john deere POWERTECH 4.5L Technical Manual

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PowerTech 4.5L &

6.8L

PowerTech Plus 4.5L

& 6.8L

Diesel Engines

Base Engine

TECHNICAL MANUAL

PowerTech Plus 4.5L & 6.8L

Diesel Engines— Base Engine

CTM104 27JAN06 (ENGLISH)

For complete service information also see:

OWERTECH

Fuel Systems......................... CTM207

OWERTECH

Electronic Fuel Systems with Bosch VP44

Pump ............................... CTM170

OWERTECH

Electronic Fuel Systems with Stanadyne

DE10 Pump .......................... CTM331

OWERTECH

Electronic Fuel Systems with Delphi/Lucas

DP201 Pump ......................... CTM284

OWERTECH

Electronic Fuel Systems with Denso

HPCR ............................... CTM220

OWERTECH

PowerTech Plus—Level 14 Electronic Fuel

Systems with Denso HPCR.............. CTM320

Alternators and Starter Motors........... CTM77

OEM Engine Accessories ......CTM67 (English Only)

 Diesel Engines—Mechanical  Diesel Engines—Level 4

 Diesel Engines—Level 12

Diesel Engines—Level 1

 Diesel Engines—Level 11

 Diesel Engines and

John Deere Power Systems

LITHO IN U.S.A.

Foreword

Introduction

This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

This manual (CTM104) covers only the base engine. It is one of seven volumes on 4.5L and 6.8L engines. The following six companion manuals cover fuel system and electronics repair, operation and diagnostics:

• CTM207—Mechanical Fuel Systems

• CTM170—Level 4 Electronic Fuel Systems with

Bosch VP44 Pump

• CTM331—Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump

• CTM284—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump

• CTM220—Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail

• CTM320—Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail

Other manuals will be added in the future to provide additional information on electronic fuel systems as needed.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

the machine technical manual for information on component removal and installation, and gaining access to the components.

Information is organized in sections and groups for the various components requiring service instruction. Section 05 summarizes all applicable essential tools, service equipment and tools, other materials needed to do the job, and service parts kits. Section 06 summarizes all specifications, wear tolerances, and torque values.

Before beginning repair on an engine, clean the engine and mount on a repair stand. (See Section 02, Group

010.) This manual contains SI Metric units of measure

followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric sized.

Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manual for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures.

Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the engine model number you are working on. If only one procedure is given, that procedure applies to all the engines in the manual.

Use this component technical manual in conjunction with the machine technical manual. An application listing in Section 01, Group 001 identifies product-model/component type-model relationship. See

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

DPSG,OUO1004,2767 –19–27SEP05–1/1

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About This Manual

Introduction

The changes listed below make your CTM obsolete. Repair, operation and diagnostics on 4.5L and 6.8L diesel engines is now covered in seven manuals.

Discard CTM104 dated 30Jun05 and replace with this new manual. Also refer to the following manuals:

• CTM104—4.5L and 6.8L Diesel Engines—Base Engine

• CTM207—4.5L and 6.8L Diesel Engines— Mechanical Fuel Systems

• CTM170—4.5L and 6.8L Diesel Engines—Level 4 Electronic Fuel Systems with Bosch VP44 Pump

• CTM331—4.5L and 6.8L Diesel Engines—Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump

• CTM284—4.5L and 6.8L Diesel Engines—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump

• CTM220—4.5L and 6.8L Diesel Engines—Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail

• CTM320—4.5L and 6.8L Diesel Engines—Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail

Also, copy this page listing changes and route through your Service Department.

SECTION 01—GROUP 001 (Engine Identification)

SECTION 02—GROUP 010 (Engine Rebuild)

• Revised engine disassembly/assembly procedure.

SECTION 02—GROUP 080 (Air Intake and Exhaust System)

• Added EGR retest information.

SECTION 02—GROUP 090 (Fuel System)

NOTE: Repair procedures for fuel systems have been

moved to Section 02, Group 090 in six other technical manuals: CTM207—Mechanical Fuel Systems, CTM170—Level 4 Electronic Fuel Systems with Bosch VP44 Pump, CTM331— Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump, CTM284—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump, CTM220—Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail and CTM320—Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail.

SECTION 02—GROUP 100 (Starting and Charging Systems)

• Starting and charging systems are covered in this section/group.

• Updated engine serial plate engine application

SECTION 03—GROUP 120 (Base Engine Operation)

charts.

• Added EGR system operation.

SECTION 01—GROUP 002 (Fuels, Lubricants and Coolants)

SECTION 04—GROUP 150 (Observable Diagnostics and Tests)

• Revised diesel engine fuel guidelines.

OUO1080,000023A –19–12JUN02–1/2

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

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Introduction

NOTE: Fuel system testing and diagnostics has been

moved to Section 04, Group 150 in five other technical manuals: CTM207—Mechanical Fuel Systems, CTM170—Level 4 Electronic Fuel Systems with Bosch VP44 Pump, CTM331— Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump, CTM284—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump, CTM220—Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail and CTM320—Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail.

SECTION 5 (Tools and Other Materials)

• All essential tools, service tools, dealer fabricated tools and other materials listed throughout this manual are consolidated in this section for ease of reference.

SECTION 6 (Specifications)

• All repair, test and diagnostic specifications listed throughout this manual are consolidated in this section for ease of reference.

OUO1080,000023A –19–12JUN02–2/2

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POWERTECH4.5L Engine—Tier 1/Stage I

Introduction

3/4 Right Rear View

3/4 Right Front View

RG7636 –UN–23NOV97

RG7639 –UN–23NOV97

3/4 Left Rear View

RG7638 –UN–23NOV97

RG7637 –UN–23NOV97

3/4 Left Front View

OWERTECH

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

is a registered trademark of Deere & Company

DPSG,OUO1004,129 –19–15MAY02–1/1

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POWERTECH4.5L Engine—Tier 2/Stage II

Introduction

3/4 Right Front View—Two-Valve Head Engine

3/4 Right Front View—Four-Valve Head Engine

RG11932 –UN–06NOV01

RG13617A –UN–18MAY04

3/4 Left Rear View—Two-Valve Head Engine

RG11931 –UN–06NOV01

RG13618A –UN–18MAY04

3/4 Left Rear View—Four-Valve Head Engine

OWERTECH

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

is a registered trademark of Deere & Company

OUO1080,0000238 –19–03JUN04–1/1

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POWERTECH6.8L Engine—Tier 1/Stage I

Introduction

3/4 Right Front View

3/4 Right Rear View

RG7641 –UN–23NOV97

RG7643 –UN–23NOV97

3/4 Left Front View

RG7640 –UN–23NOV97

RG7642 –UN–23NOV97

3/4 Left Rear View

OWERTECH

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

is a registered trademark of Deere & Company

DPSG,OUO1004,130 –19–15MAY02–1/1

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POWERTECH6.8L Engine—Tier 2/Stage II

Introduction

3/4 Right Front View—Two-Valve Head Engine

OWERTECH

is a registered trademark of Deere & Company

RG11934 –UN–24OCT01

3/4 Left Rear View—Two-Valve Head Engine

RG11933 –UN–24OCT01

OUO1080,0000239 –19–06JUN02–1/1

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

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Introduction

POWERTECH6.8L Engine With Electronic Fuel System—Tier 2/Stage II

6068HF475 Four-Valve Engine (Level 11 Electronic Fuel System

with Denso High Pressure Common Rail)

OWERTECH

is a registered trademark of Deere & Company

RG12199 –UN–24MAY02

6068HF475 Four-Valve Engine

RG12200 –UN–24MAY02

OUO1083,00005FC –19–21OCT05–1/1

CTM104 (27JAN06) PowerTech Plus 4.5L & 6.8L Diesel Engines

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Introduction

POWERTECH6.8L Engine With Electronic Fuel System—Tier 3/Stage IIIA

6068HF485 Engine Shown (Electronic Fuel System With Denso

High Pressure Common Rail)

OWERTECH

is a registered trademark of Deere & Company

RG13547 –UN–11NOV04

6068HF485 Shown

RG13546 –UN–11NOV04

OUO1083,00005FC –19–17DEC03–1/1

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Contents

SECTION 01—General Information

Group 000—Safety Group 001—Engine Identification and Application

Charts

Group 002—Fuels, Lubricants and Coolants

SECTION 02—Repair and Adjustments

Group 010—Engine Rebuild Group 020—Cylinder Head and Valves (Two-Valve

Head Engines)

Group 021—Cylinder Head and Valves (Four-Valve

Head Engines)

Group 030—Cylinder Block, Liners, Pistons and

Rods

Group 040—Crankshaft, Main Bearings and

Flywheel

Group 050—Camshaft, Balancer Shafts and Timing

Gear Train Group 060—Lubrication System Group 070—Cooling System Group 080—Air Intake and Exhaust System Group 090—Fuel System Group 100—Starting and Charging Systems

SECTION 03—Theory of Operation

Group 120—Base Engine Operation

SECTION 04—Diagnostics

Group 150—Observable Diagnostics and Tests

SECTION 05—Tools and Other Materials

Group 170—Repair Tools and Other Materials Group 180—Diagnostic Service Tools Group 190—Dealer Fabricated Service Tools

SECTION 06—Specifications

Group 200—Repair and General OEM

Specifications Group 210—Diagnostic Specifications

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

INDX

CTM104 (27JAN06)

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

PowerTech Plus 4.5L & 6.8L Diesel Engines

Previous Editions

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Contents

INDX

CTM104 (27JAN06)

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Page

Group 000—Safety ....................01-000-1

Group 001—Engine Identification and Application

Charts

Engine Serial Number Plate Information .....01-001-1

OEM Engine Option Code Label...........01-001-3

Information Relative to Emissions

Regulations .........................01-001-3

Engine Application Charts................01-001-4

Group 002—Fuels, Lubricants and Coolants

Diesel Fuel ...........................01-002-1

Bio-Diesel Fuel ........................01-002-2

Lubricity of Diesel Fuel ..................01-002-3

Testing Diesel Fuel .....................01-002-3

Diesel Engine Break-In Oil ...............01-002-4

Diesel Engine Oil—Non-Certified and Tier 1

Certified Engines .....................01-002-5

Diesel Engine Oil—Tier 2/Stage II

Certified Engines .....................01-002-6

Diesel Engine Oil —Tier 3/Stage IIIA Certified

Engines ............................01-002-7

OILSCAN, OILSCAN Plus,

COOLSCAN and COOLSCAN PLUS . . .01-002-8

Oil Filters.............................01-002-8

Grease ..............................01-002-9

Diesel Engine Coolant..................01-002-10

Additional Information About Diesel

Engine Coolants and Supplemental Coolant

Additives ..........................01-002-12

Testing Diesel Engine Coolant ...........01-002-13

Supplemental Coolant Additives ..........01-002-14

Operating in Warm Temperature Climates . .01-002-14

Flush and Service Cooling System ........01-002-15

Disposing of Coolant...................01-002-16

Section 01

General Information

Contents

CTM104 (27JAN06)

01-1

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Contents

CTM104 (27JAN06)

01-2

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn

spontaneously.

Group 000

Safety

01 000 1

TS227 –UN–23AUG88

DX,FLAME –19–29SEP98–1/1

Handle Starting Fluid Safely

Starting fluid is highly flammable. Keep all sparks and flame away when using it. Keep

starting fluid away from batteries and cables. To prevent accidental discharge when storing the

pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns.

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

CTM104 (27JAN06)

01-000-1

DX,RCAP –19–04JUN90–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

TS281 –UN–23AUG88

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000

Install Fan Guards

Rotating cooling system fans can cause serious injury. Keep fan guards in place at all times during engine

operation. Wear close fitting clothes. Stop engine and be sure fan is stopped before making adjustments or connections, or cleaning near the front of the engine.

Safety

Avoid Hot Parts

Avoid skin contact with exhaust manifolds, turbochargers and mufflers. Keep flammable materials clear of the turbocharger.

External dry exhaust parts become very hot during operation. Turbochargers may reach temperatures as high as 500°C (932°F) under full load, and naturally aspired exhaust manifolds may reach 600°C (1112°F) under full load. This may ignite paper, cloth or wooden materials. Parts on engines that have been at full load and reduced to no load idle will maintain approximately 150°C (302°F).

Rotating Fan

TS677 –UN–21SEP89

OUO1083,00005FE –19–17DEC03–1/1

TS271 –UN–23AUG88

Hot Surface

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

CTM104 (27JAN06)

01-000-2

OUO1083,00005FF –19–22DEC05–1/1

DX,SPARKS –19–03MAR93–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

TS204 –UN–23AUG88

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Safety

Prepare for Emergencies

Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

01 000 3

Handling Batteries Safely

DX,FIRE2 –19–03MAR93–1/1

TS291 –UN–23AUG88

TS204 –UN–23AUG88TS203 –UN–23AUG88

CTM104 (27JAN06)

Continued on next page

01-000-3

DPSG,OUO1004,2758 –19–22DEC05–1/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

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PN=17

000

Safety

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Always remove grounded (-) battery clamp first and replace it last.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed2L(2quarts).

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

CTM104 (27JAN06)

01-000-4

DPSG,OUO1004,2758 –19–22DEC05–2/2

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Safety

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

01 000 5

X9811 –UN–23AUG88

Wear Protective Clothing

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,FLUID –19–03MAR93–1/1

TS206 –UN–23AUG88

DX,WEAR –19–10SEP90–1/1

CTM104 (27JAN06)

01-000-5

PowerTech Plus 4.5L & 6.8L Diesel Engines

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000

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Safety

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area

Work in Clean Area

Before starting a job:

• Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt

shortcuts.

DX,LOOSE –19–04JUN90–1/1

TS228 –UN–23AUG88

TS220 –UN–23AUG88

DX,AIR –19–17FEB99–1/1

CTM104 (27JAN06)

01-000-6

DX,CLEAN –19–04JUN90–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

T6642EJ –UN–18OCT88

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Safety

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch. Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

01 000 7

TS220 –UN–23AUG88

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

DX,PAINT –19–24JUL02–1/1

TS953 –UN–15MAY90

DX,TORCH –19–10DEC04–1/1

CTM104 (27JAN06)

01-000-7

PowerTech Plus 4.5L & 6.8L Diesel Engines

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000

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Safety

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials and good workmanship.

Do not weld tools unless you have the proper equipment and experience to perform the job.

DX,LIGHT –19–04JUN90–1/1

TS223 –UN–23AUG88

TS226 –UN–23AUG88

DX,LIFT –19–04JUN90–1/1

CTM104 (27JAN06)

01-000-8

Construct Dealer-Made Tools Safely

DPSG,OUO1004,899 –19–19MAY99–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

LX1016749 –UN–01JUL97

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Safety

Practice Safe Maintenance

Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

01 000 9

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

TS218 –UN–23AUG88

DX,SERV –19–17FEB99–1/1

TS779 –UN–08NOV89

Use only service parts meeting John Deere specifications.

CTM104 (27JAN06)

01-000-9

DX,REPAIR –19–17FEB99–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

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000

Dispose of Waste Properly

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Safety

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Live With Safety

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

TS1133 –UN–26NOV90

DX,DRAIN –19–03MAR93–1/1

CTM104 (27JAN06)

01-000-10

DX,LIVE –19–25SEP92–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

TS231 –19–07OCT88

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Engine Identification and Application Charts

Engine Serial Number Plate Information

IMPORTANT: The engine serial number plate (A) can

be easily destroyed. Before “hot tank” cleaning the block, remove the plate.

NOTE: Four-valve head engines have “16V” or “24V”

printed on a plate located on the rocker arm cover. The 4045HF475 model has “16V” to denote 16 valves total while 6068HF475 has “24V” to denote 24 valves total.

Engine Serial Number (B)

Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine model designation, and a 6-digit sequential number. The following is an example:

CD4045L123456

CD ...................... Engine Manufacturing Location

CD ............ Saran, France

T0 ............. Dubuque, Iowa

PE ............. Torreon, Mexico

J0 .............. Rosario, Argentina

4 ........................ Number of Cylinders

045 .................... Displacement in Liters ( 4.5 Liters)

L ........................ Aspiration Code (Early Engines) or Emission

Tier Level (Later Engines)

D ............... Naturally aspirated

T ............... Turbocharged, no aftercooling

A ............... Turbocharged and air-to-coolant aftercooled

H ............... Turbocharger and air-to-water aftercooled

S ............... Turbocharged and air-to sea water aftercooled

B ................ Non-certified engine

C,E or F ..... Tier 1/Stage I emission certified engine

G, J or K .... Tier 2/Stage II emission certified engine

L, M, N or P Tier 3/Stage IIIA emission certified engine

123456 ............... 6-digit unique sequence number

Engine Model Designation (C)

Group 001

01 001 1

RG7778 –UN–11NOV97

RG13806 –UN–23JAN06

Saran Serial Number Plate

RG13716 –UN–23JAN06

Torreon Serial Number Plate

The second line of information on the serial number plate identifies the engine/machine or OEM relationship. See ENGINE APPLICATION CHARTS later in this group.

