Payment Conditions. Return and Refund Policy. Contact us. Quick Send E-Mail. All repair manual spare parts catalog Diagnostic Software Diagnostic adapter interface. Have something to exchange? If you have a catalog, that we do not have in our list, we would gladly discuss the details of exchange or purchase. Always release the overhead lifting equipment slowly. Carefully remove lift sling from engine. The following sequence is suggested when complete disassembly for overhaul is required.
Refer to the appropriate repair group when removing individual engine components. Drain all coolant and engine oil. Check engine oil for metal contaminates. Remove turbocharger oil inlet line. Remove fan pulley and water manifold assembly. Remove turbocharger exhaust elbow and connector. Remove turbocharger.
Remove rocker arm assembly and push rods. Identify parts for re-assembly. Remove alternator and mounting brackets.
Remove front crankshaft pulley and damper assembly. Remove fuel injection lines and injection nozzles. Remove engine oil filter and oil conditioning housing. Remove injection pump gear cover and remove injection pump. Remove fuel filter and mounting base.
On A Engines, remove aftercooler cover and aftercooler assembly. Remove exhaust manifold and air intake manifold. Remove turbocharger oil return line. Remove cylinder head with valve assembly. Remove head gasket. On SAE No. Roll engine over and remove oil pan and engine. Remove front timing gear cover.
Rotate engine to vertical position. Remove pistons and connecting rods. Identify for re-assembly. Remove main bearing caps. Remove crankshaft and main bearings. Remove camshaft and cam followers. Rotate engine and remove liners and their O-ring seals. Mark liners for reassembly in same bore from which removed.
Remove piston cooling orifices. Refer to appropriate group for inspection and repair of engine components. Listed below are sealants which have been tested and are used by the John Deere factory to control leakage and assure hardware retention. If excessive machine oil or poor cleanliness quality exist, clean with solvent. The following assembly sequence is suggested when engine has been completely disassembled.
Be sure to check run-out specifications, clearance tolerances, torques, etc. Refer to the appropriate repair group when assembling engine components. Install all plugs in cylinder block that were removed to service block.
Install engine serial number plate. Install clean piston cooling orifices. Install cylinder liners without O-rings and measure liner stand-out. Install liner O-rings in block and. NOTE: If new piston and liner kit assemblies are being installed, install the crankshaft first. Install main bearings and crankshaft. Rotate crankshaft to assure correct assembly.
Check crankshaft end play. Install engine oil pump assembly. Install crankshaft rear oil seal housing, oil seal, and wear sleeve. Install cam followers in hole from which originally removed.
Install camshaft. Align timing marks camshaft to crankshaft gears with No. Install fuel injection pump and drive gear. Install engine oil conditioning assembly, if removed.
Install cylinder head, push rods, and rocker arm assembly. Measure valve lift and adjust valve clearance. Install rocker arm cover. Install breather hose. Install exhaust manifold and water manifold. Install timing gear cover. Install front crankshaft wear sleeve and oil seal. Install air intake manifold. Install aftercooler assembly on A Engines. Install turbocharger with elbow and oil lines. Install injection nozzles and line assembly. Install front pulley and damper as an assembly.
Install alternator. Install fan pulley assembly. Install fuel filter base, supply lines, and filter. Fill engine with clean oil and the proper coolant. Install dipstick. Perform engine break-in and normal standard performance checks. Welcome to ManualMachine. We have sent a verification link to to complete your registration. Log In Sign Up. Forgot password? Enter your email address and check your inbox. Please check your email for further instructions. Enter a new password. John Deere.
John Deere Repair Manual Download for 1. Read each module completely before performing any service. Page Group 00—Safety Safety. Check and Adjust Valve Clearance. Check Valve Lift. Inspect and Measure Valve Springs. Clean Valves. Knurl Valve Guides. Clean and Inspect Valve Seats. Measure Valve Seats. All information, illustrations and specifications in this manual are based on 35 the latest information available at the time of publication.
The right is reserved to make changes at any time without notice. Cap Screws Check Piston Ring Groove Wear Measure Piston Skirt OD Measure Cylinder Liner ID Page Inspect Piston Pins and Bushings. Contents Page Page.
Housing Page Fan Belt Tension Specifications. How the Hydraulic Aneroid Activator Works. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. Do not charge a frozen battery; it may explode. Keep a first aid kit and fire extinguisher handy. These values can be asked by the factory for further investigations. To record bolt torque, proceed as follows:. NOTE: Do not turn crankshaft after removal of cylinder head until each liner has been secured with washer and cap screw.
