John Deere PowerTech 4.5L 6.8L Engine Components Technical Manual CTM104

[Martin Welker]

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John Deere PowerTech 4.5L 6.8L Engine Components Technical Manual CTM104
Size: 20.70 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Engine
Type of Manual: Components Technical Manual
Model: John Deere PowerTech 4.5L 6.8L Engine
Part Number: CTM104
Publication Date: 2012
Number of Pages: 626 Pages

Contents:
General Information
Safety
Work In Ventilated Area
Recognize Safety Information
Work in Clean Area
Dispose of Waste Properly
Avoid Harmful Asbestos Dust
Handle Fuel Safely—Avoid Fires
Prepare for Emergencies
Handle Starting Fluid Safely
Handle Fluids Safely—Avoid Fires
Avoid High-Pressure Fluids
Use Proper Lifting Equipment
Illuminate Work Area Safely
Live With Safety
Service Machines Safely
Handle Chemical Products Safely
Protect Against Noise
Remove Paint Before Welding or Heating
Stay Clear of Rotating Drivelines
Service Cooling System Safely
Follow Safety Instructions
Use Proper Tools
Construct Dealer-Made Tools Safely
Practice Safe Maintenance
Understand Signal Words
Replace Safety Signs
Prevent Battery Explosions
Protect Against High Pressure Spray
Avoid Heating Near Pressurized Fluid Lines
Wear Protective Clothing
Wait Before Opening High-Pressure Fuel System
Handle Agricultural Chemicals Safely
Handling Batteries Safely
Install All Guards
Avoid Hot Exhaust
Engine Identification and Application Charts
Engine Serial Number Plate Information
OEM Engine Option Code Label
Information Relative to Emissions Regulations
Fuels, Lubricants and Coolants
Diesel Fuel
Diesel Fuel Additive Products
Biodiesel Fuel
Minimizing the Effect of Cold Weather on Diesel Engines
Handling and Storing Diesel Fuel
Lubricity of Diesel Fuel
Testing Diesel Fuel
Oil Information for Uncertified or Tier 1 Engines
Diesel Engine Oil
Oil Information for Tier 2 Engines
Diesel Engine Oil
Oil Information for Tier 3 Engines
Diesel Engine Oil
Diesel Engine Break-In Oil
Oil Filters
Grease
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Heavy Duty Diesel Engine Coolant
Supplemental Coolant Additives
Operating in Warm Temperature Climates
Additional Information About Diesel Engine Coolants and John Dee
Diesel Engine Coolant
Testing Diesel Engine Coolant
Drain Intervals for Diesel Engine 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 Mounted on Repair Stand
Engine Disassembly Sequence
Sealant Application Guidelines
Engine Assembly Sequence
Engine Break-In Guidelines
Perform Engine Break-In
Cylinder Head and Valves (Two-Valve Head Engines)
General Information
Check and Adjust Valve Clearance
Measure Valve Lift
Remove Cylinder Head
Disassemble and Inspect Rocker Arm Shaft Assembly
Assemble Rocker Arm Assembly
Inspect, Measure, and Install Fuel Supply Pump Push Rod (If Appl
Inspect, Measure, and Assemble Camshaft Followers
Measure Valve Recess in Cylinder Head
Preliminary Cylinder Head and Valve Checks
Remove Valve Assembly
Inspect and Measure Valve Springs
Inspect Valve Rotators
Clean Valves
Inspect and Measure Valves
Grind Valves
Head Gasket Inspection and Repair Sequence
Inspect and Clean Cylinder Head
Check Cylinder Head Flatness
Measure Cylinder Head Thickness
Remove Fuel Injector Sleeves (2-Valve Head Engines with HPCR Fue
Remove Fuel Injector Sleeves (2-Valve Head Engines with HPCR Fue
Install Fuel Injector Sleeves (2-Valve Head Engines with HPCR Fu