A—Engine Serial Number Plate B—Engine Serial Number C—Engine Application Data D—Empty, Coefficient of Absorption or Saran internal

factory identification

CTM104 (27JAN06)

01-001-1

Dubuque Engine Serial Number Plate

Continued on next page

PowerTech Plus 4.5L & 6.8L Diesel Engines

RG9060 –UN–16MAR98

RG19661,0000005 –19–27JAN06–1/2

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Engine Identification and Application Charts

001

4045HF485

4 ..................................................... Number of Cylinders

045 ................................................. Displacement in Liters ( 4.5 Liters)

H .................................................... Aspiration Code )

F ..................................................... User Code

485 Application Code See Engine Application Charts later in this group

D ...................................... Naturally aspirated

T ....................................... Turbocharged, no aftercooling

A ...................................... Turbocharged and air-to-coolant aftercooled

H ...................................... Turbocharger and air-to-water aftercooled

S ...................................... Turbocharged and air-to sea water aftercooled

AT .................................... Agritalia srl (Vittoria, Sicily, Italy)

BE .................................... Bell Equipment Co. (Richards Bay, South Africa)

CQ ................................... John Deere Brazil (Horizontina, Brazil)

DW ................................... John Deere Davenport Works (Davenport, Iowa)

E ...................................... John Deere Ottumwa Works (Ottumwa, Iowa)

F ....................................... OEM (Original Equipment Manufacturers)

FG .................................... Goldoni S.P.A. (Modena, Italy)

FM .................................... Marine Engine

H ....................................... John Deere Harvester Works (East Moline, Illinois)

KV ..................................... John Deere Commercial Worksite Products (Knoxville, Tennessee/Dubuque, Iowa)

L ........................................ John Deere Werke Mannheim (Germany)

LA ...................................... John Deere Werke Manheim (Germany) (Engines with Bosch VP44 Injection Pump)

LV ...................................... John Deere Commercial Product (Augusta, Georgia)

N ....................................... John Deere Des Moines Works (Des Moines, Iowa)

P ........................................ Industrias John Deere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)

PY ..................................... Larson & Toubro Ltd. (Pune, India)

RW .................................... John Deere Waterloo Tractor Works (Waterloo, Iowa)

T ........................................ John Deere Dubuque Works (Dubuque, Iowa)

T8 ...................................... Cameco Industries (Thibodaux, Louisiana)

TJ ...................................... John Deere Forestry (formerly Timberjack) (Sweden/Finland/Canada/USA)

YC ..................................... John Deere Jialian Harvester Co. Limited (China)

Z ........................................ John Deere Werke Zweibrucken (Germany)

Coefficient of Absorption (D) — (Early Saran-Built Engines - Later Engines, Internal Factory Identification)

The second line of information on Saran serial number plate may also contain the coefficient of absorption value for smoke emissions or, for later engines, an internal factory identification number.

RG19661,0000005 –19–27JAN06–2/2

CTM104 (27JAN06)

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PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

OEM Engine Option Code Label

An option code label is secured to the top of the valve cover and identifies the factory installed options on each OEM engine to ensure correct parts acquisition.

Always provide option code information and engine base code when ordering repair parts. A listing of option codes is given in Parts Catalogs and Operator’s Manuals.

NOTE: Before “hot tank” cleaning, ensure that option

codes are recorded elsewhere.

Information Relative to Emissions Regulations

01 001 3

CD30433 –UN–10MAY95

DPSG,OUO1004,482 –19–07NOV98–1/1

Depending on the final destination, engines can meet the emissions regulations according to the US Environmental Protection Agency (EPA), California Air Resources Board (CARB) and for Europe, the Directive 97/68/EC relating the measures against the emissions of particles and gaseous pollutant from internal combustion engines. Such engines are called “CERTIFIED” and receive an emission label on the engine.

The regulations prohibit tampering with the emission-related components listed below which would render that component inoperative or to make any adjustment on the engine beyond published specifications. It is also illegal to install a part or component where the principle effect of that

component is to bypass, defeat, or render inoperative any engine component or device which would affect the engine’s conformance to the emission regulations.

To summarize, it is illegal to do anything except return the engine to its original published specifications.

List of emission-related components:

• Fuel injection system

• Intake manifold

• Turbocharger

• EGR cooler

• EGR valve

• Charge air cooling system

• Piston

OUO1080,0000035 –19–29AUG01–1/1

CTM104 (27JAN06)

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PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

001

Engine Application Charts

JOHN DEERE AGRICULTURAL EQUIPMENT Machine Model Engine Model Bell Equipment, South Africa

884 Cane Loader CD4045TBE50 (Tier 1) 904 Haul Tractor CD4045TBE51 (Tier 1) 1266 Haul Tractor CD6068TBE50 (Tier 1) 1866 Haul Tractor CD6068TBE51 (Tier 2) 2256 Haul Tractor CD6068HBE50 (Tier 1)

Des Moines, Iowa

4700 Sprayer (138 kW) T06068TN050, PE6068TN050, T06068TN053, PE6068TN053 4700 Sprayer (149 kW) PE6068TN052 4710 Sprayer PE6068TN052 4720 Sprayer PE6068HN051 (Tier 2) 6700 Sprayer T04045TN050, PE4045TN050 7455 Cotton Stripper T06068TN051, PE6068TN051 7460 Cotton Stripper PE6068TN054 9935 Cotton Picker T06068TN051, PE6068TN051 9970 Cotton Picker PE6068HN052 (Tier 2)

East Moline, Illinois

9400 Combine T06068HH050 9410 Combine T06068HH051 9450 Combine T06068HH052, PE6068HH052 9550 Combine (Low Power) PE6068HH054 (4-Valve) (Tier 2) 9550/9550SH Combine (High Power) PE6068HH055 (4-Valve) (Tier 2) 9560 Combine (Low Power) PE6068HH054 (4-Valve) (Tier 2) 9560 Combine (High Power) PE6068HH055 (4-Valve) (Tier 2)

9965 Peanut Combine PE6068HH057

Horizontina, Brazil

1165 Combine J06068TCQ11 1170 Combine CD6068TCQ50 1175 Combine J06068TCQ12 1450 Combine J06068TCQ04 1450 CWS/WTS Combine CD6068HCQ60, JO6068TCG04(Tier 2) 1550 CWS/WTS Combine CD6068HCQ61, JO6068ACQ04(Tier 2) 3518 Combine J06068TYC51 9650 Combine J06068HCQ01 5403/5605 Tractor J04045DCQ01 5705 Tractor J04045TCQ02 6405 Tractor J04045TCQ01

PE6068HH058 (4-Valve) Tier 3)

CTM104 (27JAN06)

Continued on next page

01-001-4

RG19661,0000008 –19–25JAN06–1/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

JOHN DEERE AGRICULTURAL EQUIPMENT

Machine Model Engine Model

6415 Tractor J04045TCQ03 6605 Tractor J06068TCQ02 6615 Tractor J06068TCQ15 7505 Tractor J06068TCQ03 7515 Tractor J06068TCQ14

Jiamusi, China

1075 Combine CD6068TYC50, J06068TYC50 3518 Combine CD6068TYC51, CD6068HYC50, J06068TYC51

Zweibrucken, Germany

2254 Combine CD6068HZ050 3200/3400 Telehandler CD4045TZ250 3215/3415 Telehandler (European Version) CD4045HZ275, CD4045TZ270 3215/3415 Telehandler (North American Version) CD4045HZ275, CD4045TZ270 3220/3420 Telehandler (European Version) CD4045HZ275 3220/3420 Telehandler (North American Version) CD4045HZ275 3800 Telehandler, Articulated CD4045HZ050, 4045HZ060 9540/9540 Hillmaster Combine CD6068HZ060

CD6068HZ480 (4-Valve) (Tier 3)

9560/9560HM Combine CD6068HZ470 (4-Valve) (Tier 2)

CD6068HZ481 (4-Valve) (Tier 3)

Ottumwa, Iowa

4890 Windrower T04045TE050, PE4045TE050 4895 Windrower T04045TE051, PE4045TE051 4990 Windrower T06068TE050, PE6068TE050 4995 Windrower PE6068TE051

Waterloo, Iowa

7210 (SYNCROPLUS) Tractor T06068TRW53 7210 (POWRQUAD) Tractor T06068TRW50, PE6068TRW50 7220 Tractor CD6068TRW01, PE6068TRW01, PE6068HRW59 7220 IVT Tractor PE6068HRW61 7320 Tractor CD6068HRW01, PE6068HRW01, PE6068HRW59 7320 IVT Tractor PE6068HRW61 7410 (SYNCROPLUS) Tractor T06068TRW54, PE6068HRW54 7410 (POWRQUAD) Tractor T06068TRW51, PE6068TRW51 7420 Tractor CD6068HRW01, PE6068HRW01 7510 (POWRQUAD) Tractor T06068TRW70, PE6068TRW70 7520 Tractor CD6068HRW01, PE6068HRW01 7610 Tractor (105 kW) T06068TRW52, PE6068TRW52

01 001 5

SYNCROPLUS is a trademark of Deere & Company POWRQUAD is a trademark of Deere & Company

CTM104 (27JAN06)

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01-001-5

RG19661,0000008 –19–25JAN06–2/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

001

Machine Model Engine Model

7610 Tractor (110 kW) T06068TRW72, PE6068TRW72 7720 Tractor (Auxilliary Drive) PE6068HRW54 (4-Valve) (Tier 2) 7810 Tractor (Export-Brazil) PE6068TRW73 7815 Tractor (Export-Brazil) PE6068HRW63 7820 Tractor (Non-Auxilliary Drive) PE6068HRW54 (4-Valve) (Tier 2)

Mannheim, Germany (European Market)

3210 Tractor CD4045DRT50 3310 Tractor CD4045DRT51 3410 Tractor CD4045TRT50 5620 Tractor CD4045DL270 5720 Tractor CD4045TL273 5820 Tractor CD4045TL274 6010 Tractor CD4045DL050 6020 Tractor CD4045DL070 6020SE Tractor CD4045TL270 (Tier 2) 6110 Tractor (Direct Fan Drive) CD4045TL058 6110 Tractor (Viscous Fan Drive) CD4045TL050 6120 Tractor CD4045TL070 6120 Tractor (Premium) CD4045TL271 6120SE Tractor CD4045TL271 6205 Tractor CD4045TL064 6210 Tractor (Direct Fan Drive) CD4045TL059 6210 Tractor (Viscous Fan Drive) CD4045TL051 6215 Tractor (Classic) CD4045TL072 6215 Tractor (Classic) CD4045TL071 6215 Tractor (Classic) CD4045TL272 (Tier 2) 6220 Tractor CD4045TL071 6220 Tractor (Premium) CD4045TL272 (Tier 2) 6220SE Tractor CD4045TL272 6310 Tractor (Direct Fan Drive) CD4045TL060 6310 Tractor (Viscous Fan Drive) CD4045TL052 6310 Tractor (ECU Level 4) CD4045TLA50 6320 Tractor CD4045HL072 6320 IVT Tractor CD4045HLA70 6320 Tractor (Premium) CD4045HL472 6320SE Tractor CD4045TL073, CD4045HL270 (Tier 2) 6410 Tractor (Direct Fan Drive) CD4045TL061 6410 Tractor (Viscous Fan Drive) CD4045TL053 6410 Tractor (ECU Level 4) CD4045TLA51

JOHN DEERE AGRICULTURAL EQUIPMENT

CTM104 (27JAN06)

Continued on next page

01-001-6

RG19661,0000008 –19–25JAN06–3/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

JOHN DEERE AGRICULTURAL EQUIPMENT

Machine Model Engine Model

6420 Tractor CD4045HL070 6420 IVT Tractor CD4045HLA72 6420 Tractor (Premium) CD4045HL473 (Tier 2) 6420S Tractor CD4045HLA73 (Tier 2) 6420SE Tractor CD4045HL271 (Tier 2) 6505 Tractor CD6068DL051 6510 Tractor CD6068DL050 6515 Tractor (Classic) (77 kW) CD6068DL071 6515 Tractor (Classic) (85 kW) CD6068DL070 6515 Tractor (Classic) CD6068HL270 (Tier 2) 6520 Tractor CD6068DL070 6520SE Tractor CD6068TL073 6520 Tractor (Premium) CD6068HL470 (4-Valve) (Tier 2), CD6068HL475 (4-Valve) (Tier 2) 6610 Tractor CD6068TL050 6610 Tractor (ECU Level 4) CD6068TLA50 6620 Tractor CD6068HLA70 6620 Tractor (Premium) CD6068HL471 6620SE2 Tractor CD6068HL272 6810 Tractor CD6068TL051 6810 Tractor (ECU Level 4) CD6068TLA51 6820 Tractor CD6068HLA71 6820 Tractor (Premium) CD6068HL472 (4-Valve) (Tier 2) 6910 Tractor (99 kW) CD6068TL052 6910 Tractor (107 kW) CD6068TL054 6910 Tractor (107 kW) (ECU Level 4) CD6068TLA52 6910S Tractor (ECU Level 4) CD6068TLA53 6920 Tractor CD6068HLA72 6920 Tractor (Premium) CD6068HL473 (4-Valve) (Tier 2) 6920S Tractor CD6068HLA73, CD6068HL474 (4-Valve) (Tier 2)

Mannheim, Germany (North American Market)

6110/6110L Tractor CD4045TL063 6120 Tractor CD4045TL070 6120/6120L Tractor CD4045TL271 (Tier 2) 6210/6210L Tractor CD4045TL054 6215 Tractor (Advantage) CD4045TL071 (Tier 1), CD4045TL272 (Tier 2) 6220 Tractor CD4045TL071 6220S Tractor CD4045TL272 (Tier 2) 6310/6310L/6310S Tractor CD4045TL055 6320 Tractor CD4045TL074, CD4045HL073

01 001 7

CTM104 (27JAN06)

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01-001-7

RG19661,0000008 –19–25JAN06–4/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

001

Machine Model Engine Model

6320 IVT Tractor CD4045HLA71, CD4045HL472 6320 IVT Tractor CD4045HL476 (Tier 2) 6320/6320L/S Tractor CD4045HL470, CD4045HL472, CD4045HL270 (Tier 2) 6403, 6405 Tractor (Advantage) CD4045TL062 6410/6410L/6410S Tractor CD4045TL056 6415 Tractor (Advantage) CD4045TL075, CD4045HL272 (Tier 2) 6420 Tractor CD4045HL070 6420 IVT Tractor CD4045HLA72 6420/6420L/S Tractor CD4045HL271 (Tier 2) 6420 IVT Tractor CD4045HL473 (Tier 2) 6510L/6510S Tractor CD4045TL057 6520 Tractor CD4045HL071 6520L/S Tractor CD4045HL273 (Tier 2) 6603 Tractor (Advantage) CD6068TL053 6605 Tractor (Advantage) CD6068TL053 6615 Tractor (Advantage) CD6068TL071 6615 Tractor (Advantage) CD6068HL271 (Tier 2) 6715 Tractor (Advantage) CD6068TL072 6715 Tractor (Advantage) CD6068HL273 (Tier 2)

Saltillo/Monterrey, Mexico

5415 Tractor PE4045DP052 5615 Tractor PE4045DP053 5615 Tractor (Export-Turkey) PE4045DLV51 (Tier 1), PE4045DP054 (Tier 1) 5715 Tractor PE4045TP059 5715 Tractor (Export-Turkey) PE4045TLV51 (Tier 1), PE4045TP062 (Tier 1) 6103 Tractor PE4045TP055 6203 Tractor PE4045TP056 6400 Tractor PE4045TP054 6403 Tractor PE4045TP057 (Non-Certified)

6403 Tractor (Export-U.S.A.) PE4045TP060 (Tier 1)

6415 Tractor PE4045TP061 (Tier 2) 6603 Tractor PE6068TP053 (Non-Certified)

6603 Tractor (Export-U.S.A.) PE6068TP054 (Tier 1)

7220 Tractor PE6068TP055 7320 Tractor PE6068TP056 (Tier 2) 7405 Tractor (Advantage) CD6068TP051, PE6068TP051

JOHN DEERE AGRICULTURAL EQUIPMENT

PE4045TP063 (Non-Certified)

PE4045TP064 (Tier 1)

PE6068TP061 (Non-Certified)

PE6068TP062 (Tier 2)

CTM104 (27JAN06)

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01-001-8

RG19661,0000008 –19–25JAN06–5/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

JOHN DEERE AGRICULTURAL EQUIPMENT

Machine Model Engine Model

7410 Tractor CD6068TP052 7420 Tractor PE6068TP057 (Tier 2) 7500 Tractor PE6068TP052 7520 Tractor PE6068TP058 (Tier 2)

Tekirdag, Turkey

5615 Tractor CD4045DTK20, PE4045DP054 (Tier 1) 5715 Tractor PE4045TP062

Thibodaux, Louisiana (Cameco Industries) (Deere)

S30 Harvester PE6068DT850 SP1800 Cane Loader PE6068DT850 SP1850 Cane Loader PE4045TF150, PE4045TT852 SP2252 Cane Loader PE6068TT850 SP3000 Cane Loader PE6068DT850 100 Loader/ Harvester (Kanaf) PE6068TT850 110 Cane Tractor PE4045TT851 215 4WD Tractor PE6068DT850 220 Tractor PE6068TT851 220 4WD Tractor/Pineapple Harvester/Sprayer PE6068TT850, PE6068DT850 404 Vegetable Sprayer T04045TT850, T04045TT801, PE4045TT850

01 001 9

CTM104 (27JAN06)

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01-001-9

RG19661,0000008 –19–25JAN06–6/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

001

Augusta, Georgia

5410 Tractor CD4045DLV50, PE4045DLV50 5410 Tractor (No Engine Air Heater Option) PE4045DLV51 5420/5420N Tractor PE4045DLV50 5420/5420N Tractor (No Engine Air Heater Option) PE4045DLV51 5425 Tractor PE4045TLV53 5510/5510N Tractor CD4045TLV50, PE4045TLV50 5510/5510N Tractor (No Engine Air Heater Option) PE4045TLV51 5510 Tractor (LUK Clutch Option) PE4045TLV52 5520/5520N Tractor PE4045TLV50 5520/5520N Tractor (No Engine Air Heater Option) PE4045TLV51 5520 Tractor PE4045TLV52 5525 Tractor PE4045TLV54

Agritalia srl (Vittoria, Sicily, Italy)

5410 Tractor CD4045TAT50 5415 Tractor CD4045DAT70 5510 Tractor CD4045TAT50 5515 Tractor CD4045TAT70 5615 Tractor CD4045TAT71

JOHN DEERE COMMERCIAL AND CONSUMER EQUIPMENT

CTM104 (27JAN06)

Continued on next page

01-001-10

RG19661,0000008 –19–25JAN06–7/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