Lift cylinder head from block. If cylinder head sticks, use a soft hammer to tap cylinder head. Do not use screw driver or prybar which can damage the sealing surface. Otherwise tool will get dull.
Release spring tension and remove valve rotator and valve spring. Mark each part so that it can be reassembled in the same position it was removed from. Check lengthwise, crosswise, and diagonally in several places. Specification Combustion face—Flatness Maxi New cylinder head—Thickness Refaced cylinder head—Minimum thickness Cylinder head combustion face— Surface finish Valve guide—Specification Cylinder head bore—Diameter Guide-to-valve stem—Clearance Wear tolerance Oversized valve stem—Specification 1st size—Diameter If valve guide-to-stem oil clearance exceeds the wear limit, 0.
Have valve guides reamed by a qualified workshop to assure the proper guide-to-stem clearance. If valve guide-to-stem oil clearance exceeds the wear limit, but is less than 0. However, installing oversize valve stems is preferred. Be sure, when valve guides are reamed that this groove is restored.
Use kit exactly as directed by the manufacturer. After knurling, ream valve guide to finished size to provide specified stem-to-guide clearance. Specification Valve seat—Width Maximum runout Check seat width and contact pattern between seat and valve with blueing.
If necessary lap the valve onto its seat using a lapping tool and lapping compound. Specification Intake Valve—Recess After lapping valve seat or remachining combustion face, install refaced or new valves in cylinder head and check valve recess A. Remove Valve Seat Inserts Valve seat inserts are made of sintered metal. Following methods, performed by experienced personnel or specialized workshop, can be used to remove inserts.
Using an Arc Welder 1. Protect the valve guide by installing a cap screw or dowel in guide to protect from weld spatter. Apply a thin bead of weld B around internal diameter of valve seat insert. Allow insert to cool and use a screwdriver C or similar tool and carefully pry insert from bore.
After removal of inserts, thoroughly clean area around valve seat bore and inspect for damage or cracks. Replace cylinder head as necessary. Machine insert according to valve seat bore specifications as shown, until a thin layer of material stays in cylinder head.
Exhaust valve seat—Specification Bore—Diameter Chamfer height Reference Depth Chamfer angle Maxi Intake valve seat—Specification Bore—Diameter Lap valve seats to maintain correct valve recess and valve to valve seat sealing.
Specification Intake valve insert—Outside diameter Exhaust valve insert—Outside diameter Thoroughly clean and inspect valves to help determine if they can be reused. Replace valves that are burned, cracked, eroded, or chipped. Specification Intake valve head—Diameter Exhaust valve head—Diameter Specification Intake Valve Stem—Diameter Exhaust Valve Stem—Diameter Check for valve face runout and bent valves.
Specification Valve Face—Maximum permissible runout Specification Valve face—Angle Replace if necessary. Specification Valve Spring Compression—Free length Load with spring compressed to 46 mm 1.
Load with spring compressed to Install Valves 1. Apply engine oil to valve stems and guides. Insert valves in head in same location as found during removal. NOTE: After having installed the valves, strike end of each valve three times with a soft mallet to ensure proper positioning of the keepers. Use compressed air to remove debris or any fluids from cap screw holes. Install new cylinder head gasket dry without sealant.
IMPORTANT: Without guide studs, the Viton O-ring attached to cylinder head gasket at rocker arm lube oil passage could be damaged when repositioning cylinder head on engine block to align cap screw holes. Install two guide studs in cylinder block at locating holes B.
NOTE: Always use new cap screws to install cylinder head. Dip new cap screws entirely in clean engine oil. Remove guide studs and install cap screws in all open bores. Tighten cap screws in sequence to the torque specified, beginning with No.
Cylinder head bolts—Specification 1st step—Torque Line scribe method:. JT Torque Angle Gauge. Place socket on cap screw so that first mark aligns with mark on cylinder head. Tighten in sequence all cap screws until second mark on socket aligns with mark on cylinder head. NOTE: The torque turn method eliminates the need to retorque the cylinder head bolts after the first hours of engine operation. However, valve clearance adjustment is still required. Disassembling and Checking Rocker Arm Shaft 1.
Remove plugs C and bowed washers F from rocker arm shaft. Slide springs, rocker arms and supports off rocker arm shaft, identifying their sequence for reassembly in the same order. Clean all parts with solvent and dry with compressed air. Check all parts for good condition. Rocker arm—Specification Shaft—Diameter Spring—Load at 46 mm 1. NOTE: If the rocker arm has been damaged by a valve failure, replace it together with the corresponding push rod, valve rotator and keepers.
