Engine Coolant Temperature Below Normal
C3 - Coolant in Oil or Oil in Coolant
A2 - Glow Plug Check
Test Engine Compression Pressure
Test Engine Cranking Speed
Dynamometer Test
Engine Oil Consumption
Check Engine Oil Pressure
Check for Excessive Engine Crankcase Pressure (Blow-By)
Check for Turbocharger Oil Seal Leak
Inspect Thermostat and Test Opening Temperature
Pressure Test Cooling System and Radiator Cap
Check for Head Gasket Failures
Check and Service Cooling System
Check Air Intake System
Measure Intake Manifold Pressure (Turbocharger Boost)
Check for Intake and Exhaust Restrictions
Test for Intake Air Leaks
Check for Exhaust Air Leaks (Turbocharged Engines)
Test Turbocharger Wastegate
Glow Plug Operation
Test Fuel Shutoff Solenoid
Cylinder Misfire Test
Fuel System Observable Diagnostics and Tests
E1 - Engine Cranks/Won't Start
E1 - Engine Cranks/Won't Start Diagnostic Procedure
E2 - Engine Misfires/Runs Irregularly
E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure
E3 - Engine Does Not Develop Full Power
E3 - Engine Does Not Develop Full Power Diagnostic Procedure
E4 - Engine Emits Excessive White Exhaust Smoke
E4 - Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure
E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke
E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke Diagnostic Procedure
E6 - Engine Will Not Crank
E7 - Engine Idles Poorly
E8 - Abnormal Engine Noise
F1 - Fuel Supply System Check
F1 - Fuel Supply System Check Diagnostic Procedure
F2 - Excessive Fuel Consumption
F3 - Fuel in Oil
Check Fuel Supply Quality
Test for Fuel Drain Back
Test Air in Fuel
Bleed the Fuel System
Check for Restricted Fuel Return Line
Measure Fuel Transfer Pump Pressure
Bench Test Fuel Transfer Pump
Check Cold Start Advance Operation
Check Fuel Shut-Off Solenoid Operation
Check and Adjust Fast Idle Speed
Check and Adjust Slow Idle Speed
Governor Adjustment
Disable Fuel Control Rack Magnet
Fuel Control Rack Magnet Adjustment
Check Engine Power
Adjust Engine Power
Test Cylinder Misfire
Electronic Controller Diagnostics and Tests
About this Group of the Manual
Electrical Concepts
Using a Digital Multimeter
Electrical Circuit Malfunctions
Troubleshooting Circuit Malfunctions
Engine Control Unit (ECU) Wiring
Connecting Parameter Setup Tool (PST)
Parameter Reference
Viewing and Modifying ECU Parameters
Reprogramming the ECU
Electronic Governor Calibration
LED Status Indicators
Electronically Controlled Governor System Diagnostics
Tools and Other Materials
Repair Tools and Other Materials
Engine Rebuild Essential Tools
Engine Rebuild Service Equipment and Tools
Group 020 — Cylinder Head and Valves Essential Tools
Group 020 — Cylinder Head and Valves Service Equipment and Tools
Group 020 — Cylinder Head and Valves Other Materials
Group 030 — Cylinder Block, Liners, Pistons, and Rods Essential Tools
Group 040 — Crankshaft, Main Bearings and Flywheel Essential Tools
Group 040 — Crankshaft, Main Bearings and Flywheel Service Equipment and Tools
Group 040 — Crankshaft, Main Bearings and Flywheel Other Materials
Group 050 — Camshaft and Timing Gear Train Essential Tools
Group 060 — Lubrication System Essential Tools
Group 090 — Fuel Injection System Essential Tools
Diagnostic Service Tools
Base Engine Diagnostic Tools
Fuel System Observable Diagnostic Tools
Dealer Fabricated Service Tools
How to Make Tools
DFRG7 — Notched Screwdriver Spring Tool
Specifications
Repair and General OEM Specifications
General OEM Engine Specifications—2.4 L Engines
General OEM Engine Specifications—3.0 L Engines
Engine Power Rating and Speed Specifications
Engine Crankcase Oil Fill Quantities
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Engine Rebuild Specifications
Cylinder Head and Valves Specifications
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 Systems Specifications
Fuel System
Diagnostic Specifications
Intake Manifold Pressure (Turbocharger Boost) Specifications
Electronic Governor Specifications
Page Numbers