JOHN DEERE CONSTRUCTION AND FORESTRY EQUIPMENT

Machine Model Engine Model

Backhoe, Loader

310E Backhoe Loader T04045DT055, T04045TT056 310E Backhoe Loader (Alt Comp) T04045TT056 310SE Backhoe Loader T04045TT050 310G Backhoe Loader ( S.N. —910005) T04045DT056, PE4045DT056 310G Backhoe Loader (S.N.—910006) T04045DT058, PE4045TT058 (Tier 2) 310G Backhoe Loader (Alt Comp) (S.N. —910007) T04045TT080, PE4045TT080 (Tier 1) 310G Backhoe Loader (Alt Comp) (S.N. 910057— ) PE4045TT088 (Tier 2) 310J AC Backhoe Loader PE4045TT094 (Tier 2) 310J Backhoe Loader PE4045TT094 (Tier 2) 310J SJ-EH Backhoe Loader PE4045TT094 (Tier 2) 310SG Backhoe Loader (Alt Comp) (S.N. 909514— ) T04045TT080 310SG Backhoe Loader ( S.N. —910004) T04045TT081, PE4045TT081 (Tier 1) 310SG Backhoe Loader (S.N. 910056— ) PE4045TT089 (Tier 2), PE4045HT054 (Tier 3) 315SE Backhoe Loader T04045TT060 315SG Backhoe Loader ( S.N. —909995) T04045TT081, PE4045TT081 315SG Backhoe Loader (S.N. 910069— ) PE4045TT089 (Tier 2) 410E Backhoe Loader T04045TT053 410G Backhoe Loader T04045TT082, PE4045TT082,

PE4045TT093 (Tier 2) PE4045HT055 (Tier 3) 410J Backhoe Loader PE404TT095 (Tier 2) 710D Backhoe Loader (S.N. —834729) T06068TT050, PE6068TT050 710D Backhoe Loader (S.N. 834730— ) T06068TT055, PE6068TT055 710G Backhoe Loader T06068TT057, PE6068TT057 710J Backhoe Loader PE4045TT061 (Tier 2) 710J EH Backhoe Loader PE6068TT061 (Tier 2)

Crawler Dozer, Crawler Loader

DX75 Crawler Dozer (Japan) T04045DT006, T04045DT052 DX75 HST Crawler Dozer (Japan) T04045TT070, PE4045TT070 450G Crawler Dozer (Direct Drive) (S.N. 840528—840890) T04045DT004, T04045TT005 (Non Certified) 450G Crawler Dozer (Direct Drive) (S.N.841246—879425) T04045TT061, PE4045TT061 (Tier 1) 450G Crawler Dozer (Torque Converter) (S.N. 840529— ) T04045TT013 (Non Certified) 450G Crawler Dozer (Torque Converter) T04045TT067, PE4045TT067 450H, 450HLT Crawler Dozer T04045DT053 450H Crawler Dozer (Nat. Asp.) T04045DT057, PE4045DT057 (Tier 2) 450H LGP Crawler Dozer T04045TT058, PE4045TT058 450H LGP Crawler Dozer T04045TT085, PE4045TT085, PE4045TT090 (Tier 2) 450H Crawler Dozer (Alt Comp) T04045TT057, PE4045TT057 450H Crawler Dozer (Alt Comp) T04045TT084, PE4045TT084, PE4045TT090 (Tier 2)

01 001 11

CTM104 (27JAN06)

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01-001-11

RG19661,0000008 –19–25JAN06–8/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=35

Engine Identification and Application Charts

001

Machine Model Engine Model

455G Crawler Loader (Direct Drive) T04045TT061, PE4045TT061 (Tier 1) 455G (Torque Converter) Crawler Loader T04045TT067, PE4045TT067 550G Crawler Dozer T04045TT006, T04045TT014, T04045TT062 550G Crawler Dozer (Torque Converter) T04045TT062, T04045TT068 550H Crawler Dozer (S.N. —909830) T04045TT064, PE4045TT064 550H Crawler Dozer (S.N. 910019— ) PE4045TT086, PE4045TT090 (Tier 2) 550H Forest Fire Plow (S.N.898487—909788) T04045TT083, PE4045TT083 550H LGP Crawler Dozer (S.N. —909667) T04045TT065, PE4045TT065 550H LGP Crawler Dozer (S.N. 910017— ) PE4045TT087, PE4045TT090 (Tier 2) 555G Crawler Loader (Direct Drive) (S.N. 840461— ) T04045TT063, PE4045TT063 555G Crawler Loader (Torque Converter) T04045TT069, PE4045TT069 650G Crawler Dozer (Direct Drive) T04045TT007, T04045TT063, PE4045TT063 650G Crawler Dozer (Torque Converter) T04045TT015, T04045TT063, PE4045TT063, T04045TT069,

650H Crawler Dozer T04045TT066, PE4045TT066 650H Crawler Dozer PE4045HT050 (Tier 2) 650H Forest Fire Plow—71 kw (95 hp) PE4045HT051 (Tier 2) 650H Forest Fire Plow—85 kW (114 hp) T04045TT091, PE4045TT091 700H Crawler Dozer T06068TT056, PE6068TT056 700H Crawler Dozer PE6068TT060 (Tier 2) 750C Crawler Dozer (S.N.—831315) T06068TT007 750C Crawler Dozer (S.N. 831316— ) T06068TT052, PE6068TT052

690D Excavator T06068TT051, PE6068TT051 690ELC Excavator (S.N. 559603— ) T06068TDW56 110 Excavator T04045TT054, PE4045TP052 110C Excavator PE4045TP058 110CFX Excavator PE4045TP058 HYEX Military Excavator PE4045TT050 120 Excavator T04045TT052, PE4045TP051 120C Excavator PE4045HP050 (Tier 2) 160CLC Excavator PE4045HP051 (Tier 2) 160LC Excavator T04045TT055, PE4045TP053 200LC Excavator T06068TT051, PE6068TT051 200CLC Excavator PE6068HT053, PE6068HT059 (Tier 2) 230LC, 230LR Excavator T06068HT051, PE6068HT051 230CLC Excavator PE6068HT054 (Tier 2) 240 Excavator PE6068HT061 (Tier 3) 240DLC Excavator PE6068HT061 (Tier 3)

JOHN DEERE CONSTRUCTION AND FORESTRY EQUIPMENT

PE4045TT069

Excavator

CTM104 (27JAN06)

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01-001-12

RG19661,0000008 –19–25JAN06–9/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Engine Identification and Application Charts

JOHN DEERE CONSTRUCTION AND FORESTRY EQUIPMENT

Machine Model Engine Model

270CLC Excavator PE6068HT055 (Tier 2) 270LC Excavator T06068HT052, PE6068HT052 270 Excavator PE6068HT062 (Tier 3) 790ELC Excavator T06068TT005 CFX270CLC Excavator PE6068HT055 (Tier 2) CFX270LC Excavator T06068HT052, PE6068HT052

Feller Buncher

643G Feller Buncher T06068TT053, PE6068TT053 643H Feller Buncher PE6068TT058 643J Feller Buncher PE6068HTJ55 (4-Valve) (Tier 2) 653E Feller Buncher T06068TT053, PE6068TT053 653G Feller Buncher—120 kW (160 hp) T06068TT053, PE6068TT053, PE6068TT059 653G Feller Buncher—140 kW (188 hp) PE6068HT057 843G Feller Buncher T06068HT050, PE6068HT050 843H Feller Buncher PE6068HT056 843J Feller Buncher PE6068HT056, PE6068HTJ54 (Tier 2)

Forklift

485E, 486E, 488E Forklift T04045DT050, PE4045DT050

Forwarder

810 Forwarder CD4045HTJ75 1010D Forwarder CD4045HTJ76 1110D Forwarder CD6068HTJ75 1410D Forwarder CD6068HTJ77

Grader

670C, 670C Series II Grader T06068HDW53, PE6068HDW53 670CH, 672CH Grader T06068HDW55, PE6068HDW55 670CH Series II, 672CH Series II Grader (S.N. —589368) T06068HDW58, PE6068HDW58 670CH Series II, 672CH Series II Grader (S.N. 589369— ) PE6068HDW61 (Tier 2) 670D Grader PE6068HDW61 (Tier 2) 672D Grader PE6068HDW68 (Tier 3)

Harvester, Wheeled

770D Wheel Harvester CD4045HTJ77 1070D Wheel Harvester CD6068HTJ76

Landscape Loader

210LE Landscape Loader T04045DT050, PE4045DT050, PE4045DT059 (Tier 2), PE4045TT092

(Tier 2)

Log Loader, Knuckleboom

330, 330B, 430, 430B PE6068TTJ50 Knuckleboom Log Loader

01 001 13

CTM104 (27JAN06)

Continued on next page

01-001-13

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PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=37

Engine Identification and Application Charts

001

Machine Model Engine Model

335B, 335C, 435B, 435C, 437C PE6068TTJ51 Knuckleboom Log Loader

2054 Logger PE6068HT053, PE6068TT053, PE6068HT059 PE6068HT065 (Tier 2) 2554 Logger PE6068HT054, PE6068HT064 (Tier 2)

LX80 Loader T04045HDW51 LX100 Loader (Hitachi Construction Machine) T06068TDW53, PE6068TDW53 LX100-3 Loader (Hitachi Construction Machine) T06068TDW50, PE6068TDW50 LX120 Loader (Hitachi Construction Machine) T06068HDW52, T06068HDW70, PE6068HDW70 324H Loader CD4045DF153 344H Loader T04045TF152, PE4045TF152 344H Loader T04045TF273, CD4045TF273 (Tier 2) TC44H Tool Carrier T04045TDW50, PE4045TDW50 444H Loader T04045TDW50, T04045HDW50, PE4045TDW50 444J Loader PE4045HDW52 (Tier 2), PE4045HDW53 (Tier 3) TC54H Tool Carrier T06068TDW50, PE6068TDW50 544H Loader T06068TDW50, PE6068TDW50 544J Loader PE6068HDW56 (Tier 2), PE4045HDW63 (Tier 3) TC62H Tool Carrier T06068HDW50, PE6068HDW50 624G Loader T06068TDW010 624H Loader T06068HDW50, PE6068HDW50 624J Loader PE6068HDW57 (Tier 2), PE6068HDW67 (Tier 3) 644 Loader PE6068HDW69 (Tier 3) 1204C Loader (Bell Equipment) CD4045TBE52 (Tier 2) 1706C Loader (Bell Equipment) CD6068TBE53 (Tier 1) 1806C Loader CD6068TBE52 (Tier 2)

JD7 Skid Steer Loader PE4045DKV50, PE4045DKV51 270 Skid Steer Loader (Auxiliary Drive) PE4045DKV50 270 Skid Steer Loader (Non-Auxiliary Drive) PE4045DKV51 280 Skid Steer Loader PE4045TKV50

360D Skidder (Timberjack) T06068TDW54, PE6068TDW54 360D Skidder (Timberjack) (S.N. 589337— ) PE6068TDW58 (Tier 2) 460D Skidder (Direct Drive) (Timberjack) T06068TDW55, PE6068TDW55 460D Skidder (Direct Drive) (Timberjack) (S.N. 589337— ) PE6068HDW60 (Tier 2), PE6068HDW65 (Tier 3) 460D Skidder (Torque Converter) (Timberjack) (S.N. —586336) T06068TDW57, PE6068TDW57 460D Skidder (Torque Converter) (Timberjack) (S.N. 589337— ) PE6068HDW59 (Tier 2)

JOHN DEERE CONSTRUCTION AND FORESTRY EQUIPMENT

Loggers

Loader, Four Wheel Drive

Skid Steer Loader

Skidder

CTM104 (27JAN06)

Continued on next page

01-001-14

RG19661,0000008 –19–25JAN06–11/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=38

Engine Identification and Application Charts

JOHN DEERE CONSTRUCTION AND FORESTRY EQUIPMENT

Machine Model Engine Model

460D Skidder (Torque Converter) (Timberjack) (Europe) PE6068HDW63 (Tier 2), PE6068HDW64 (Tier 3) 540G, 548G Skidder (S.N. 558205—565684) T06068TDW51 540G-II, 548G-II Skidder (S.N. 565685—576602) T06068TDW54, PE6068TDW54 540G-III, 548G-III Skidder (S.N. 576603—586336) T06068TDW54, PE6068TDW54 540G-III, 548G-III Skidder (S.N. 586337— ) PE6068HDW58 (Tier 2) 560 Skidder PE6068HDW66 (Tier 3) 640G, 648G Skidder (S.N. 558205—565684) T06068TDW52 640G-II, 648G-II Skidder (S.N. 565685—576602) T06068TDW55, PE6068TDW55 640G-III, 648G-III Skidder (Direct Drive) (S.N. 576603—586336) T06068TDW55, PE6068TDW55 640G-III, 648G-III Skidder (Direct Drive) (S.N. 589337— ) PE6068HDW60 (Tier 2) 640G-III, 648G-III Skidder (Torque Converter) (S.N. —586336) T06068TDW57, PE6068TDW57 640G-III, 648G-III Skidder (Torque Converter) (S.N. 586337— ) PE6068HDW59 (Tier 2) 640G-III, 648G-III Skidder (Torque Converter) (Europe) PE6068HDW63 (Tier 2) 748 Skidder (Direct Drive) PE6068HDW66 (Tier 3)

01 001 15

Continued on next page

RG19661,0000008 –19–25JAN06–12/16

CTM104 (27JAN06)

01-001-15

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=39

Engine Identification and Application Charts

001

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

Engine Model Emission Engine Model Emission Engine Model Emission

CD4045DF120 Non-Certified CD4045TF120 Non-Certified CD4045HF120 Non-Certified CD4045DF150 Tier 1 Certified CD4045TF150 Tier 1 Certified CD4045HF150 Tier 1 Certified CD4045DF151 Tier 1 Certified CD4045TF151 Tier 1 Certified CD4045HF152 Tier 1 Certified CD4045DF152 Tier 1 Certified CD4045TF152 Tier 1 Certified CD4045HF157 Tier 1 Certified CD4045DF153 Tier 1 Certified CD4045TF154 Tier 1 Certified CD4045HF158 Tier 1 Certified CD4045DF154 Tier 1 Certified CD4045TF155 Tier 1 Certified CD4045HF252 Non-Certified

CD4045DF157 Tier 1 Certified CD4045TF157 Tier 1 Certified CD4045HF275 Tier 2 Certified CD4045DF158 Tier 1 Certified CD4045TF158 Tier 1 Certified CD4045HF475 Tier 2 Certified

CD4045DF270 Tier 2 Certified CD4045TF161 Tier 1 Certified CD6068HF120 Non-Certified CD4045DFG70 CD4045TF162 Tier 1 Certified CD6068HF150 Tier 1 Certified CD4045DFM50 Non-Certified CD4045TF220 Non-Certified CD6068HF157 Tier 1 Certified

CD4045DFM70 Tier 2 Certified CD4045TF250 Tier 1 Certified CD6068HF158 Tier 1 Certified

CD6068DF150 Tier 1 Certified CD4045TF252 Tier 1 Certified CD6068HF252 Tier 1 Certified J04045DJ31 CD4045TF253 Tier 1 Certified CD6068HF254 Tier 1 Certified PE4045DF120 Non-Certified CD4045TF254 Tier 1 Certified CD6068HF258 Tier 1 Certified PE4045DF150 Tier 1 Certified CD4045TF257 Tier 1 Certified CD6068HF275 Tier 2 Certified PE4045DF151 Tier 1 Certified CD4045TF258 Tier 1 Certified CD6068HF475 Tier 2 Certified

PE4045DF152 Tier 1 Certified CD4045TF270 Tier 2 Certified PE4045HF120 Non-Certified PE4045DF153 Tier 1 Certified CD4045TF271 Tier 2 Certified PE4045HF150 Tier 1 Certified PE4045DF154 Tier 1 Certified CD4045TF275 Tier 2 Certified PE4045HF152 Tier 1 Certified PE4045DF157 Tier 1 Certified CD4045TFM50 Non-Certified PE4045HF157 Tier 1 Certified

PE4045DF158 Tier 1 Certified CD4045TFM75 Tier 2 Certified PE4045HF158 Tier 1 Certified

PE4045DF270 Tier 2 Certified CD4045TFM75 (Marine) PE4045HF252 Non-Certified

PE4045DFM50 Non-Certified CD6068TF120 Non-Certified PE4045HF475 Tier 2 Certified

Naturally Aspirated Turbocharged Turbocharged,

Air-to-Air Aftercooled

Certification Certification Certification

CD4045HF254 Tier 1 Certified

(4-Valve) CD4045HF485 Tier 3 Certified

(4-Valve)

(Marine)

CD4045TF251 Tier 1 Certified CD6068HF250 Tier 1 Certified

(4-Valve) CD6068HF485 Tier 3 Certified

(4-Valve)

(Marine)

CD6068SFM50 Non-Certified PE4045HF275 Tier 2 Certified

(Marine)

(Marine) (4-Valve)

CTM104 (27JAN06)

Continued on next page

01-001-16

RG19661,0000008 –19–25JAN06–13/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=40

Engine Identification and Application Charts

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

Naturally Aspirated Turbocharged Turbocharged,

Air-to-Air Aftercooled

PE4045HF485 Tier 3 Certified

(4-Valve) CD6068TF150 Tier 1 Certified PE6068HF120 Non-Certified CD6068TF151 Tier 1 Certified PE6068HF150 Tier 1 Certified

PE6068DF150 Tier 1 Certified CD6068TF152 Tier 1 Certified PE6068HF157 Tier 1 Certified T04045DF120 Non-Certified CD6068TF157 Tier 1 Certified PE6068HF158 Tier 1 Certified T04045DF150 Tier 1 Certified CD6068TF158 Tier 1 Certified PE6068HF250 Tier 1 Certified T04045DF151 Tier 1 Certified CD6068TF159 Tier 1 Certified PE6068HF252 Tier 1 Certified T04045DF152 Tier 1 Certified CD6068TF220 Non-Certified PE6068HF258 Tier 1 Certified T04045DF153 Tier 1 Certified CD6068TF250 Tier 1 Certified PE6068HF275 Tier 2 Certified T04045DF154 Tier 1 Certified CD6068TF251 Tier 1 Certified PE6068HF475 Tier 2 Certified

(4-Valve) CD6068TF254 Tier 1 Certified PE6068HF485 Tier 3 Certified

(4-Valve)