In this case, when re-assembling this engine, use the R flanged head cap screws without washer. NOTE: Effective with following engine serial numbers, shaft A and cap screw D with washer E have been replaced by a new shaft and flanged head cap screws. Lubricate shaft, bores of rocker arms and supports. Slide springs, rocker arms and supports onto shaft. Assemble in the same order in which they were removed during disassembly.
Refer to appropriate Parts Catalog for more details. Some engines built after above engine serial numbers may have been assembled with the. Install bowed washers F and new plugs C on shaft. Lubricate the rocker arms with engine oil.
Tighten attaching cap screws to specifications. Specification Rocker arm support cap screw— Torque Specification Intake Valve—Clearance Exhaust Valve—Clearance Adjust valve clearance on No. Specification Valve clearance—Firing order Specification Rocker arm cover cap screw— Torque Install the cap screws by hand and tighten to specifications, starting from center and moving towards both front and rear ends of the cover. Clean cover sealing ring groove with acetone and dry with compressed air.
Install new sealing ring with grease in cover groove. Cut the sealing ring slightly longer than necessary. Put the sealing ring ends edge to edge then press the sealing ring all along the groove to ensure proper installation.
Re-install parts previously removed. Check crankcase vent tube hose A for proper condition. When re-installing, be sure that the hose is not pinched. Earlier engines have the traditional tongue-and-groove between the connecting rod body and cap A. Then a precision mandrel in the rod bore is powered to separate the cap from the body at the joints C.
Never scrape these surfaces with a wire brush or other tool. The extra grooves are not used. Install cap and rod with tangs to same side. Once bolts have been tightened to final torque, they must not be reused. Do not mix hardware. Torque procedure is identical to the conventional connecting rod.
Do not. Specification Cylinder Liner Bore—Diameter Maximum wear Maximum taper Maximum out-of-round Compare liner measurements with piston skirt diameter. Specification Piston-to-cylinder liner— Clearance, measured at bottom of skirt Place cylinder liners in a suitable clamping device. Follow instructions supplied with tool to obtain 45 degree crosshatch pattern.
NOTE: After deglazing, clean cylinder liner bore with a mixture of warm water and soap. Rinse with clear water until rinse water is clear. Dry with clean towels and coat bore with clean engine oil. Cylinder Block Cleaning 1. Remove liner O-rings from cylinder block. Clean block with cleaning solvent or pressure steam. Make sure all passages and openings are free from sludge, rust and grease.
Reinstall jets and tighten to specifications. Specification Piston cooling jet—Torque NOTE: A cooling jet failure could cause damage to pistons, piston pins, rod pin bushings and liners.
If diameter is more than specified, install a new cylinder block. Service bushings are not available through service parts. Specification Cam Follower Bore—Diameter Maximum clearance Camshaft bore—Specification Without bushing—Diameter For bushing installation No. With bushing installed No. If only diameter of No. In other cases, install a new cylinder block. Slide bushing onto driver so notched end A of bushing will be toward front end of engine when installed. If diameter is more than specified or bearing cap is damaged, replace all caps and line bore to specifications.
After having positioned block on a boring machine, bore new bearing caps to below specified diameter. Take care to remain within the specified dimension A crankshaft bore center line to block top face. NOTE: Service bearing caps are supplied with unfinished bore undersized radius Specification Crankshaft main bearing bores— Diameter Distance with block top face A Measure cylinder block top desk flatness using a precision straightedge.
If flatness is not as specified, resurface cylinder block according to specifications below:. Specification Top Desk—Out-of Flat for every mm 5.
Surface finish CLA Liner counterbore—Depth A Install liner without packing or O-rings. If liner does not rotate smoothy by hand, remove liner and polish lower pilot bore in block with emery cloth or DBR brush.
Align liner and cylinder block marks, then secure at four points with cap screws and thick washers appro. Specification Liner—Protrusion Maximum permissible difference between adjacent cylinders Specification CD Liner shim—Thickness R Liner shim—Thickness If protrusion is below specifications, install one liner shim A under liner flange. Two sizes of shims are available as specified.
If liner protrusion or permissible difference is above specifications, apply lapping compound to liner flange shoulder in the block. Install liner then, using KCD special tool, turn to left and right to rub off enough material to seat liner as necessary.