Clean Valve Guides
Measure Valve Guides
Knurl Valve Guides
Clean and Inspect Valve Seats
Grind Valve Seats
Remove Valve Seat Inserts
Measure Valve Seat Bore in Cylinder Head
Install Valve Seat Inserts
Install Valves
Inspect Cylinder Head Cap Screws
Inspect and Clean Exhaust Manifold
Clean and Inspect Top Deck of Cylinder Block
Check Cylinder Liner Standout (Height Above Block)
Install Cylinder Head
Torque-Turn Method for Proper Torque
Install Rocker Arm Assembly
Inspect and Clean Ventilator Outlet Hose
Remove, Inspect, and Install Closed Crankcase Ventilation System
Install Rocker Arm Cover
Complete Final Assembly
Cylinder Head and Valves (Four-Valve Head Engines)
General Information
Check and Adjust Valve Clearance
Measure Valve Lift
Do Not Open High-Pressure Fuel System
Remove Cylinder Head
Inspect and Measure Valve Bridges
Disassemble and Inspect Rocker Arm Shaft Assembly
Assemble Rocker Arm Shaft
Inspect, Measure, and Install Fuel Supply Pump Push Rod
Inspect, Measure, and Assemble Camshaft Followers
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
Measure Cylinder Head Thickness
Remove Fuel Injector Sleeves (4-Valve Head Engines with HPCR Fue
Clean Fuel Injector Bores
Install Fuel Injector Sleeves
Clean Glow Plug Bores
Clean Valve Guides
Measure Valve Guides
Knurl Valve Guides
Clean and Inspect Valve Seats
Grind Valve Seats
Remove Valve Seat Inserts
Measure Valve Seat Bore in Cylinder Head
Install Valve Seat Inserts
Install Valves
Inspect Cylinder Head Cap Screws
Inspect and Clean Exhaust Manifold
Clean and Inspect Top Deck of Cylinder Block
Check Cylinder Liner Standout (Height Above Block) — Four-Valve
Install Cylinder Head
Torque-Turn Method for Proper Torque
Install Fuel Injectors
Install Injector Leak-Off Fittings (External fuel Leak-off syste
Install Glow Plugs
Install Rocker Arm Carrier (External fuel leak-off system)
Install Rocker Arm Carrier (Internal fuel leak-off system)
Install Rocker Arm Shaft Assembly
Inspect and Clean Ventilator Outlet Hose
Remove, Inspect, and Install Closed Crankcase Ventilation System
Install Rocker Arm Cover
Complete Final Assembly
Cylinder Block, Liners, Pistons and Rods
Connecting Rods—General Information
Remove Pistons and Connecting Rods
Remove Cylinder Liners
Complete Disassembly of Cylinder Block (If Required)
Preliminary Liner, Piston and Rod Checks
Disassemble Piston and Rod Assembly
Clean Pistons
Visually Inspect Pistons
Clean Cylinder Liners
Visually Inspect Cylinder Liners
Check Piston Ring Groove Wear
Measure Piston Pin Bore
Measure Piston Skirt
Measure Piston Height
Determine Piston-to-Liner Clearance
Deglaze Cylinder Liners
Replace Piston and Liner Sets
Inspect and Measure Connecting Rod Bearings (Rods Removed from E
Connecting Rod Bearings — Inspection and Measurement (Rod and Cr
Inspect Rod and Cap
Inspect Piston Pins and Bushings
Remove Piston Pin Bushing
Clean and Inspect Connecting Rod Pin Bore
Install Piston Pin Bushing in Connecting Rod
Measure Rod Center-to-Center Bores
Inspect and Clean Cylinder Block
Clean Cylinder Liner O-Ring Bore
Measure Cylinder Block Main Bearing Bore
Measure Camshaft Follower Machined Bore in Block
Measure Camshaft Bushing Bores in Block
Measure Balancer Shaft Bushing ID in Block (4-Cylinder Engines)
Measure Cylinder Liners and Block Bores
Measure Liner Flange Counterbore Depth in Block
Measure Liner Flange Thickness
Measure Cylinder Block Top Deck Flatness