T04045DF157 Tier 1 Certified CD6068TF257 Tier 1 Certified T04045HF120 Non-Certified T04045DF158 Tier 1 Certified CD6068TF258 Tier 1 Certified T04045HF150 Tier 1 Certified T04045DF270 Tier 2 Certified CD6068TF275 Tier 2 Certified T04045HF152 Tier 1 Certified

CD6068TFM50 Non-Certified T04045HF157 Tier 1 Certified

(Marine)

T04045DFM50 Non-Certified CD6068TFM75 Tier 2 Certified T04045HF158 Tier 1 Certified

(Marine) (Marine)

T06068DF150 Tier 1 Certified CD6068TFM76 Tier 2 Certified T04045HF252 Non-Certified

(Marine) J04045TJ31 J06068TJ31 J06068TJ32 PE4045TF120 Non-Certified T04045HF275 Tier 2 Certified PE4045TF150 Tier 1 Certified T04045HF475 Tier 2 Certified

(4-Valve) PE4045TF151 Tier 1 Certified T06068HF120 Non-Certified PE4045TF152 Tier 1 Certified T06068HF150 Tier 1 Certified PE4045TF154 Tier 1 Certified T06068HF157 Tier 1 Certified PE4045TF155 Tier 1 Certified T06068HF158 Tier 1 Certified PE4045TF157 Tier 1 Certified T06068HF250 Tier 1 Certified PE4045TF158 Tier 1 Certified T06068HF252 Tier 1 Certified PE4045TF161 Tier 1 Certified T06068HF258 Tier 1 Certified PE4045TF162 Tier 1 Certified T06068HF275 Tier 2 Certified PE4045TF220 Non-Certified T06068HF475 Tier 2 Certified

(4-Valve) PE4045TF250 Tier 1 Certified PE4045TF251 Tier 1 Certified PE4045TF252 Non-Certified PE4045TF253 Tier 1 Certified

01 001 17

CTM104 (27JAN06)

Continued on next page

01-001-17

RG19661,0000008 –19–25JAN06–14/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=41

Engine Identification and Application Charts

001

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

Naturally Aspirated Turbocharged Turbocharged,

PE4045TF257 Tier 1 Certified PE4045TF258 Tier 1 Certified PE4045TF270 Tier 2 Certified PE4045TF271 Tier 2 Certified PE4045TF275 Tier 2 Certified PE4045TFM50 Non-Certified

PE4045TFM75 Non-Certified

PE6068SFM50 Non-Certified

PE6068TF120 Non-Certified PE6068TF150 Tier 1 Certified PE6068TF151 Tier 1 Certified PE6068TF152 Tier 1 Certified PE6068TF157 Tier 1 Certified PE6068TF158 Tier 1 Certified PE6068TF159 Tier 1 Certified PE6068TF220 Non-Certified PE6068TF250 Tier 1 Certified PE6068TF251 Tier 1 Certified PE6068TF252 Non-Certified PE6068TF257 Tier 1 Certified PE6068TF258 Tier 1 Certified PE6068TF275 Tier 2 Certified PE6068TFM50 Non-Certified

T04045TF120 Non-Certified T04045TF150 Tier 1 Certified T04045TF151 Tier 1 Certified T04045TF152 Tier 1 Certified T04045TF154 Tier 1 Certified T04045TF155 Tier 1 Certified T04045TF157 Tier 1 Certified T04045TF158 Tier 1 Certified T04045TF161 Tier 1 Certified T04045TF162 Tier 1 Certified T04045TF220 Non-Certified T04045TF250 Tier 1 Certified T04045TF251 Tier 1 Certified T04045TF252 Non-Certified T04045TF253 Tier 1 Certified T04045TF257 Tier 1 Certified T04045TF258 Tier 1 Certified

Air-to-Air Aftercooled

(Marine)

CTM104 (27JAN06)

Continued on next page

01-001-18

RG19661,0000008 –19–25JAN06–15/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=42

Engine Identification and Application Charts

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

Naturally Aspirated Turbocharged Turbocharged,

T04045TF270 Tier 2 Certified T04045TF271 Tier 2 Certified T04045TF275 Tier 2 Certified T04045TFM50 Non-Certified

T06068SFM50 Non-Certified

T06068TF120 Non-Certified T06068TF150 Tier 1 Certified T06068TF151 Tier 1 Certified T06068TF152 Tier 1 Certified T06068TF157 Tier 1 Certified T06068TF158 Tier 1 Certified T06068TF159 Tier 1 Certified T06068TF220 Non-Certified T06068TF250 Tier 1 Certified T06068TF251 Tier 1 Certified T06068TF257 Tier 1 Certified T06068TF258 Tier 1 Certified T06068TF275 Tier 2 Certified T06068TFM50 Non-Certified

01 001 19

Air-to-Air Aftercooled

(Marine)

CTM104 (27JAN06)

01-001-19

RG19661,0000008 –19–25JAN06–16/16

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=43

001

Engine Identification and Application Charts

CTM104 (27JAN06)

01-001-20

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=44

Diesel Fuel

Consult your local fuel distributor for properties of the diesel fuel available in your area.

Group 002

Fuels, Lubricants and Coolants

01 002 1

scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 are recommended.

Required fuel properties

In all cases, the fuel shall meet the following properties:

Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft).

Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5°C(9°F) below the expected low temperature.

Fuel lubricity should pass a minimum level of 3100 grams as measured by ASTM D6078 or maximum

Sulfur content:

• Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates.

• Sulfur content less than 1000 ppm (0.10%) is strongly recommended.

• If diesel fuel with sulfur content greater than 1000 ppm (0.10%) is used, crankcase oil service intervals may be affected.

• Diesel fuel sulfur content greater than 5000 ppm (0.50%) is NOT recommended.

• DO NOT use diesel fuel with sulfur content greater than 10,000 ppm (1.00%).

IMPORTANT: Do not mix used diesel engine oil or

any other type of lubricating oil with diesel fuel.

IMPORTANT: Improper fuel additive usage may

cause damage on fuel injection equipment of diesel engines.

CTM104 (27JAN06)

01-002-1

RG19661,0000017 –19–27JUN05–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=45

002

Bio-Diesel Fuel

Consult your local fuel distributor for properties of the bio-diesel fuel available in your area.

Fuels, Lubricants and Coolants

leaving deposits on injectors and in the combustion chamber.

Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM D6751, EN 14214, or equivalent specification.

It is recommended to purchase bio-diesel fuel blended with B100 from a BQ-9000 Accredited Producer or a BQ-9000 Certified Marketer as recommended by the National Bio-diesel Board.

The maximum allowable bio-diesel concentration is a 5% blend (also known as B5) in petroleum diesel fuel. It has been found that bio-diesel fuels may improve lubricity in concentrations up to this 5% blend.

When using a blend of bio-diesel fuel, the engine oil level must be checked daily when the air temperature is –10°C (14°F) or lower. If oil becomes diluted with fuel, shorten oil change intervals accordingly.

IMPORTANT: Raw pressed vegetable oils are NOT

acceptable for use as fuel in any concentration in John Deere engines.

These oils do not burn completely, and will cause engine failure by

A major environmental benefit of bio-diesel fuel is its ability to biodegrade. This makes proper storage and handling of bio-diesel fuel especially important. Areas of concern include:

• Quality of new fuel

• Water content of the fuel

• Problems due to aging of the fuel

Potential problems resulting from deficiencies in the above areas when using bio-diesel fuel in concentrations above 5% may lead to the following symptoms:

• Power loss and deterioration of performance

• Fuel leakage

• Corrosion of fuel injection equipment

• Coked and/or blocked injector nozzles, resulting in

engine misfire

• Filter plugging

• Lacquering and/or seizure of internal components

• Sludge and sediments

• Reduced service life of engine components

Consult your fuel supplier for additives to improve storage and performance of bio-diesel fuels.

CTM104 (27JAN06)

01-002-2

DX,FUEL7 –19–14NOV05–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=46

Fuels, Lubricants and Coolants

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States, Canada, and the European Union have adequate lubricity to ensure proper operation and durability of fuel injection system components. However, diesel fuels manufactured in some areas of the world may lack the necessary lubricity.

IMPORTANT: Make sure the diesel fuel used in

your machine demonstrates good lubricity characteristics.

Testing Diesel Fuel

01 002 3

Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration.

DX,FUEL5 –19–27OCT05–1/1

DIESELSCAN is a John Deere fuel analysis program that can be used to monitor the quality of your fuel. The DIESELSCAN analysis verifies fuel type, cleanliness, water content, suitability for cold weather operation, and whether the fuel meets specifications.

Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

DX,FUEL6 –19–14NOV05–1/1

CTM104 (27JAN06)

01-002-3

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=47

Fuels, Lubricants and Coolants

002

Diesel Engine Break-In Oil

New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level.

Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine.

After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL.

• ACEA Oil Sequence E1 After the break-in period, use John Deere PLUS-50

or other diesel engine oil as recommended in this manual.

IMPORTANT: Do not use PLUS-50 oil or engine

oils meeting any of the following during the first 100 hours of operation of a new or rebuilt engine:

If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the following during the first 100 hours of operation:

• API Service Classification CE

• API Service Classification CD

• API Service Classification CC

• ACEA Oil Sequence E2

PLUS-50 is a trademark of Deere & Company.

API CI-4 PLUS API CF API CI-4 ACEA E7 API CH-4 ACEA E6 API CG-4 ACEA E5 API CF-4 ACEA E4 API CF-2 ACEA E3

These oils will not allow the engine to break-in properly.

DX,ENOIL4 –19–19DEC05–1/1

CTM104 (27JAN06)

01-002-4

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=48

Fuels, Lubricants and Coolants

Diesel Engine Oil—Non-Certified and Tier 1 Certified Engines

Use oil viscosity based on the expected air temperature range during the period between oil changes.

John Deere PLUS-50 oil is preferred

Oils meeting one of the following specifications are also recommended:

• ACEA Oil Sequence E7

• ACEA Oil Sequence E6

• ACEA Oil Sequence E5

• ACEA Oil Sequence E4

Extended service intervals may apply when John Deere PLUS-50, ACEA E5, or ACEA E4 engine oils are used. Consult your John Deere dealer for more information.

Other oils may be used if they meet one or more of the following:

01 002 5

TS1681 –UN–18DEC03

• John Deere TORQ-GARD SUPREME

• API Service Category CI-4 Plus

• API Service Category CI-4

• API Service Category CH-4

• API Service Category CG-4

• API Service Category CF-4

• ACEA Oil Sequence E3

• ACEA Oil Sequence E2

If oils meeting API CG-4, API CF-4, or ACEA E2 are used, reduce the service interval by 50%.

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% (5000 ppm) is used, reduce the service interval by 50%.

DO NOT use diesel fuel with sulfur content greater than

1.0% (10 000 ppm).

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company

CTM104 (27JAN06)

01-002-5

OUO1082,0000236 –19–25JAN06–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=49

Fuels, Lubricants and Coolants

002

Diesel Engine Oil—Tier 2/Stage II Certified

Engines

Use oil viscosity based on the expected air temperature range during the period between oil changes.

John Deere PLUS-50 oil is preferred.

Oils meeting one of the following specifications are also recommended

• ACEA Oil Sequence E7

• ACEA Oil Sequence E6

• ACEA Oil Sequence E5

• ACEA Oil Sequence E4

Extended service intervals may apply when John Deere PLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 engine oils are used. Consult your John Deere dealer for more information.

Other oils may be used if they meet one or more of the following:

TS1675 –UN–31OCT03

• John Deere TORQ-GARD SUPREME

• API Service Category CI-4n Plus

• API Service Category CI-4

• API Service Category CH-4

• ACEA Oil Sequence E3

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates.

DO NOT use diesel fuel with sulfur content greater than

1.0% (10 000 ppm).

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company

RG19661,0000014 –19–22JUN05–1/1

CTM104 (27JAN06)

01-002-6

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=50

Fuels, Lubricants and Coolants

Diesel Engine Oil —Tier 3/Stage IIIA Certified Engines

Use oil viscosity based on the expected air temperature range during the period between oil changes.

John Deere PLUS-50 oil is preferred.

Oils meeting one of the following specifications are also recommended

• ACEA Oil Sequence E6

• ACEA Oil Sequence E7

Extended service intervals may apply when John Deere PLUS-50, ACEA E6, or ACEA E7 engine oils are used. Consult table in following block for more information.

Other oils may be used if they meet one or more of the following:

• John Deere TORQ-GARD SUPREME

• API Service Category CI-4 PLUS

• API Service Category CI-4

• ACEA Oil Sequence E4

• ACEA Oil Sequence E5

01 002 7

RG13865 –UN–08FEB05

Oil Viscosities for Various Air Temperatures

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which the engine operates.

DO NOT use diesel fuel with sulfur content greater than

1.0% (10 000 ppm).

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company

RG19661,0000013 –19–25JAN06–1/1

CTM104 (27JAN06)

01-002-7

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=51

Fuels, Lubricants and Coolants

002

OILSCAN, OILSCAN Plus, COOLSCAN and COOLSCAN PLUS

T104220 –UN–03OCT96

OILSCAN, OILSCAN Plus, COOLSCAN and COOLSCAN PLUSare John Deere sampling fluid programs to help you monitor machine maintenance and system condition. The objective of a fluid sampling program is to ensure machine availability when you need it and to reduce repair costs by identifying potential problems before they become critical.

Oil and coolant samples should be taken from each system prior to its recommended change interval.

OILSCAN is a registered trademark of Deere & Company. OILSCAN Plus is a registered trademark of Deere & Company. COOLSCAN is a trademark of Deere & Company. COOLSCAN PLUS is a trademark of Deere & Company

Oil Filters

Filtration of oils is critical to proper operation and lubrication.

Check with your John Deere dealer on a maintenance program for your specific application. Your dealer has the sampling products and expertise to assist you in lowering your overall operating costs through fluid sampling.

RG,01,DT7040 –19–05JAN00–1/1

Always change filters regularly as specified in this manual. Use filters meeting John Deere performance

specifications.

CTM104 (27JAN06)

01-002-8

DX,FILT –19–18MAR96–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=52

Fuels, Lubricants and Coolants

Grease

Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.

John Deere SD POLYUREA GREASE is preferred.

The following greases are also recommended

• John Deere HD LITHIUM COMPLEX GREASE

• John Deere HD WATER RESISTANT GREASE

• John Deere GREASE-GARD

Other greases may be used if they meet the following: NLGI Performance Classification GC-LB

IMPORTANT: Some types of grease thickeners are

not compatible with others. Consult your grease supplier before mixing different types of grease

01 002 9

TS1673 –UN–31OCT03

GREASE-GARD is a trademark of Deere & Company

DX,GREA1 –19–07NOV03–1/1

CTM104 (27JAN06)

01-002-9

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=53

Fuels, Lubricants and Coolants

002

Diesel Engine Coolant

The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37°C (-34°F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

John Deere COOL-GARD Prediluted Coolant is preferred for service.

John Deere COOL-GARD Prediluted Coolant is available in a concentration of either 50% ethylene glycol or 55% propylene glycol.

Additional recommended coolants

The following engine coolant is also recommended:

Other low silicate ethylene glycol base coolants for heavy-duty engines may also be used if they meet one of the following specifications:

• ASTM D4985 ethylene glycol base prediluted (50%) coolant

• ASTM D4985 ethylene glycol base coolant concentrate in a 40% to 60% mixture of concentrate with quality water

Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives, formulated for protection of heavy duty diesel engines against corrosion and cylinder liner erosion and pitting. They also require periodic replenishment of additives during the drain interval.

• John Deere COOL-GARD Coolant Concentrate in a 40% to 60% mixture of concentrate with quality water.

John Deere COOL-GARD coolants do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Other fully formulated coolants

Other fully formulated low silicate ethylene or propylene glycol base coolants for heavy-duty engines may be used if they meet one of the following specifications:

• ASTM D6210 prediluted (50%) coolant

• ASTM D6210 coolant concentrate in a 40% to 60%

mixture of concentrate with quality water

Coolants meeting ASTM D6210 do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Coolants requiring supplemental coolant additives

Other coolants

It is possible that neither John Deere COOL-GARD nor coolants meeting one of the coolant standards listed above is available in the geographical area where service is performed. If these coolants are unavailable, use a coolant concentrate or prediluted coolant with a quality additive package that provides cylinder liner cavitation protection and protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion.

The additive package must be part of one of the following coolant mixtures:

• ethylene glycol or propylene glycol base prediluted (40% to 60%) coolant

• ethylene glycol or propylene glycol base coolant concentrate in a 40% to 60% mixture of concentrate with quality water

Water quality

COOL-GARD is a trademark of Deere & Company

CTM104 (27JAN06)

Continued on next page

01-002-10

DX,COOL3 –19–27OCT05–1/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=54

Fuels, Lubricants and Coolants

IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains sealing additives.

IMPORTANT: Do not mix ethylene glycol and

propylene glycol base coolants.

DX,COOL3 –19–27OCT05–2/2

01 002 11

CTM104 (27JAN06)

01-002-11

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=55

Fuels, Lubricants and Coolants

002

Additional Information About Diesel Engine Coolants and Supplemental Coolant

Additives

Engine coolants are a combination of three chemical components: ethylene glycol or propylene glycol antifreeze, inhibiting coolant additives, and quality water.

Coolant specifications

Some products, including John Deere COOL-GARD Prediluted Coolant, are fully formulated coolants that contain all three components in their correct concentrations. Do not add an initial charge of supplemental coolant additives to these fully formulated products.

Coolants meeting ASTM D6210 do not require an initial charge of supplemental coolant additives.

Some coolant concentrates, including John Deere COOL-GARD Coolant Concentrate, contain both glycol antifreeze and inhibiting coolant additives. Mix these products with quality water, but do not add an initial charge of supplemental coolant additives.

Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives.

Replenish coolant additives

simple mixture of ethylene glycol or propylene glycol and water will not give adequate protection.

Use of supplemental coolant additives reduces corrosion, erosion, and pitting. These chemicals reduce the number of vapor bubbles in the coolant and help form a protective film on cylinder liner surfaces. This film acts as a barrier against the harmful effects of collapsing vapor bubbles.