If liner requires more than one shim, install either a new liner or cylinder block. Specification Liner packing—Minimum dimension for proper compression Apply lubricating soap to new packing and install over liner until it contacts liner shoulder. Liner packing must be compressed to the minimum specified. Install O-rings in respective grooves. The 0. On liners with 0. If clearance is not within specifications, grind crankshaft journals to match undersized bearings specified.
Specification Connecting rod cap screw— Torque Specification Undersized connecting rod bearing—1st Size Specification Connecting rod bearing assembled —Diameter Crankshaft journal—Diameter Maximum permissible clearance Remove connecting rod cap.
Install cap and tighten cap screws according to specifications. Pin to bushing oil clearance NOTE: D engines are equipped with straight pin-end connecting rods while T engines receive the tapered pin-end conrods. If diameter or oil clearance are more than specified, replace bushing. Connecting rod bushing—Specification D—Bore diameter When bushing need to be replaced, bring connecting rod, pin and the new bushing to a specialized workshop for replacing and boring bushing to obtain the specified oil clearance and positioning.
Specification Connecting rod bushing D —Bore diameter Oil clearance Bore-to-bore Distance A Turn driver until taper on driver flange matches up with taper on bushing. Install receiver cup JDG onto opposite side of rod bushing. NOTE: Stud in cup keeps rod properly located on the cup. Use JDG pilot ring B as a hollow spacer when pressing bushing out of rod. Using hydraulic press, push bushing out of rod until driver and bushing fall into receiver cup.
Apply TY grease1 to:. Insert driver into rod pin bore so pilot ring pilots in rod bore and bushing taper aligns with taper on driver flange. Align oil hole in bushing D with oil hole in end of rod E. Install JDG receiver cup F onto opposite side of rod so taper on rod aligns with taper on receiver cup. Press bushing into rod until edge of bushing is flush machined surface on connecting rod face.
If holes are not aligned, remove and discard bushing then re-install a NEW bushing. DO NOT attempt to reuse a bushing. Have the new bushing reamed by a specialized workshop to obtain the specified oil clearance and positioning. Specification Connecting rod bushing T —Bore diameter Piston pin—Specification D—Diameter Clean pistons, using a commercial cleaner and a jet rinse gun or glass bead blasting machine.
NOTE: Do not attempt to stamp top of piston. Distance from top of piston and top of first ring is 4 mm 0. Piston pin bore—Specification D—Diameter NOTE: Some piston pin bores are elliptical, the width being 0.
Specification 2nd and 3rd Piston ring groove— Clearance Measure piston diameter 11 mm 0. Specification Piston skirt—Diameter at 11 mm 0. Piston-to-cylinder liner— Clearance Use KJD or any other suitable piston ring expander for a proper installation and to prevent any damage to the piston. Install oil control ring C in bottom ring groove over ring expander.
Be sure that the ring expander and the wire are correctly fitted. Install top ring A in top ring groove. Top ring can be identified by a blue paint mark E. Install second ring B in center ring groove.
Second ring can be identified by a yellow paint mark F. NOTE: Liner, piston ring set and liner seal set are available separately. Before to open the bag, be sure that the parts will be installed immediately to prevent any risk of getting corroded parts. NOTE: Pistons must be installed on connecting rods from which they were removed.
Push piston out of liner bottom only far enough to install piston pin. The long side of the connecting rod should face camshaft side of block. Coat piston pin B with engine oil and insert it through piston and connecting rod bores.
Install NEW piston pin retaining rings C with sharp edge of ring facing away from piston pin. Make sure retaining rings are seated correctly in their grooves. Coat pistons and rings with clean engine oil. Install pistons in liners, using JDE84 piston ring compressor. Push piston down until top ring is in liner. Cylinder Block, Liners, Pistons and Rods 3. Install bearing insert in connecting rod with tang A in groove B.
Apply clean engine oil on insert and crankshaft journal. Carefully place connecting rod against crankshaft journal. The extra grooves C are not used. Apply clean engine oil to bearing insert. Install cap on connecting rod with tangs A to same side. Once bolts have been tightened to final torque-turn specification, they must not be reused for another final assembly.
DO NOT mix hardware. Specification Connecting rod bolts—Torque Check for proper side clearance in all rods. Each rod must have a slight side-to-side movement. Place KJD Gauge with flat side up on cylinder block so that indicator point rests on block surface.