Remove, Inspect, and Install Piston Cooling Orifices
Measure Fuel Supply Pump Push Rod Bore and Push Rod OD
Measure and Adjust Cylinder Liner Standout (Height Above Block)
Install Packing on Cylinder Liner and O-Rings in Block
Install Cylinder Liner in Block
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
Complete Final Assembly
Crankshaft, Main Bearings and Flywheel
Crankshaft and Main Bearing Failure Analysis
Inspect Vibration Damper (6.8 L Engines)
Remove Pulley or Vibration Damper and Pulley
Install Pulley or Vibration Damper and Pulley
Replace Front Crankshaft Oil Seal and Wear Sleeve
Check Crankshaft End Play
Inspect Flywheel
Check Flywheel Face Flatness
Check Pilot Bearing Bore Concentricity
Remove Flywheel
Replace Flywheel Ring Gear
Replace Pilot Bearing in Flywheel (If Equipped)
Replace Sleeve in Flywheel (If Equipped)
Install Flywheel
Install Flywheel Adapter on CD6068HT480 Engine
Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions
Remove Crankshaft Rear Oil Seal and Wear Sleeve
Clean and Inspect Crankshaft Flange
Install Crankshaft Rear Oil Seal and Wear Sleeve
Remove Flywheel Housing
Remove and Install Crankshaft Timing Wheel (If Equipped)
Remove Crankshaft Main Bearings
Check Main Bearing Oil Clearance
Remove and Install Crankshaft Gear (Crankshaft Installed in Engi
Remove Crankshaft
Inspect Crankshaft
Measure Crankshaft Journals and Main Bearing ID
Measure Main Thrust Journal Width and Thrust Bearing Width
Crankshaft Grinding Guidelines
Crankshaft Grinding Specifications
Measure Assembled ID of Main Bearing Caps
Install Main and Thrust Bearing Inserts in Block
Install Crankshaft
Install Flywheel Housing
Complete Final Assembly
Camshaft, Balancer Shafts and Timing Gear Train
Remove Timing Gear Cover
Remove and Install Camshaft Bushing with Front Plate Installed
Remove and Install Camshaft Gear-Driven Auxiliary Drive
Measure Camshaft End Play
Measure Balancer Shaft End Play (If Equipped—4-Cylinder Engines)
Measure Idler Gear End Play
Measure Timing Gear Backlash
Remove Camshaft
Visually Inspect Camshaft
Measure Camshaft Thrust Plate Clearance and Thickness
Inspect and Measure Camshaft Bushing ID and Journal OD
Measure Camshaft Lobe Height
Inspect Camshaft Gear
Inspect Camshaft Followers
Inspect, Measure, and Install Fuel Supply Pump Push Rod
Remove Balancer Shafts (If Equipped—4-Cylinder Engines)
Inspect and Measure Balancer Shaft Bushings and Journals
Remove and Install Balancer Shaft Bushings
Inspect Balancer Shaft Gears and Thrust Plates
Remove and Install Balancer Shaft Gears
Remove Cylinder Block Front Plate
Measure Idler Gear Bushing and Shaft
Remove Idler Gear Bushings
Install Idler Gear Bushings
Remove Lower and Upper Idler Shafts
Clean and Inspect Front Plate
Transfer Fuel Injection Pump Timing Mark onto Replacement Front
Install Idler Shaft Spring Pins (If Equipped)
Install Upper Idler Shaft in Front Plate
Install Lower Idler Shaft in Front Plate
Install Cylinder Block Front Plate
Install and Time Balancer Shafts (If Equipped—4-Cylinder Engines
Install Camshaft
Time Camshaft and Fuel Injection Pump (Non-HPCR Engines)
Install Upper Idler Gear (Non-HPCR Engines)
Time Camshaft and Install Upper Idler Gear (4-Valve and HPCR/2-V
Clean and Inspect Timing Gear Cover
Timing Gear Cover Gaskets
Install Timing Gear Cover
Remove and Install Magnetic Pick-Up Sensor
Complete Final Assembly
Lubrication System
General Lubrication System Information
Remove, Inspect, and Install Oil Filter Base