Avoid automotive-type coolants

Never use automotive-type coolants (such as those meeting ASTM D3306). These coolants do not contain the correct additives to protect heavy-duty diesel engines. They often contain a high concentration of silicates and may damage the engine or cooling system.

Water quality

Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate. All water used in the cooling system should meet the following minimum specifications for quality:

The concentration of coolant additives is gradually depleted during engine operation. Periodic replenishment of inhibitors is required, even when John Deere COOL-GARD or another fully formulated coolant is used. Follow the recommendations in this manual for the use of supplemental coolant additives.

Why use supplemental coolant additives?

Operating without proper coolant additives will result in increased corrosion, cylinder liner erosion and pitting, and other damage to the engine and cooling system. A

COOL-GARD is a trademark of Deere & Company

CTM104 (27JAN06)

Chlorides <40 mg/L Sulfates <100 mg/L Total dissolved solids <340 mg/L Total hardness <170 mg/L pH 5.5 to 9.0

Freeze protection

The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit.

Continued on next page

01-002-12

DX,COOL7 –19–19DEC03–1/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=56

Ethylene Glycol Freeze Protection Limit

40% -24°C (-12°F) 50% -37°C (-34°F) 60% -52°C (-62°F)

Propylene Glycol Freeze Protection Limit

40% -21°C (-6°F) 50% -33°C (-27°F) 60% -49°C (-56°F)

Testing Diesel Engine Coolant

Fuels, Lubricants and Coolants

DO NOT use a coolant-water mixture greater than 60% ethylene glycol or 60% propylene glycol.

01 002 13

DX,COOL7 –19–19DEC03–2/2

Testing Diesel Engine Coolant

Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting.

Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating.

Coolant test strips

Coolant test strips are available from your John Deere dealer. These test strips provide a simple, effective

COOLSCAN is a trademark of Deere & Company COOLSCAN PLUS is a trademark of Deere & Company

method to check the freeze point and additive levels of your engine coolant.

Compare the results to the supplemental coolant additive (SCA) chart to determine the amount of inhibiting additives in your coolant and whether more John Deere COOLANT CONDITIONER should be added.

COOLSCAN and COOLSCAN PLUS

For a more thorough evaluation of your coolant, perform a COOLSCAN or COOLSCAN PLUS analysis, where available. See your John Deere dealer for information.

DX,COOL9 –19–19DEC03–1/1

CTM104 (27JAN06)

01-002-13

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=57

Fuels, Lubricants and Coolants

002

Supplemental Coolant Additives

The concentration of coolant additives is gradually depleted during engine operation. For all recommended coolants, replenish additives between drain intervals by adding a supplemental coolant additive every 12 months or as determined necessary by coolant testing.

John Deere COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines.

IMPORTANT: Do not add a supplemental coolant

additive when the cooling system is drained and refilled with John DeereCOOL-GARD.

If other coolants are used, consult the coolant supplier and follow the manufacturer’s recommendation for use of supplemental coolant additives.

The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant.

Add the manufacturer’s recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount.

COOL-GARD is a trademark of Deere & Company

Operating in Warm Temperature Climates

John Deere engines are designed to operate using glycol base engine coolants.

Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required.

IMPORTANT: Water may be used as coolant

emergency situations only

DX,COOL4 –19–07NOV03–1/1

Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added.

Drain cooling system and refill with recommended glycol base engine coolant as soon as possible.

RG,01,DT7034 –19–29OCT97–1/1

CTM104 (27JAN06)

01-002-14

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=58

Fuels, Lubricants and Coolants

Flush and Service Cooling System

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing cap completely.

IMPORTANT: Air must be expelled from cooling

system when system is refilled. Follow procedure given in your operator’s manual.

Whenever the aluminum timing gear cover or coolant pump are replaced, the cooling system should be completely drained. In addition to opening petcock on radiator, remove lower radiator hose when draining cooling system.

01 002 15

TS281 –UN–23AUG88

The ethylene glycol base (antifreeze) can become depleted of SCAs, allowing various acids to form that will damage engine components. In addition, heavy metals, such as lead, copper and zinc, accumulate in the ethylene glycol base. The heavy metals come from corrosion that occurs to some degree within a cooling system. When a coolant is saturated to the point where it can no longer hold heavy metals and other dissolved solids, they settle out and act as abrasives on engine parts.

NOTE: Refer to your operator’s manual for a specific

service interval.

Flush cooling system as described in your operator’s manual. Clean cooling system with clean water and a cleaner such as FLEETGUARDRESTORE or RESTORE PLUS. Follow the instructions provided with the cleaner. Refill cooling system with the appropriate coolant solution. See DIESEL ENGINE COOLANT, earlier in this group.

FLEETGUARD is a registered trademark of the Cummins Engine Company. RESTORE is a trademark of FLEETGUARD. RESTORE PLUS is a trademark of FLEETGUARD.

CTM104 (27JAN06)

Continued on next page

01-002-15

RG,01,DT7033 –19–29OCT97–1/2

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013006

PN=59

Fuels, Lubricants and Coolants

002

IMPORTANT: NEVER overfill the system. A

pressurized system needs space for heat expansion without overflowing at the top of the radiator. Coolant level should be at bottom of radiator filler neck.

Air must be expelled from cooling system when system is refilled. Loosen plug in side of thermostat housing to allow air to escape when filling system. Retighten plug when all the air has been expelled.

After adding new coolant solution, run engine until it reaches operating temperature. This mixes the coolant solution uniformly and circulates it through the entire system. After running engine, check coolant level and entire cooling system for leaks.

Contact your engine servicing dealer, if there are further questions.

Disposing of Coolant

Improperly disposing of engine coolant can threaten the environment and ecology.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your engine servicing dealer.

RG,01,DT7033 –19–29OCT97–2/2

TS1133 –UN–26NOV90

RG,01,DT7032 –19–29OCT97–1/1

CTM104 (27JAN06)

01-002-16

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=60

Section 02

Repair and Adjustments

Contents

Page Page

Group 010—Engine Rebuild

Engine Overhaul Guidelines ..............02-010-1

Engine Repair Stand....................02-010-1

Engine Stand Safety Precautions ..........02-010-2

Install Adapters on Engine Repair Stand.....02-010-3

Engine Lifting Procedure.................02-010-4

Clean Engine .........................02-010-5

Disconnect Turbocharger Oil Inlet Line ......02-010-6

Mount Engine on Repair Stand ............02-010-7

Engine Mounted on Repair Stand ..........02-010-8

Engine Disassembly Sequence............02-010-8

Sealant Application Guidelines ...........02-010-12

Engine Assembly Sequence .............02-010-13

Engine Break-In Guidelines..............02-010-17

Perform Engine Break-In................02-010-18

Group 020—Cylinder Head and Valves (Two-Valve

Head Engines)

General Information.....................02-020-1

Check and Adjust Valve Clearance.........02-020-2

Measure Valve Lift .....................02-020-5

Remove Cylinder Head..................02-020-7

Disassemble and Inspect Rocker Arm Shaft

Assembly..........................02-020-14

Assemble Rocker Arm Assembly .........02-020-15 Group 021—Cylinder Head and Valves (Four-Valve

Pump Push Rod (If Applicable) .........02-020-15 General Information.....................02-021-1

Followers..........................02-020-17 Measure Valve Lift .....................02-021-5

Preliminary Cylinder Head and Valve Remove Cylinder Head ..................02-021-7

Remove Valve Assembly................02-020-21 Disassemble and Inspect Rocker Arm Shaft

Inspect Valve Rotators .................02-020-22 Assemble Rocker Arm Assembly .........02-021-18

Inspect and Measure Valves.............02-020-23 Pump Push Rod ....................02-021-18

Head Gasket Inspection and Repair Followers..........................02-021-20

Inspect and Clean Cylinder Head .........02-020-27 Preliminary Cylinder Head and Valve

Measure Cylinder Head Thickness ........02-020-29 Remove Valve Assembly................02-021-24

Clean Valve Guides ...................02-020-30

Measure Valve Guides .................02-020-31

Knurl Valve Guides ....................02-020-32

Clean and Inspect Valve Seats ...........02-020-32

Grind Valve Seats.....................02-020-33

Remove Valve Seat Inserts..............02-020-35

Measure Valve Seat Bore in Cylinder

Head .............................02-020-38

Install Valve Seat Inserts................02-020-39

Install Valves.........................02-020-39

Inspect Cylinder Head Cap Screws........02-020-40

Inspect and Clean Exhaust Manifold .......02-020-40

Clean and Inspect Top Deck of Cylinder

Block .............................02-020-41

Check Cylinder Liner Standout (Height Above

Block) ............................02-020-42

Install Cylinder Head...................02-020-43

Torque-Turn Method for Proper Torque.....02-020-46

Install Rocker Arm Assembly.............02-020-47

Inspect and Clean Ventilator Outlet Hose . . .02-020-48 Remove, Inspect, and Install Closed

Crankcase Ventilation System (If

Equipped) .........................02-020-49

Install Rocker Arm Cover ...............02-020-50

Complete Final Assembly ...............02-020-53

Head Engines)Inspect, Measure, and Install Fuel Supply

Check and Adjust Valve Clearance.........02-021-1Inspect, Measure, and Assemble Camshaft

Do Not Open High-Pressure Fuel System....02-021-6Measure Valve Recess in Cylinder Head . . .02-020-19

Inspect and Measure Valve Bridges .......02-021-16Checks ...........................02-020-20

Assembly..........................02-021-17Inspect and Measure Valve Springs .......02-020-21

Inspect, Measure, and Install Fuel SupplyClean Valves.........................02-020-22

Inspect, Measure, and Assemble CamshaftGrind Valves .........................02-020-24

Measure Valve Recess in Cylinder Head . . .02-021-22Sequence .........................02-020-25

Checks ...........................02-021-23Check Cylinder Head Flatness ...........02-020-28

Inspect and Measure Valve Springs .......02-021-25Clean Injection Nozzle Bores ............02-020-30

Continued on next page

CTM104 (27JAN06)

02-1

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=1

Contents

Page Page

Clean Valves.........................02-021-25 Check Piston Ring Groove Wear..........02-030-15

Measure Piston Pin Bore................02-030-16Inspect and Measure Valves.............02-021-26

Grind Valves .........................02-021-27 Measure Piston Skirt ...................02-030-17

Measure Piston Height .................02-030-17Head Gasket Inspection and Repair

Sequence .........................02-021-28 Determine Piston-to-Liner Clearance.......02-030-18

Deglaze Cylinder Liners ................02-030-20Inspect and Clean Cylinder Head .........02-021-30

Check Cylinder Head Flatness ...........02-021-30 Replace Piston and Liner Sets ...........02-030-20

Inspect and Measure Connecting RodMeasure Cylinder Head Thickness ........02-021-31

Remove Fuel Injector Sleeves............02-021-32 Bearings (Rods Removed from Engine). . .02-030-21

Inspect and Measure Connecting RodClean Fuel Injector Bores ...............02-021-33

Install Fuel Injector Sleeves .............02-021-34 Bearings (Rod and Crankshaft in Engine)

.................................02-030-22Clean Glow Plug Bores.................02-021-35

Clean Valve Guides ...................02-021-35 Inspect Rod and Cap ..................02-030-23

Inspect Piston Pins and Bushings .........02-030-25Measure Valve Guides .................02-021-36

Knurl Valve Guides ....................02-021-37 Remove Piston Pin Bushing .............02-030-26

Clean and Inspect Connecting Rod PinClean and Inspect Valve Seats ...........02-021-37

Grind Valve Seats.....................02-021-38 Bore..............................02-030-28

Install Piston Pin Bushing in ConnectingRemove Valve Seat Inserts..............02-021-38

Measure Valve Seat Bore in Cylinder Rod ..............................02-030-29

Measure Rod Center-to-Center Bores......02-030-31Head .............................02-021-42

Install Valve Seat Inserts................02-021-43 Inspect and Clean Cylinder Block .........02-030-32

Clean Cylinder Liner O-Ring Bore.........02-030-35Install Valves.........................02-021-44

Inspect Cylinder Head Cap Screws........02-021-45 Measure Cylinder Block Main Bearing

Bore..............................02-030-35Inspect and Clean Exhaust Manifold .......02-021-45

Clean and Inspect Top Deck of Cylinder Measure Camshaft Follower Machined Bore

in Block ...........................02-030-36Block .............................02-021-46

Check Cylinder Liner Standout (Height Measure Camshaft Bushing Bores in

Block .............................02-030-36Above Block) Four-Valve Head .........02-021-47

Install Cylinder Head...................02-021-48 Measure Balancer Shaft Bushing ID in Block

(4-Cylinder Engines) .................02-030-38Torque-Turn Method for Proper Torque.....02-021-51

Install Fuel Injectors ...................02-021-52 Measure Cylinder Liners and Block Bores. . .02-030-39

Measure Liner Flange Counterbore DepthInstall Carrier Assembly ................02-021-53

Install Rocker Arm Assembly.............02-021-54 in Block ...........................02-030-40

Measure Liner Flange Thickness..........02-030-40Inspect and Clean Ventilator Outlet Hose . . .02-021-56

Remove, Inspect, and Install Closed Measure Cylinder Block Top Deck

Flatness...........................02-030-41Crankcase Ventilation System (If

Equipped) .........................02-021-57 Remove, Inspect, and Install Piston

Cooling Orifices .....................02-030-42Install Rocker Arm Cover ...............02-021-58

Complete Final Assembly ...............02-021-59 Measure Fuel Supply Pump Push Rod

Bore and Push Rod OD...............02-030-43

Measure and Adjust Cylinder LinerGroup 030—Cylinder Block, Liners, Pistons and

Rods Standout (Height Above Block) .........02-030-44

Install Packing on Cylinder Liner and O-RingsConnecting Rods—General Information .....02-030-1

Remove Pistons and Connecting Rods......02-030-2 in Block ...........................02-030-45

Install Cylinder Liner in Block ............02-030-47Remove Cylinder Liners .................02-030-5

Complete Disassembly of Cylinder Block (If Assemble Piston and Connecting Rod .....02-030-49

Install Piston Rings ....................02-030-50Required)...........................02-030-7

Preliminary Liner, Piston and Rod Checks . . .02-030-8 Install Piston and Connecting Rod

Assembly..........................02-030-51Disassemble Piston and Rod Assembly .....02-030-9

Clean Pistons ........................02-030-10 Torque-Turn Connecting Rod Cap

Screws............................02-030-55Visually Inspect Pistons.................02-030-11

Clean Cylinder Liners ..................02-030-12

Visually Inspect Cylinder Liners...........02-030-13

Continued on next page

CTM104 (27JAN06)

02-2

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=2

Contents

Page Page

Check Engine Rotation for Excessive Install Main and Thrust Bearing Inserts in

Tightness..........................02-030-56

Measure Piston Protrusion ..............02-030-57

Complete Final Assembly ...............02-030-60

Block .............................02-040-52

Install Crankshaft .....................02-040-54

Install Flywheel Housing ................02-040-57

Complete Final Assembly ...............02-040-60

Group 040—Crankshaft, Main Bearings and

Flywheel

Crankshaft and Main Bearing Failure

Analysis............................02-040-1

Inspect Vibration Damper (6.8 L Engines)....02-040-2

Remove Pulley or Vibration Damper and

Pulley .............................02-040-3

Install Pulley or Vibration Damper and

Pulley .............................02-040-5

Replace Front Crankshaft Oil Seal and Wear

Sleeve .............................02-040-8

Check Crankshaft End Play .............02-040-19

Inspect Flywheel ......................02-040-20

Check Flywheel Face Flatness ...........02-040-21

Check Pilot Bearing Bore Concentricity.....02-040-21

Remove Flywheel .....................02-040-22

Replace Flywheel Ring Gear.............02-040-23

Replace Pilot Bearing in Flywheel (If

Equipped) .........................02-040-24

Replace Sleeve in Flywheel (If Equipped). . .02-040-25

Install Flywheel .......................02-040-26

Crankshaft Rear Oil Seal and Wear Sleeve

Handling Precautions.................02-040-27

Remove Crankshaft Rear Oil Seal and Wear

Sleeve ............................02-040-27

Clean and Inspect Crankshaft Flange ......02-040-32

Install Crankshaft Rear Oil Seal and Wear

Sleeve ............................02-040-32

Remove Flywheel Housing ..............02-040-38

Remove and Install Crankshaft Timing Wheel

(Two-Valve Head Engines with VP44 or

DE10 Fuel Injection Pumps and All

Four-Valve Head Engines).............02-040-39

Remove Crankshaft Main Bearings........02-040-40

Check Main Bearing Oil Clearance ........02-040-42

Remove and Install Crankshaft Gear

(Crankshaft Installed in Engine).........02-040-43

Remove Crankshaft....................02-040-45

Inspect Crankshaft ....................02-040-46

Measure Crankshaft Journals and Main

Bearing ID .........................02-040-47

Measure Main Thrust Journal Width and

Thrust Bearing Width.................02-040-48

Crankshaft Grinding Guidelines...........02-040-49

Crankshaft Grinding Specifications ........02-040-50

Group 050—Camshaft, Balancer Shafts and Timing

Gear Train

Measure Valve Lift .....................02-050-1

Remove Timing Gear Cover ..............02-050-3

Remove and Install Camshaft Bushing

with Front Plate Installed ...............02-050-6

Remove and Install Camshaft Gear-Driven

Auxiliary Drive ......................02-050-10

Measure Camshaft End Play.............02-050-11

Measure Balancer Shaft End Play (If

Equipped—4-Cylinder Engines) .........02-050-11

Measure Idler Gear End Play ............02-050-12

Measure Timing Gear Backlash ..........02-050-13

Remove Camshaft.....................02-050-14

Visually Inspect Camshaft...............02-050-17

Measure Camshaft Thrust Plate Clearance

and Thickness ......................02-050-17

Inspect and Measure Camshaft Bushing

ID and Journal OD...................02-050-18

Measure Camshaft Lobe Height ..........02-050-19

Inspect Camshaft Gear .................02-050-19

Inspect Camshaft Followers .............02-050-20

Inspect, Measure, and Install Fuel Supply

Pump Push Rod ....................02-050-21

Remove Balancer Shafts (If Equipped—

4-Cylinder Engines) ..................02-050-22

Inspect and Measure Balancer Shaft

Bushings and Journals................02-050-23

Remove and Install Balancer Shaft

Bushings ..........................02-050-24

Inspect Balancer Shaft Gears and Thrust

Plates ............................02-050-25

Remove and Install Balancer Shaft Gears. . .02-050-26

Remove Cylinder Block Front Plate........02-050-27

Measure Idler Gear Bushing and Shaft .....02-050-30

Remove Idler Gear Bushings ............02-050-31

Install Idler Gear Bushings ..............02-050-32

Remove Lower and Upper Idler Shafts .....02-050-33

Clean and Inspect Front Plate............02-050-33

Transfer Fuel Injection Pump Timing Mark

onto Replacement Front Plate

(Two-Valve Head Engine with Mechanical Fuel

Injection) ..........................02-050-34

Install Idler Shaft Spring Pins (If

Equipped) .........................02-050-35

Measure Assembled ID of Main Bearing

Caps .............................02-040-51

Continued on next page

CTM104 (27JAN06)