Piston protrusion should not exceed 0. Accidental slippage may result in personal injury. Attach JDG23 engine lifting sling A , or other suitable sling, to JD engine lifting eyes B and hoist the engine using a lifting device. NOTE: Use of an engine lifting sling as shown is the preferred method for lifting engines. However, if a sling is not on hand, engine can be lifted by chain s attached to lifting eyes and lifting device.
Cap or plug all openings on engine. If electrical components starting motor, alternator, etc Steam-clean engine thoroughly. To do so may cause seizure of pump parts. Failure to do so may cause a hydraulic lock upon starting engine. Hydraulic lock may cause severe engine damage.
Hydraulic lock occurs when trapped oil in the oil filter housing drains through the turbocharger, the exhaust and intake manifolds, and then into the cylinder head. After starting the engine, the trapped oil in the manifold and head is released into the cylinders filling them with oil causing hydraulic lock and severe engine damage. The following sequence is suggested when complete disassembly for overhaul is required. Refer to the appropriate repair group when removing individual engine components.
Drain all coolant and engine oil. Check engine oil for metal contaminates see Groups 25 and Remove fan belts, fan, and alternator see Group Remove turbocharger if equipped and exhaust manifold see Group Remove rocker arm cover with vent tube. On engines having an Option Code label on rocker arm cover, be careful not to damage label see. Remove water manifold with thermostats see Group Remove oil cooler piping and water pump see Groups 25 and Remove dipstick, oil filter, and engine oil cooler.
Discard standard-flow oil cooler if oil contained metal particles see Group Remove oil pressure regulating valve assembly see Group Remove fuel filter, fuel transfer pump, and fuel lines see Group Remove injection lines, injection pump, and injection nozzles see Group Remove rocker arm assembly and push rods.
Keep rods in sequence see Group Check for bent push rods and condition of wear pad contact surfaces on rockers. Remove cylinder head. Check piston protrusion. Verify piston height selection see Groups 05 and Remove cam followers. Keep in same sequence as removed see Group Measure cylinder block see Groups 10, 15, and Remove lube oil system by-pass valve see Stamp cylinder number on rod if required.
Remove pistons and rods. On 4 and 6-cylinder engines, remove two at a time see Group The following assembly sequence is suggested when engine has been completely disassembled. Be sure to check run-out specifications, clearance tolerances, torques, etc. Refer to the appropriate repair group when assembling engine components. Install all plugs and serial number plates in cylinder block that were removed to service block see Groups 10 and Install clean piston cooling orifices and new balancer shaft and camshaft bushings see Groups 10 and Install cylinder liners without O-rings and measure protrusion.
Install liners with O-rings see Group Install crankshaft and main bearings. Install pistons and rods. Check for piston protusion see Group Install lube oil system by-pass valve.
Install front plate see Group Install balancer shafts. Check end play see Group Install oil outlet tube, O-ring in block, and oil pump see Group Install injection pump on front plate see. Install camshaft, timing gears, and oil slinger see Group Time all gears to TDC, No. Install timing gear cover with new front seal , see Group Install oil pan see Group Install oil pressure regulating valve if equipped , see Group Install cam follower in the same sequence as removed see Group Install cylinder head gasket, cylinder head, push rods, and rocker arm assembly see Group Install injection nozzles with new seals and injection lines see Group Install fuel filter, fuel transfer pump, and fuel lines see Group Install engine oil cooler, new oil filter, and dipstick.
Never clean or reuse a contaminated standard-flow oil cooler. Install a new one see Group Install exhaust manifold and turbocharger. Prelube the turbocharger see Group Install water pump and hoses see Group Install alternator, fan, and fan belts see 5 Group Adjust valves and install rocker arm cover see Group Fill engine with clean oil and proper coolant. Perform engine break-in and perform normal standard performance checks see Group Use with standard torque wrench to tighten head bolts under rocker arm assembly.
Use JDG on engines with a tooth flywheel ring gear and a flywheel housing tool guide bore of Use with JDG Adapter to install intake and exhaust valve seat inserts in cylinder head. Thickness of new cylinder head. Minimum thickness of cylinder head. Combustion face surface finish. Intake valve. Exhaust valve. Maximum valve seat runout. Maximum valve face runout.
Center Line Average corresponds to a measure of surface. Valve springs free height. Rocker arm shaft clamp. Step 1. Step 2. Step 3. Step 4. Adjust valve to zero clerance. Rotate engine and observe indicator reading as valve moves to the fully open position. Compare readings with specifications given below:. Repeat above procedure for all valves and readjust valves to specified clearance after this operation.
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