Remove, Inspect, and Install Oil Cooler
Remove, Inspect, and Install Oil Bypass Valve
Remove and Install Oil Filter Bypass Valve (Extended-Life Filter
Remove and Install Oil Pressure Regulating Valve
Remove and Install Oil Fill Adapter
Remove and Install Dipstick Tube with Oil Pan Installed
Remove and Install Dipstick Tube with Fitting
Remove and Install Oil Fill Tube (if equipped)
Remove, Inspect, and Install Oil Pump Pick-Up Tube Assembly
Engine Oil Pump Assembly
Remove Engine Oil Pump
Inspect and Measure Clearances
Complete Oil Pump Disassembly
Assemble Engine Oil Pump
Install Engine Oil Pump
Install Oil Pan
Cooling System
Remove Coolant Manifold/Thermostat Cover and Thermostat
Install Coolant Manifold/Thermostat Cover and Thermostat
Remove and Install Coolant Manifold/Thermostat Cover and Thermos
Remove and Install Coolant Manifold and Thermostats (Dual Thermo
Remove and Install Coolant Manifold, Thermostats and Side Port (
Remove and Install Thermostat Cover and Thermostats (Engines wit
Test Thermostat(s)
Remove Coolant Pump
Coolant Pump Assembly
Disassemble Coolant Pump
Inspect, Clean, and Measure Coolant Pump Parts
Assemble Coolant Pump
Install Coolant Pump
Cooling System — De-aeration
Remove and Install Automatic (Spring) Belt Tensioner
Checking Belt Tensioner Spring Tension and Belt Wear
Manual Belt Tensioner Adjustment Using Belt Tension Gauge
Manual Belt Tensioner Adjustment Using Belt Tension Tool (Altern
Inspect and Install Fan Assembly
Remove and Inspect Fan Drive Assembly
Replace Bearings in Adjustable Fan Drive Assembly
Replace Bearings in Heavy-Duty, Adjustable Fan Drive Assembly
Install Fan Drive Assembly
Remove and Install Fan Drive Assembly (2254 Combine)
Remove and Install Coolant Heater (If Equipped)
Remove and Install Cold Start Advance Switch (If Equipped)
Air Intake and Exhaust System
Extending Turbocharger Life
Remove Turbocharger
Turbocharger Failure Analysis
Turbocharger Inspection
Perform Radial Bearing Clearance Test
Adjust Turbocharger Wastegate Actuator (If Equipped)
Remove and Install Variable Geometry Turbocharger Actuator (4-Cy
Remove and Install Variable Geometry Turbocharger Actuator (6-Cy
Remove and Install Turbocharger Actuator Linkage (6-Cylinder Eng
Remove and Install Turbocharger Turbine Housing (6-Cylinder Engi
Repair Turbocharger
Prelube Turbocharger
Install Turbocharger (with Spacer between Turbocharger and Exhau
Install Turbocharger (without Spacer between Turbocharger and Ex
Turbocharger Break-In
Recommendations for Turbocharger Use
Remove, Inspect, and Install Exhaust Manifold
Remove and Install Air-to-Air Aftercooler
Remove and Install EGR Exhaust Tube (Tier 3/Stage IIIA)
Remove and Install EGR Coolant Inlet Tube (Tier 3/Stage IIIA)
Remove and Install EGR Cooler (Tier 3/Stage IIIA)
Remove, Inspect, and Install EGR Valve (Tier 3/Stage IIIA)
Remove and Install Air Intake Pipe
Remove, Inspect, and Install Intake Manifold (Four-Valve Head)
Remove, Inspect, and Install Air Inlet and Mixing Sleeve (Tier 3
Remove, Inspect, and Install Intake Manifold (Tier 3/Stage IIIA)
Remove and Install Air Heater (If Equipped)
Remove and Install Starting Aid (If Equipped)
Fuel System
Fuel System
Starting and Charging Systems
Remove and Install Starter
Remove and Install Alternator
Theory of Operation
Base Engine Operation
Base Engine Theory of Operation
General Engine Operation
General Engine Operation—Continued
Lubrication System Operation