02-3

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=3

Contents

Page Page

Install Upper Idler Shaft in Front Plate......02-050-35 Remove and Install Thermostat Cover and

Install Lower Idler Shaft in Front Plate......02-050-36

Install Cylinder Block Front Plate..........02-050-37

Install and Time Balancer Shafts (If

Equipped—4-Cylinder Engines) .........02-050-38

Install Camshaft ......................02-050-43

Clean and Inspect Timing Gear Cover .....02-050-49

Install Timing Gear Cover ...............02-050-50

Remove and Install Magnetic Pick-Up

Sensor............................02-050-54

Complete Final Assembly ...............02-050-55

Thermostats (Tier 3) ..................02-070-9

Test Thermostat(s) ....................02-070-10

Remove Coolant Pump.................02-070-11

Coolant Pump Assembly................02-070-12

Disassemble Coolant Pump .............02-070-13

Inspect, Clean, and Measure Coolant

Pump Parts ........................02-070-14

Assemble Coolant Pump................02-070-15

Install Coolant Pump...................02-070-17

Cooling System Deaeration..............02-070-19

Remove and Install Automatic (Spring) Belt

Group 060—Lubrication System

General Lubrication System Information .....02-060-1

Remove, Inspect, and Install Oil Filter

Base ..............................02-060-1

Remove, Inspect, and Install Oil Cooler .....02-060-7

Remove, Inspect, and Install Oil Bypass

Valve.............................02-060-13

Remove and Install Oil Filter Bypass Valve

(Extended-Life Filter) .................02-060-14

Remove and Install Oil Pressure

Regulating Valve ....................02-060-14

Remove and Install Oil Fill Adapter........02-060-19

Remove and Install Dipstick Tube with Oil

Pan Installed .......................02-060-21

Remove and Install Dipstick Tube with

Fitting ............................02-060-23

Remove, Inspect, and Install Oil Pump

Pick-Up Tube Assembly...............02-060-24

Engine Oil Pump Assembly..............02-060-24

Remove Engine Oil Pump...............02-060-25

Inspect and Measure Clearances .........02-060-26

Tensioner .........................02-070-19

Checking Belt Tensioner Spring Tension and

Belt Wear..........................02-070-21

Manual Belt Tensioner Adjustment Using Belt

Tension Gauge .....................02-070-23

Manual Belt Tensioner Adjustment Using Belt

Tension Tool (Alternate Method for

Engines without Auxiliary Drive.) ........02-070-24

Inspect and Install Fan Assembly .........02-070-26

Remove and Inspect Fan Drive Assembly. . .02-070-27 Replace Bearings in Adjustable Fan Drive

Assembly..........................02-070-28

Replace Bearings in Heavy-Duty,

Adjustable Fan Drive Assembly .........02-070-31

Install Fan Drive Assembly ..............02-070-33

Remove and Install Fan Drive Assembly

(2254 Combine).....................02-070-36

Remove and Install Coolant Heater (If

Equipped) .........................02-070-37

Remove and Install Cold Start Advance

Switch (If Equipped)..................02-070-38

Complete Oil Pump Disassembly .........02-060-28

Assemble Engine Oil Pump..............02-060-29

Install Engine Oil Pump.................02-060-30

Install Oil Pan ........................02-060-32

Group 080—Air Intake and Exhaust System

Extending Turbocharger Life ..............02-080-1

Remove Turbocharger...................02-080-3

Turbocharger Failure Analysis.............02-080-5

Group 070—Cooling System

Remove Coolant Manifold/Thermostat Cover

and Thermostat ......................02-070-1

Install Coolant Manifold/Thermostat Cover

and Thermostat ......................02-070-2

Remove and Install Coolant

Manifold/Thermostat Cover and Thermostat (High Flow Single

Thermostat).........................02-070-4

Turbocharger Inspection .................02-080-7

Perform Radial Bearing Clearance Test ....02-080-14

Adjust Turbocharger Wastegate Actuator (If

Equipped) .........................02-080-16

Remove and Install Variable Geometry

Turbocharger Actuator (If Equipped) .....02-080-17

Remove and Install Actuator Linkage ......02-080-19

Repair Turbocharger ...................02-080-23

Prelube Turbocharger ..................02-080-23

Remove and Install Coolant Manifold and Install Turbocharger ...................02-080-24

Thermostats (Dual Thermostats) .........02-070-7

Remove and Install Coolant Manifold,

Turbocharger Break-In .................02-080-28

Recommendations for Turbocharger Use . . .02-080-28

Thermostats and Side Port (Four-Valve

Head) .............................02-070-8

Continued on next page

CTM104 (27JAN06)

02-4

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=4

Contents

Page

Remove, Inspect, and Install Exhaust

Manifold...........................02-080-29

Remove and Install Air-to-Air Aftercooler....02-080-30

Remove and Install EGR Exhaust Tube (Tier

3/Stage IIIA) .......................02-080-31

Remove and Install EGR Coolant Inlet

Tube (Tier 3/Stage IIIA)...............02-080-32

Remove and Install EGR Cooler (Tier

3/Stage IIIA) .......................02-080-33

Remove, Inspect, and Install EGR Valve (Tier

3/Stage IIIA) .......................02-080-34

Remove and Install Air Intake Pipe ........02-080-35

Remove, Inspect, and Install Intake Manifold

(Four-Valve Head) ...................02-080-36

Remove, Inspect, and Install Air Inlet and

Mixing Sleeve (Tier 3/Stage IIIA) ........02-080-37

Remove, Inspect, and Install Intake

Manifold (Tier 3/Stage IIIA) ............02-080-38

Remove and Install Air Heater (If

Equipped) .........................02-080-39

Remove and Install Starting Aid (If

Equipped) .........................02-080-40

Group 090—Fuel System

Fuel System ..........................02-090-1

Group 100—Starting and Charging Systems

Remove and Install Starter ...............02-100-1

Remove and Install Alternator.............02-100-2

CTM104 (27JAN06)

02-5

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=5

Contents

CTM104 (27JAN06)

02-6

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=6

Engine Overhaul Guidelines

Engine life and performance will vary depending on operating conditions and the level of regular engine maintenance. Engines can be brought back to original performance standards through proper overhaul procedures and replacement of parts with genuine John Deere service parts. Overhauling the engine prior to failure can avoid costly repairs and downtime.

Consider installing a John Deere overhaul kit when:

• The engine begins to experience power loss and there

are no known engine component failures.

• The engine is hard to start due to low cranking

compression.

• The engine begins to smoke and there are no known

engine component failures.

• The engine begins to use oil. Refer to Section 04 for

acceptable oil consumption.

• The engine has high usage hours and the owner wants

to take preventive measures to avoid high-cost repairs

and costly downtime.

Group 010

Engine Rebuild

02 010 1

Overhaul kits may be available for John Deere engines in your area.

Engine Repair Stand

NOTE: Only the 2722 kg (6000 lb) heavy duty engine

repair stand (A) No. D05223ST manufactured by Owatonna Tool Co., Owatonna, Minnesota, is referenced in this manual. When any other repair stand is used, consult the manufacturer’s instructions for mounting the engine.

Refer to machine technical manual for steps to remove engine from machine.

A—D05223ST Engine Repair Stand

DPSG,OUO1032,3410 –19–15JUN00–1/1

CTM104 (27JAN06)

02-010-1

Engine Repair Stand

RG,01,DT7044 –19–01OCT01–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

RG4929 –UN–05DEC97

013006

PN=63

Engine Stand Safety Precautions

Engine Rebuild

The engine repair stand should be used only by qualified service technicians familiar with this equipment.

010

To maintain shear strength specifications, alloy steel

Class 12.9 or SAE Grade 8 or higher cap screws must be used to mount adapters and engine to repair stand. Use LOCTITE242 Thread Lock and Sealer (Medium Strength) on cap screws when installing lifting straps on engine. Tighten cap screws to specifications given.

For full thread engagement, be certain that tapped holes in adapters and engine blocks are clean and not damaged. A thread length engagement equal to 1-1/2 screw diameters minimum is required to maintain strength requirements.

To avoid structural or personal injury, do not exceed the maximum capacity rating of 2722 kg (6000 lb). Maximum capacity is determined with the center of the engine located not more than 330 mm (13 in.) from the mounting hub surface of the engine stand.

The center of balance of an engine must be located within 51 mm (2 in.) of the engine stand rotating shaft.

Engine center of balance is generally located a few millimeters above the crankshaft.

To prevent possible personal injury due to engine slippage, recheck to make sure engine is solidly mounted before releasing support from engine lifting device.

Never permit any part of the body to be positioned under a load being lifted or suspended. Accidental slippage may result in personal injury.

The lifting jack is to be used when it is necessary to lift the engine for rotation. When working on the engine, the jack should be at its lowest position to keep the center of gravity and the possibility of tipping low.

To prevent possible personal injury due to sudden engine movement, lower the engine by operating jack release valve slowly. Do not unscrew release valve knob more than two turns from its closed position.

LOCTITE is a registered trademark of Loctite Corp.

CTM104 (27JAN06)

02-010-2

RG,RG34710,45 –19–01OCT01–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=64

Engine Rebuild

Install Adapters on Engine Repair Stand

1. Attach the D05226ST Special Adapter (B) to mounting

hub (A) of the engine repair stand, using SAE Grade 8 socket head cap screws (D), to the following specifications.

Specification

D05226ST Special Adapter-to-Mounting Hub SAE Grade 8 Socket Head Cap

Screws.—Torque 600 N•m (450 lb-ft).........................................................

2. Attach the 628351Engine Adapter (C) to the special

adapter, using four SAE Grade 8 caps screws (E), to the following specifications.

02 010 3

RG7783 –UN–11NOV97

Engine Repair Stand Adapters

628351Engine Adapter-to-Special Adapter SAE Grade 8 Cap

Screws.—Torque 135 N•m (100 lb-ft).........................................................

A—Mounting Hub B—D05226ST Special Adapter C—62835 Engine Adapter D—Socket Head Cap Screws E—Cap Screws

Part of JT07268 Engine Repair Stand Adapter Kit

Specification

Engine Repair Stand Adapters

RG7781 –UN–11NOV97

RG7938 –UN–13NOV97

Engine Repair Stand Adapters

RG,01,DT7049 –19–07NOV03–1/1

CTM104 (27JAN06)

02-010-3

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=65

Engine Lifting Procedure

CAUTION: The only recommended method for lifting the engine is with JDG23 Engine Lifting

010

Sling and safety approved lifting straps that come with engine. Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an engine being lifted or suspended.

Engine Rebuild

NOTE: If engine lifting straps are misplaced, they should

be procured through service parts.

1. Apply TY9370 LOCTITE242 Thread Lock and Sealer to lifting strap cap screws. Install lifting straps (B) and tighten cap screws to the following specifications.

Specification

Engine Lifting Strap Cap

Screws—Torque 170 N•m (125 lb-ft)..........................................................

IMPORTANT: Lift engine with longitudinal loading on

lifting sling and lifting brackets only. Angular loading greatly reduces lifting capacity of sling and brackets.

Lift spacing on sling is adjustable. Position each lifting point so that engine hangs level when lifted.

2. Attach the JDG23 Engine Lifting Sling (A) to engine lifting straps (B) and overhead hoist or floor crane.

Lifting Engine with Lifting Sling

RG7784 –UN–11NOV97

A—JDG23 Engine Lifting Sling B—Lifting Straps

LOCTITE is a registered trademark of Loctite Corp.

CTM104 (27JAN06)

Continued on next page

02-010-4

RG,03,JW7723 –19–21NOV03–1/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=66

Engine Rebuild

Lifting straps are designed to lift the engine and small accessories, such as hydraulic pumps and air compressors mounted to the engine auxiliary gear drive, or belt-driven components, such as air conditioning compressors and alternators. If larger components, such as PTOs, transmissions, generators or air compressors, are attached to other locations on the engine, the lifting straps provided with the engine are not intended for this purpose. Technician is responsible for providing adequate lifting devices under these situations. See machine technical manual for additional information on removing engine from machine.

NOTE: Use of an engine lifting sling (as shown) is the

ONLY APPROVED method for lifting engine.

3. Carefully lift engine and slowly lower to desired location.

02 010 5

Clean Engine

1. Cap or plug all openings (air intake, exhaust, fuel, coolant, etc.).

2. Remove electrical components (electronic control module-ECM, starter, alternator, etc.). Cover electrical components that are not removed (sensors, wiring harness, ECM connectors, etc.) with plastic and tape securely to prevent moisture damage.

IMPORTANT: Never steam clean or pour cold water

on an injection pump while it is still warm. To do so may cause seizure of pump parts. Avoid fuel pumps, injectors, bearings, belts and hoses, etc.

3. Thoroughly steam clean engine.

RG,03,JW7723 –19–21NOV03–2/2

CTM104 (27JAN06)

02-010-5

RG,RG34710,49 –19–07NOV03–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=67

Disconnect Turbocharger Oil Inlet Line

1. Drain all engine oil and coolant, if not previously done.

IMPORTANT: When servicing turbocharged engines

010

on a rollover stand, disconnect turbocharger oil inlet line (A) from oil filter housing or turbocharger before rolling engine over. Failure to do so may cause a hydraulic lock upon starting engine. Hydraulic lock may cause possible engine failure.

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 cylinder(s), filling them with oil, causing hydraulic lock and possible engine failure.

Engine Rebuild

RG7407 –UN–03NOV97

Turbocharger Oil Inlet Line

A—Oil Inlet Line

2. Disconnect turbocharger oil inlet line at turbocharger or oil filter housing.

RG,01,DT7046 –19–29OCT97–1/1

CTM104 (27JAN06)

02-010-6

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=68

Engine Rebuild

Mount Engine on Repair Stand

CAUTION: NEVER remove the overhead lifting equipment until the engine is securely mounted onto the repair stand and all mounting hardware is tightened to specified torque. Always release the overhead lifting equipment slowly.

On engines equipped with a low-profile turbocharger, remove turbocharger before attaching engine to repair stand.

On engines with a left-hand oil fill tube, remove tube before mounting engine to repair stand.

NOTE: See next procedure for illustration of an engine

that has been mounted on repair stand.

Mount the engine to 628351Engine Adapter as described below. A label (H) is affixed to the engine adapter for aid in explaining spacer used for each engine model.

02 010 7

RG9058 –UN–16MAR98

4045 Engine

NOTE: No. 2216681Spacer (G) is used on the outside of

the engine adapter for the 4045 Engines and on the inside (next to engine) on 6068 Engines.

Some later engines may not require the spacer.

4045 Engines

Hole A—(2) No. 2144901(M12 x 1.75 x 35 mm) Hole B—(1) No. 2216641(M14 x 2.00 x 35 mm) Hole C—(1) No. 2216651(M14 x 2.00 x 60 mm) with No.

2216681Spacer

6068 Engines

Hole D—(2) No. 2144901(M12 x 1.75 x 35 mm) Hole E—(1) No. 2216641(M14 x 2.00 x 35 mm)

6068 Engine

RG7787 –UN–11NOV97

RG8089 –UN–18NOV97

Engine Mounting Label

G—No. 221668 Spacer H—Label

Part of JT07268 Engine Adapter Kit

CTM104 (27JAN06)

Continued on next page

02-010-7

RG,03,JW7724 –19–18MAY00–1/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=69

Hole F—(1) No. 2216651(M14 x 2.00 x 60 mm) with No. 2216681Spacer

NOTE: Four threaded holes in engine mounting adapter

010

Engine Repair Stand M12 Cap

Screws—Torque 140 N•m (105 lb-ft)..........................................................

Engine Repair Stand M14 Cap

Screws—Torque 225 N•m (165 lb-ft)..........................................................

Part of JT07268 Engine Adapter Kit

are for storing mounting hardware.

Specification

Engine Mounted on Repair Stand

Engine Rebuild

RG,03,JW7724 –19–18MAY00–2/2

A—Engine B—62835 Engine Adapter C—D05226ST Special Adapter D—Engine Repair Stand

Engine Disassembly Sequence

The following sequence is suggested when complete disassembly for overhaul is required. Refer to the appropriate repair group for removal, inspection and repair of individual engine components.

6068 Engine

RG7780 –UN–11NOV97

RG,03,DT7334 –19–11NOV97–1/1

CTM104 (27JAN06)

Continued on next page

02-010-8

RG,04,JW7725 –19–15MAY02–1/4

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=70

Engine Rebuild

ENGINE DISASSEMBLY SEQUENCE

Procedure Reference

Mount engine on a safety approved repair stand. See MOUNT ENGINE ON REPAIR STAND in this group. Drain coolant and oil. Perform John Deere OILSCAN Plusand See OILSCAN Plusand COOLSCANin Section 01, Group 002.

COOLSCANanalysis. Remove fan belts, fan, and belt tensioner. See REMOVE AND INSTALL AUTOMATIC (SPRING) BELT

TENSIONER in Group 070. Remove alternator. See REMOVE AND INSTALL ALTERNATOR in Group 100. Remove turbocharger (if equipped). See REMOVE TURBOCHARGER in Group 080.