Cooling System Operation
Head Gasket Joint Construction and Operation
Air Intake and Exhaust System Operation
Air Cleaner Operation
Turbocharger Operation
Variable Geometry Turbocharger (VGT) Operation (Tier 3/Stage III
How the Turbocharger Is Lubricated
Diagnostics
Observable Diagnostics and Tests
About This Section of the Manual
Guideline for Acceptable Oil Consumption
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 - 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
Dynamometer Test
Engine Oil Consumption
Check Engine Oil Pressure
Check for Excessive Engine Crankcase Pressure (Blow-By) (Base Pr
Check for Turbocharger Oil Seal Leak
Inspect Thermostat and Test Opening Temperature
Pressure Test Cooling System and Radiator Cap
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/
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)
Test Turbocharger Wastegate
Test Air Filter Restriction Indicator Switch
Tools and Other Materials
Repair Tools and Other Materials
Engine Rebuild Essential Tools
Engine Rebuild Service Equipment and Tools
Engine Rebuild Other Materials
Cylinder Head and Valves Essential Tools (2-Valve Head, non-HPCR
Cylinder Head and Valves Service Equipment and Tools (2-Valve He
Other Material (Two-Valve Head)
Cylinder Head and Valves Essential Tools (4-Valve and HPCR/2-Val
Service Equipment and Tools (4-Valve and HPCR/2-Valve Head Engin
Other Material (4-Valve and HPCR/2-Valve Head Engines)
Cylinder Block, Liners, Pistons and Rods Essential Tools
Cylinder Block, Liners, Pistons and Rods Service Equipment and T
Cylinder Block, Liners, Pistons and Rods Other Materials
Crankshaft, Main Bearings, Damper and Flywheel Essential Tools
Crankshaft, Main Bearings and Flywheel Service Equipment and Too
Crankshaft, Main Bearings and Flywheel Other Materials
Camshaft, Balancer Shafts and Timing Gear Train Essential Tools
Camshaft, Balancer Shafts and Timing Gear Train Service Equipmen
Camshaft, Balancer Shafts and Timing Gear Train Other Materials
Lubrication System Essential Tools
Lubrication System Service Equipment and Tools
Lubrication System Other Materials
Cooling System Essential Tools
Cooling System Service Equipment and Tools
Cooling System Other Materials
Air Intake and Exhaust System Essential Tools
Air Intake and Exhaust System Other Materials
Starting and Charging System Essential Tools
Diagnostic Service Tools
Diagnostic Essential Tools
Diagnostic Service Equipment and Tools
Dealer Fabricated Service Tools
How to Make Tools
DFRG3—Cylinder Liner Holding Fixture
DFRG5—Injection Pump Front Plate Timing Mark Transfer Tool
Engine Oil Dipstick Tube Driver (6010—6910 Series Tractor Engine
Specifications
Repair and General OEM Specifications
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
General OEM Engine Specifications
Engine Rebuild Specifications
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 Systems Specifications
Diagnostic Specifications
Engine Diagnostic Specifications
Dynamometer Test Specifications
Power Ratings on Dynamometer for OEM Engines (4 Cyl.)
Power Ratings on Dynamometer for OEM Engines (6 Cyl.)
Intake Manifold Pressure (Turbocharger Boost) Specifications
Intake Manifold Pressure (Turbocharger Boost) Specifications (Co
Intake Manifold Pressure (Turbocharger Boost) Specifications (Co
Intake Manifold Pressure (Turbocharger Boost) Specifications (Co
Effects of Altitude and Temperature on Engine Performance
Page Number