Remove exhaust manifold. See REMOVE, INSPECT AND INSTALL EXHAUST MANIFOLD in

Group 080. Remove rocker arm cover and vent tube. If option code label is See REMOVE CYLINDER HEAD in Group 020 or 021.

located on rocker arm cover, be careful not to damage label. On applications where the coolant manifold is not an integral part of See COOLING SYSTEM in Group 070.

cylinder head, remove coolant manifold or thermostat housing. Remove oil cooler piping and coolant pump. See REMOVE COOLANT PUMP in Group 070. Remove dipstick, oil filter, oil cooler, and adapter housing (if See REMOVE, INSPECT AND INSTALL OIL COOLER in Group 060.

equipped). Remove fuel filter assembly. See appropriate procedure:

• REPLACE FINAL FUEL FILTER/WATER BOWL AND PRE-FILTER/WATER BOWL in Group 090 of CTM331 (Level 12 Electronic Fuel System with Stanadyne DE10 Pump).

• REMOVE AND INSTALL FINAL FUEL FILTER/WATER SEPARATOR BASE in Group 090 of CTM170 (Level 4 Electronic Fuel Systems with Bosch VP44 Pump).

• REMOVE AND INSTALL FINAL FUEL FILTER/WATER BOWL AND/OR PRE-FILTER/WATER BOWL BASE in Group 090 of CTM331 (Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump).

• REMOVE AND INSTALL FINAL FUEL FILTER/WATER BOWL AND/OR PRE-FILTER/WATER BOWL BASE in Group 090 of CTM284 (Level 1 Electronic Fuel System with Delphi DP201 Pump).

• REMOVE AND INSTALL PRE-FILTER/WATER BOWL BASE in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

• REMOVE AND INSTALL FINAL FUEL FILTER/WATER BOWL BASE in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

02 010 9

OILSCAN is a registered trademark of Deere & Company. COOLSCAN is a trademark of Deere & Company

CTM104 (27JAN06)

Continued on next page

02-010-9

RG,04,JW7725 –19–15MAY02–2/4

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=71

Engine Rebuild

ENGINE DISASSEMBLY SEQUENCE

Procedure Reference

Remove fuel supply pump and fuel lines. See appropriate procedure:

010

Remove injection lines and injection pump. See appropriate procedure:

Remove injection nozzles. See appropriate procedure:

Remove starter motor. See REMOVE AND INSTALL STARTER in Group 100. Remove rocker arm assembly and push rods. Keep rods in order. See REMOVE CYLINDER HEAD in Group 020 or 021.

Check for bent push rods and condition of wear pad contact surfaces on rockers.

• REMOVE LUCAS AND STANADYNE FUEL SUPPLY PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• REMOVE DENSO IN-LINE FUEL SUPPLY PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• REMOVE MOTORPAL FUEL SUPPLY PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• REMOVE FUEL SUPPLY PUMP in Group 090 of CTM 331 (Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump).

• REMOVE MECHANICAL FUEL TRANSFER PUMP in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

• REMOVE STANADYNE MODEL DB2 AND DB4 INJECTION PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• REMOVE LUCAS FUEL INJECTION PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• REMOVE DENSO FUEL INJECTION PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• REMOVE MOTORPAL FUEL INJECTION PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• REMOVE BOSCH VP44 FUEL INJECTION PUMP in Group 090 of CTM170 (Level 4 Electronic Fuel Systems with Bosch VP44 Pump).

• REMOVE INJECTION PUMP in Group 090 of CTM331 (Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump).

• REMOVE FUEL INJECTION PUMP in Group 090 of CTM284 (Level 1 Electronic Fuel System with Delphi DP201 Pump).

• REMOVE AND INSTALL HIGH PRESSURE FUEL PUMP in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

• REMOVE AND INSTALL HIGH PRESSURE COMMON RAIL in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

• REMOVE FUEL INJECTION NOZZLES in Group 090 of CTM 207 (Mechanical Fuel Systems).

• REMOVE FUEL INJECTION NOZZLES in Group 090 of CTM170 (Level 4 Electronic Fuel Systems with Bosch VP44 Pump).

• REMOVE FUEL INJECTION NOZZLES in Group 090 of CTM331 (Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump).

• REMOVE FUEL INJECTION NOZZLES in Group 090 of CTM284 (Level 1 Electronic Fuel System with Delphi DP201 Pump).

• REMOVE ELECTRONIC INJECTORS in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

CTM104 (27JAN06)

Continued on next page

02-010-10

RG,04,JW7725 –19–15MAY02–3/4

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=72

Engine Rebuild

ENGINE DISASSEMBLY SEQUENCE

Procedure Reference

Remove cylinder head. See REMOVE CYLINDER HEAD in Group 020 or 021. Check piston protrusion. See MEASURE PISTON PROTRUSION in Group 030.

Remove camshaft followers. Keep followers in order. See INSPECT CAMSHAFT FOLLOWERS in Group 050. Remove flywheel. See REMOVE FLYWHEEL in Group 040.

Remove flywheel housing. See REMOVE FLYWHEEL HOUSING in Group 040. Remove oil pan. Drain oil and remove oil pan. Remove crankshaft pulley. See REMOVE PULLEY OR VIBRATION DAMPER AND PULLEY in

Group 040.

Remove oil pressure regulating valve assembly and cap (early See REMOVE AND INSTALL OIL PRESSURE REGULATING engines). VALVE in Group 060.

Remove timing gear cover. See REMOVE TIMING GEAR COVER in Group 050. Remove oil pump drive gear, outlet tube, and pump body. See REMOVE ENGINE OIL PUMP in Group 060. Remove timing gears and camshaft. Perform wear checks. See REMOVE CAMSHAFT in Group 050. Remove balancer shafts, if equipped (4045 engines). See REMOVE BALANCER SHAFTS in Group 050. Remove one piece oil pressure regulating valve assembly (later See REMOVE AND INSTALL OIL PRESSURE REGULATING

engines). VALVE in Group 060. Remove engine front plate. See REMOVE CYLINDER BLOCK FRONT PLATE in Group 050. Remove oil bypass valve. See REMOVE, INSPECT, AND INSTALL OIL BYPASS VALVE in

Group 060.

Stamp cylinder number on connecting rod. Perform wear checks with See INSPECT AND MEASURE CONNECTING ROD BEARINGS in PLASTIGAGE. Remove pistons and rods. Group 030.

Perform wear checks with PLASTIGAGE. Remove crankshaft and See REMOVE CRANKSHAFT in Group 040. main bearings.

Remove cylinder liners and mark each one with cylinder number. See REMOVE CYLINDER LINERS in Group 030. Remove piston cooling orifices. See REMOVE, INSPECT, AND INSTALL PISTON COOLING

ORIFICES in Group 030.

Remove balancer shaft bushings, if equipped (4045 engines), and See REMOVE AND INSTALL CAMSHAFT BUSHINGS in Group 050. camshaft bushing. See REMOVE AND INSTALL BALANCER SHAFT BUSHINGS in

Group 050.

Remove cylinder block plugs and serial number plate when block is See INSPECT AND CLEAN CYLINDER BLOCK in Group 030. to be put in a “hot tank”.

Clean upper and lower liner bores with nylon brush. See CLEAN CYLINDER LINERS in Group 030. Measure cylinder block. (Groups 030, 040 and 050.)

02 010 11

PLASTIGAGE is a registered trademark of the DANA Corp.

CTM104 (27JAN06)

02-010-11

RG,04,JW7725 –19–15MAY02–4/4

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=73

Sealant Application Guidelines

Engine Rebuild

Listed below are sealants which have been tested and are used by the John Deere factory to control leakage and ensure hardware retention. ALWAYS use the

following recommended sealants when assembling

010

your John Deere Engine to ensure quality

performance. LOCTITEthread sealants are designed to perform to

sealing standards with machine oil residue present. If excessive machine oil or poor cleanliness quality exist, clean with solvent. Refer to John Deere Merchandise and Parts Sales Manual for ordering information.

IMPORTANT: LOCTITEgasket materials are NOT

designed to work with oil residue present. Oil residues must be cleaned from surfaces before applying gasket material.

LOCTITE242 Thread Lock and Sealer (Medium Strength) (Blue):

TY9370, 6 ml tube/T43512, 50 ml tube

• Plugs and fittings: fuel filter base, fuel transfer pump, oil filter base housing, and cylinder block oil galleries.

• Cap screws: injection pump access cover, electronic tachometer cover, oil filler inlet, flywheel, fuel transfer pump, oil cooler housing-to-cylinder block (open holes only) and timing hole cover.

• Oil pressure sending unit.

LOCTITE271 Thread Lock and Sealer (High Strength) (Clear):

TY9371, 6 ml tube/T43513, 50 ml bottle

• Studs: water pump-to-cylinder block, injection pump-to-front plate.

• Oil filter nipple.

• Oil dipstick tube and fitting.

LOCTITE277 Rigid Form-In-Place Gasket (High Strength) (Red):

T43514, 50 ml bottle

• Steel cap plugs: cylinder block and cylinder head.

• O-ring adapter for oil pump outlet tube.

• Nipples and elbows which are pressed into place,

water pump housing, and oil cooler cover.

• Torque converter access hole plug.

LOCTITE515 Flexible Form-In-Place Gasket (General Purpose) (Purple):

PM38655, 50 ml bottle

• Flywheel housing-to-cylinder block.

• Flywheel housing-to-oil pan.

• Front and rear face of cylinder block.

• Front plate/timing gear cover-to-oil pan.

LOCTITE592 Pipe Sealant with TEFLON(White):

TY9374, 6 ml tube/TY9375, 50 ml tube

• Pipe plugs: cylinder block (water manifold), thermostat housing, water pump, flywheel housing (drain).

• Injection pump governor cover fitting (fuel return).

• Temperature sending unit.

• Oil pan (drain hose, drain valve, and elbow drain

fitting).

• Connectors: turbo line, turbo drain, and water return-to-cylinder block.

• Adapter fitting and plug for turbo lube on dual oil filter base.

• Air heater.

LOCTITE is a registered trademark of Loctite Corp.

TEFLON is a registered trademark of Du Pont Co.

CTM104 (27JAN06)

Continued on next page

02-010-12

RG,04,JW7726 –19–15MAY02–1/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=74

Engine Rebuild

LOCTITE620 High-Temperature Retaining Compound (Light Green):

TY15941, 50 ml tube

• Fuel injection nozzle sleeve (4-Valve cylinder head)

LOCTITE680 Maximum Strength Retaining Compound (Green):

TY15969, 50 ml tube

• Crankshaft wear sleeve.

• Camshaft nose.

HYLOMAR 101 Silicone Sealant (White)

PM710XX280, 85 gm tube

• Coolant pump insert.

RTV Silicone Sealant Form-In-Place Gasket (Blue):

TY16021, 50 ml tube

• Injection pump timing gear cover ONLY when traditional gasket is not available.

PT569 NEVER-SEEZCompound:

PT569, 227 g brush/PT506, 453 g spray

• Cap screws: exhaust manifold and turbine housing-to-center housing.

02 010 13

NEVER-SEEZ is a registered trademark of the Emhart Chemical

Group.

Use DD15664 LOCTITE 515 Flexible Sealant when servicing an engine within the European Market/Service Area. Follow manufacturer’s directions on package when using and storing sealant.

Engine Assembly Sequence

The following assembly sequence is suggested when engine has been completely disassembled. Be sure to check run-out specifications, clearance tolerances, torques, etc., as engine is assembled. Refer to the appropriate repair group when assembling engine components.

Continued on next page

RG,04,JW7726 –19–15MAY02–2/2

RG,04,DT7335 –19–15MAY02–1/5

CTM104 (27JAN06)

02-010-13

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=75

Engine Rebuild

ENGINE ASSEMBLY SEQUENCE

Procedure Reference

Install all plugs and serial number plate in cylinder block (if removed). See INSPECT AND CLEAN CYLINDER BLOCK in Group 030. Install piston cooling orifices. See REMOVE, INSPECT, AND INSTALL PISTON COOLING

010

Install new balancer shaft bushings, if equipped (4045 engines), and See REMOVE AND INSTALL CAMSHAFT BUSHINGS WITH FRONT

a new camshaft bushing. PLATE INSTALLED in Group 050.

Install cylinder liners without O-rings. Measure liner height. Install See INSTALL CYLINDER LINER IN BLOCK in Group 030. liners with O-rings.

Install main bearings and crankshaft. PLASTIGAGEbearings. See INSTALL CRANKSHAFT in Group 040. Install flywheel housing. See INSTALL FLYWHEEL HOUSING in Group 040.

Install rear oil seal. See INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE Install flywheel. in Group 040.

Install pistons and rods. Measure piston protrusion. See INSTALL PISTON AND CONNECTING ROD ASSEMBLY in

Install oil bypass valve. See REMOVE, INSPECT, AND INSTALL OIL BYPASS VALVE in

Install front plate. See INSTALL CYLINDER BLOCK FRONT PLATE in Group 050. Install one piece oil pressure regulating valve (later engines). See REMOVE AND INSTALL OIL PRESSURE REGULATING

Install balancer shafts, if equipped (4045 engines). Check end play. See INSTALL AND TIME BALANCER SHAFTS in Group 050. Install oil outlet tube, O-ring in block, and oil pump. See INSTALL ENGINE OIL PUMP in Group 060.

ORIFICES in Group 030.

See REMOVE AND INSTALL BALANCER SHAFT BUSHINGS in Group 050.

See INSTALL FLYWHEEL in Group 040.

Group 030.

Group 060.

VALVE in Group 060.

PLASTIGAGE is a registered trademark of the DANA Corp.

CTM104 (27JAN06)

Continued on next page

02-010-14

RG,04,DT7335 –19–15MAY02–2/5

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=76

Engine Rebuild

ENGINE ASSEMBLY SEQUENCE

Procedure Reference

Install injection lines and injection pump. See appropriate procedure:

• INSTALL STANADYNE MODEL DB2 AND DB4 INJECTION PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• INSTALL LUCAS FUEL INJECTION PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• INSTALL DENSO FUEL INJECTION PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• INSTALL MOTORPAL FUEL INJECTION PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• INSTALL BOSCH VP44 FUEL INJECTION PUMP in Group 090 of CTM170 (Level 4 Electronic Fuel Systems with Bosch VP44 Pump).

• INSTALL INJECTION PUMP in Group 090 of CTM331 (Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump).

• INSTALL FUEL INJECTION PUMP in Group 090 of CTM284 (Level 1 Electronic Fuel System with Delphi DP201 Pump).

• REMOVE AND INSTALL HIGH PRESSURE FUEL PUMP in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

• REMOVE AND INSTALL HIGH PRESSURE COMMON RAIL in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

• REMOVE AND INSTALL HIGH PRESSURE COMMON RAIL in Group 090 of CTM320 (Level 14 Electronic Fuel Systems with Denso High Pressure Common Rail).

Install camshaft and timing gears. See INSTALL CAMSHAFT in Group 050. Time all gears with No. 1 cylinder at TDC compression stroke.

Install timing gear cover. See INSTALL TIMING GEAR COVER in Group 050. Install new front seal. See REPLACE FRONT CRANKSHAFT OIL SEAL AND WEAR

SLEEVE in Group 040.

Install oil pressure regulating valve assembly and cap (early See REMOVE AND INSTALL OIL PRESSURE REGULATING engines). VALVE in Group 060.

Install oil pan. See INSTALL OIL PAN in Group 060. Install camshaft followers in same order as removed. See INSPECT, MEASURE, AND ASSEMBLE CAMSHAFT

FOLLOWERS in Group 020 or 021.

Install cylinder head gasket and cylinder head. See INSTALL CYLINDER HEAD in Group 020 or 021. Install push rods and rocker arm assembly. See INSTALL ROCKER ARM ASSEMBLY in Group 020 or 021.

Install starter motor. See REMOVE AND INSTALL STARTER in Group 100.

02 010 15

CTM104 (27JAN06)

Continued on next page

02-010-15

RG,04,DT7335 –19–15MAY02–3/5

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=77

Engine Rebuild

ENGINE ASSEMBLY SEQUENCE

Procedure Reference

Install injection nozzles. See appropriate procedure:

010

Install fuel filter assembly. See appropriate procedure:

Install fuel supply pump and fuel lines. See appropriate procedure:

Install oil cooler, new oil filter, and dipstick. See REMOVE, INSPECT, AND INSTALL OIL COOLER in Group

Install coolant manifold or thermostat housing and thermostats. See COOLING SYSTEM in Group 070.

• INSTALL FUEL INJECTION NOZZLES in Group 090 of CTM207 (Mechanical Fuel Systems).

• INSTALL FUEL INJECTION NOZZLES in Group 090 of CTM170 (Level 4 Electronic Fuel Systems with Bosch VP44 Pump).

• INSTALL FUEL INJECTION NOZZLES in Group 090 of CTM331 (Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump).

• ASSEMBLE FUEL INJECTION NOZZLES in Group 090 of CTM284 (Level 1 Electronic Fuel System with Delphi DP201 Pump).

• INSTALL ELECTRONIC INJECTORS in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

• REMOVE AND INSTALL FINAL FUEL FILTER AND/OR PRIMARY FUEL FILTER/WATER SEPARATOR BASE in Group 090 of CTM207 (Mechanical Fuel Systems).

• REMOVE AND INSTALL FINAL FUEL FILTER/WATER SEPARATOR BASE in Group 090 of CTM170 (Level 4 Electronic Fuel Systems with Bosch VP44 Pump).

• REMOVE AND INSTALL FINAL FUEL FILTER/WATER BOWL AND/OR PRE-FILTER/WATER BOWL BASE in Group 090 of CTM331 (Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump).

• REMOVE AND INSTALL FINAL FUEL FILTER/WATER BOWL AND/OR PRE-FILTER/WATER BOWL BASE in Group 090 of CTM284 (Level 1 Electronic Fuel System with Delphi DP201 Pump).

• REMOVE AND INSTALL PRE-FILTER/WATER BOWL BASE in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

• REMOVE AND INSTALL FINAL FUEL FILTER/WATER BOWL BASE in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

• INSTALL LUCAS AND STANADYNE FUEL SUPPLY PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• INSTALL DENSO IN-LINE FUEL SUPPLY PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• INSTALL MOTORPAL FUEL SUPPLY PUMP in Group 090 of CTM207 (Mechanical Fuel Systems).

• REMOVE FUEL SUPPLY PUMP in Group 090 of CTM331 (Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump).

• REMOVE MECHANICAL FUEL TRANSFER PUMP in Group 090 of CTM220 (Level 11 Electronic Fuel Systems with Denso High Pressure Common Rail).

060.

CTM104 (27JAN06)

Continued on next page

02-010-16

RG,04,DT7335 –19–15MAY02–4/5

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=78

Engine Rebuild

ENGINE ASSEMBLY SEQUENCE

Procedure Reference

Install exhaust manifold. See REMOVE, INSPECT AND INSTALL EXHAUST MANIFOLD in Install turbocharger. Prelube the turbocharger. Group 080. Install EGR cooler and coolant lines. See INSTALL TURBOCHARGER in Group 080. Install intake manifold. See INSTALL EGR COOLERin Group 080 Install EGR exhaust tube. Install EGR valve.

Install coolant pump and hoses. See INSTALL COOLANT PUMP in Group 070. Install crankshaft pulley or vibration damper. Use new damper. See INSTALL PULLEY OR VIBRATION DAMPER AND PULLEY in

Group 040. Install alternator. See REMOVE AND INSTALL ALTERNATOR in Group 100. Install belt tensioner, fan, and fan belts. See REMOVE AND INSTALL AUTOMATIC (SPRING) BELT

TENSIONER in Group 070. Adjust valves. See CHECK AND ADJUST VALVE CLEARANCE in Group 020 or

Install rocker arm cover and vent tube. 021.

See INSTALL ROCKER ARM COVER in Group 020 or 021. Fill engine with clean oil. Section 01, Group 002 Flush cooling system and refill with proper coolant. Section 01, Group 002 Perform engine break-in and standard performance checks. See PERFORM ENGINE BREAK-IN in this group.

02 010 17

Engine Break-In Guidelines

Engine break-in should be performed after overhaul or when the following repairs have been made:

• Main bearings, rod bearings, crankshaft, or any combination of these parts have been replaced.

• Pistons, rings, or liners have been replaced.

• Rear crankshaft oil seal and wear sleeve have been

replaced. (Primary objective is to see if oil seal still leaks.)

• Cylinder head has been removed.

• Injection pump has been removed or critical

adjustments have been made while it is on the engine. (Primary objective is to check power.)

RG,04,DT7335 –19–15MAY02–5/5

RG,RG34710,1053 –19–03NOV99–1/1

CTM104 (27JAN06)

02-010-17

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=79

Perform Engine Break-In

Engine Rebuild

IMPORTANT: If engine has a PTO, break-in can be

performed at the PTO if it is done as

010

specified below. To prevent possible damage to the PTO gearbox, DO NOT apply full load through the PTO for any longer than the specified 10 minutes below.

Use a dynamometer to perform the following preliminary break-in procedure. If necessary, preliminary engine break-in can be performed without a dynamometer if under controlled operating conditions.

IMPORTANT: USE ONLY John Deere Engine

Break-In Oil or equivalent. DO NOT use John Deere PLUS-50 oil or engine oils meeting API CI-4, API CH-4, API CG-4, API CF-4, API CF-2, API CF, ACEA E5, ACEA E4 or ACEA E3 performance levels during break-in period of an engine that has had a major overhaul. These oils will not allow an overhauled engine to properly wear during the break-in period.

If John Deere Engine Break-In Oil is not available, use diesel engine oil meeting API Service Classification CC, CD or CE or ACEA Specification E1 or E2.

IMPORTANT: During preliminary break-in,

periodically check engine oil pressure and coolant temperature. Also check for signs of fuel, oil, or coolant leaks.

Do not run engine at full load for more than 10 minutes at one time.

2. Start engine. Run at loads and speeds shown in following chart for time limits given.

PRELIMINARY ENGINE BREAK-IN AFTER MAJOR OVERHAUL

Time Load Engine Speed

1 minute No load 850 rpm 2 minutes No load Fast Idle 10 minutes 1/2—3/4 load 2000 rpm to rated

speed

10 minutes Full load Rated speed

3. After preliminary break-in, run engine 1—2 minutes at 1500 rpm, with no load before shut-down.

Do not add makeup oil until the oil level is BELOW the add mark. John Deere Engine Break-In Oil should be used to make up any oil consumed during break-in period.

DO NOT fill above the crosshatch pattern or FULL mark. Oil levels anywhere within the crosshatch are acceptable.

1. Fill engine crankcase to proper level with John Deere Engine Break-In Oil during break-in operation. Use break-in oil regardless of ambient temperature. This oil is specifically formulated to enhance break-in of John Deere diesel engines. Under normal conditions, do not exceed 100 hours with break-in oil.

4. Check and readjust valve clearance as necessary. Cylinder head retorque is not required.

NOTE: During the first 20 hours, avoid prolonged

periods of engine idling or sustained maximum load operation. If engine will idle longer than 5 minutes, stop engine.

5. Operate the engine at heavy loads with minimal idling during the break-in period.

If the engine has significant operating time at idle, constant speeds, and/or light load usage, an additional 100 hour break-in period is recommended, using a new change of John Deere Engine Break-In Oil and new John Deere oil filter.

CTM104 (27JAN06)

Continued on next page

02-010-18

RG,100,JW7645 –19–03JUN04–1/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=80

Engine Rebuild

Check engine oil level more frequently during engine break-in period. As a general rule, makeup oil should not need to be added during 100-hour break-in period. However, if makeup oil is required in the first 100-hour break-in, an additional 100-hour break-in period is required. Use a new change of John Deere Engine Break-In Oil and a new John Deere oil filter.

After 100 hours maximum, drain break-in oil and change oil filter. Fill crankcase with John Deere PLUS-50or TORQ-GARD SUPREMEor other heavy-duty diesel engine oil within the same service

PLUS-50 is a registered trademark of Deere & Company. TORQ-GARD SUPREME is a registered trademark of Deere & Company.

classification as recommended in this manual. See DIESEL ENGINE OIL—NON-CERTIFIED AND TIER 1 CERTIFIED ENGINES or DIESEL ENGINE OIL—TIER 2 ENGINES in Section 01, Group 002, Fuels, Lubricants, and Coolants.

NOTE: Some increase in oil consumption may be

expected when low viscosity oils are used. Check oil levels more frequently.

If air temperature is below —10°C (14°F), use an engine block heater.

RG,100,JW7645 –19–03JUN04–2/2

02 010 19

CTM104 (27JAN06)

02-010-19

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=81

010

Engine Rebuild

CTM104 (27JAN06)

02-010-20

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=82

Cylinder Head and Valves (Two-Valve Head Engines)

General Information

NOTE: Engines with four-valve head design are covered

in Group 021.

Group 020

OUO1089,0000236 –19–12JUN02–1/1

02 020 1

CTM104 (27JAN06)

02-020-1

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=83

Cylinder Head and Valves (Two-Valve Head Engines)

Check and Adjust Valve Clearance

CAUTION: To prevent accidental starting of engine while performing valve adjustments,

020

IMPORTANT: Valve clearance MUST BE checked and

always disconnect NEGATIVE (—) battery terminal.

adjusted with engine COLD.

1. Remove rocker arm cover and crankcase ventilator tube.

IMPORTANT: Visually inspect contact surfaces of

valve tips and rocker arm wear pads. Check all parts for excessive wear, breakage, or cracks. Replace parts that show visible damage.

Rocker arms that exhibit excessive valve clearance should be inspected more thoroughly to identify damaged parts.

2. Remove plastic plugs or cover plate from engine timing/rotation hole (A) and timing pin hole (B).

NOTE: Some engines are equipped with flywheel

housings which do not allow use of an engine flywheel rotation tool. These engines with straight nose crankshafts may be rotated from front nose of engine, using JDG966 Crankshaft Front/Rear Rotation Adapter.

3. Using JDE83 or JDE81-11Flywheel Turning Tool, rotate engine flywheel in running direction (clockwise viewed from front) until No. 1 cylinder is at TDC compression stroke. Insert JDG1571 or JDE81-4 Timing Pin in flywheel.

Flywheel Housing Timing Holes

RG7408 –UN–06AUG96

A—Timing/Rotation Hole B—Timing Pin Hole

If No. 1 cylinder rocker arms are loose, the engine is at No. 1 TDC compression.

JDG820 (formerly JDE81-1) Flywheel Turning Tool may be used if JDE81-1 is not available, JDG820 (formerly JDE81-1) Flywheel Turning Tool MUST be used for 6.8L engines in 7400 and 7600 Tractors.

CTM104 (27JAN06)

02-020-2

Continued on next page

PowerTech Plus 4.5L & 6.8L Diesel Engines

RG,05,DT7375 –19–07NOV03–1/5

013006

PN=84

Cylinder Head and Valves (Two-Valve Head Engines)

If No. 1 cylinder rocker arms are not loose, rotate engine one full revolution (360°) to No. 1 TDC compression.

4. With engine lock-pinned at TDC of No. 1 piston’s compression stroke, check valve clearance to following specifications. (Use sequence for 4-cylinder or 6-cylinder engines as outlined on next page.)

If valves need adjusting, loosen the jam nut (A) on rocker arm adjusting screw. Turn adjusting screw until feeler gauge slips with a slight drag. Hold the adjusting screw from turning with screwdriver and tighten jam nut to specifications. Recheck clearance again after tightening jam nut. Readjust clearance as necessary.

Specification

Intake Valve Clearance (Rocker Arm-to-Valve Tip) (Engine

Cold)—Clearance 0.36 mm (0.014 in.).......................................................

Exhaust Valve Clearance (Rocker Arm-to-Valve Tip) (Engine

Cold)—Clearance 0.46 mm (0.018 in.).......................................................

Specification

Rocker Arm Adjusting Screw Jam

Nut—Torque 27 N•m (20 lb-ft)....................................................................

Adjusting Valves

A—Adjusting Screw Jam Nut

RG,05,DT7375 –19–07NOV03–2/5

RG7409 –UN–06AUG96

02 020 3

5. Install rocker arm cover and crankcase ventilator tube.

Continued on next page

RG,05,DT7375 –19–07NOV03–3/5

CTM104 (27JAN06)

02-020-3

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=85

Cylinder Head and Valves (Two-Valve Head Engines)

4-Cylinder Engine:

NOTE: Firing order is 1-3-4-2.

1. Using JDG1571 or JDE81-4 Timing Pin, lock No. 1

020

piston at TDC compression stroke (B).

2. Adjust valve clearance on No. 1 and 3 exhaust valves and No. 1 and 2 intake valves.

3. Turn crankshaft 360°. Lock No. 4 piston at TDC compression stroke (C).

4. Adjust valve clearance on No. 2 and 4 exhaust valves and No. 3 and 4 intake valves.

A—Front of Engine B—No. 1 Piston TDC Compression C—No. 4 Piston TDC Compression E—Exhaust Valve I—Intake Valve

4-Cylinder Engine Valve Adjustment

RG4776 –UN–31OCT97

6-Cylinder Engine:

NOTE: Firing order is 1-5-3-6-2-4.

1. Lock No. 1 piston at TDC compression stroke (B).

2. Adjust valve clearance on No. 1, 3 and 5 exhaust valves and No. 1, 2, and 4 intake valves.

3. Turn crankshaft 360°. Lock No. 6 piston at TDC compression stroke (C).

4. Adjust valve clearance on No. 2, 4 and 6 exhaust valves and No. 3, 5, and 6 intake valves.

RG,05,DT7375 –19–07NOV03–4/5

RG4777 –UN–31OCT97

6-Cylinder Engine Valve Adjustment

A—Front of Engine B—No. 1 Piston TDC Compression C—No. 6 Piston TDC Compression E—Exhaust Valve I—Intake Valve

RG,05,DT7375 –19–07NOV03–5/5

CTM104 (27JAN06)

02-020-4

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=86

Cylinder Head and Valves (Two-Valve Head Engines)

Measure Valve Lift

IMPORTANT: For a more accurate measurement,

measure valve lift at 0.00 mm (0.00 in.) rocker arm-to-valve tip clearance and with engine COLD.

NOTE: Measuring valve lift provides an indication of wear

on camshaft lobes and camshaft followers or push rods.

02 020 5

1. Remove rocker arm cover.

2. Set No. 1 piston at TDC compression stroke and install JDG1571 or JDE81-4 Timing Pin in flywheel.

3. Set rocker arm-to-valve tip clearance to 0.00 mm (0.00 in.) for:

• No. 1 and 3 exhaust and No. 1 and 2 intake valves

on 4-cylinder engines.

• No. 1, 3, and 5 exhaust and No. 1, 2, and 4 intake

valves on 6-cylinder engines.

4. Place dial indicator tip on top of valve spring cap (retainer) or rotator. Preload indicator tip and set dial at

0.0 mm (0.0 in.).

5. Remove timing pin from flywheel and manually rotate engine one full revolution (360°) in running direction using appropriate flywheel turning tool.

6. Observe dial indicator reading as valve is moved to full open. Record maximum reading and compare with specifications given below.

Measuring Valve Lift

RG7410 –UN–23NOV97

RG4776 –UN–31OCT97

4-Cylinder Engine

Intake Valves—Lift 11.77—12.21 mm

Wear Limit 11.34 mm (0.447 in.)................................................................

Exhaust Valves—Lift 11.51—11.94 mm

Wear Limit 11.08 mm (0.436 in.)................................................................

.........................................................

.....................................................

Specification

(0.463—0.481 in.)

(0.453—0.470 in.)

7. Follow same procedure for all remaining valves and record readings.

CTM104 (27JAN06)

02-020-5

6-Cylinder Engine

A—Front of Engine B—No. 1 Piston TDC Compression C—No. 4 Piston or No. 6 Piston TDC

Compression E—Exhaust Valve I—Intake Valve

Continued on next page

PowerTech Plus 4.5L & 6.8L Diesel Engines

RG4777 –UN–31OCT97

RG,05,DT7374 –19–11NOV97–1/2

013006

PN=87

Cylinder Head and Valves (Two-Valve Head Engines)

If valve lift on all valves is within specifications, adjust valve lash to specified clearance. (See CHECK AND ADJUST VALVE CLEARANCE earlier in this group.)

020

If valve lift on one or more valves is not within specification, remove and inspect entire valve train and camshaft.

8. Rotate engine one full revolution (360°). Lock engine at:

• TDC No. 4 compression stroke for 4-cylinder

engines.

• TDC No. 6 compression stroke for 6-cylinder

engines.

9. Set rocker arm-to-valve tip clearance to 0.0 mm (0.0 in.) for:

• No. 2 and 4 exhaust and No. 3 and 4 intake valves

on 4-cylinder engines.

• No. 2, 4, and 6 exhaust and No. 3, 5, and 6 intake

valves on 6-cylinder engines.

10. Repeat steps 4—7.

CTM104 (27JAN06)

02-020-6

RG,05,DT7374 –19–11NOV97–2/2

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=88

Cylinder Head and Valves (Two-Valve Head Engines)

Remove Cylinder Head

In some applications, it may be necessary to remove engine from machine to service cylinder head. Refer to your Machine Technical Manual for engine removal procedure.

CAUTION: After operating engine, allow exhaust system to cool before working on engine.

Do NOT drain coolant until the coolant temperature is below operating temperature. Remove radiator filler cap only when the cap is cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

1. Drain engine oil and coolant.

NOTE: On engines equipped with a low-profile

turbocharger, remove turbocharger before attaching engine to repair stand.

02 020 7

2. Remove air inlet elbow. (See REMOVE AND INSTALL AIR INTAKE PIPE in Group 080.)

Continued on next page

RG,05,DT7373 –19–07NOV03–1/12

CTM104 (27JAN06)

02-020-7

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=89

Cylinder Head and Valves (Two-Valve Head Engines)

NOTE: Turbocharger may be removed from engine while

assembled to exhaust manifold, if desired.

3. On turbocharged engines, disconnect turbocharger oil

020

inlet and oil drain lines (A) at turbocharger (B). Remove turbocharger and exhaust elbow (shown removed). (See REMOVE TURBOCHARGER in Group

080.)

IMPORTANT: Replace rocker arm cover sealing ring

(D) every time the rocker arm cover is removed during engine or cylinder head overhaul.

4. Remove hex nuts and O-rings from rocker arm cover (C).

Lift off cover. Save O-rings for reassembly or replace as necessary.

A—Turbocharger Oil Inlet and Oil Drain Lines B—Turbocharger C—Rocker Arm Cover D—Rocker Arm Cover Sealing Ring

Turbocharger and Rocker Arm Cover

RG7454A –UN–21JUN02

5. Using guide studs, remove exhaust manifold (E).

NOTE: On some engines, the thermostat housing/coolant

manifold (F) is part of the cylinder head.

6. Remove thermostat housing/coolant manifold (F).

E—Exhaust Manifold F—Thermostat Housing/Coolant Manifold

Rocker Arm Cover Sealing Ring

RG7450A –UN–04NOV97

RG,05,DT7373 –19–07NOV03–2/12

RG7411 –UN–03NOV97

Thermostat Housing, Exhaust and Coolant Manifold

CTM104 (27JAN06)

Continued on next page

02-020-8

RG,05,DT7373 –19–07NOV03–3/12

PowerTech Plus 4.5L & 6.8L Diesel Engines

013006

PN=90

Cylinder Head and Valves (Two-Valve Head Engines)

NOTE: Position of fuel filters (A) and (B) and supply

pump (C) vary by engine and injection pump applications. See Section 02, Group 090 of CTM207—Mechanical Fuel Systems, CTM170— Level 4 Electronic Fuel Systems with Bosch VP44 Pump, CTM331—Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump, or CTM284—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump for procedures to remove filter(s) and/or supply pump as required.

02 020 9

7. Disconnect fuel lines and remove fuel filter(s) (A) and (B) and mounting brackets as required.

8. Remove fuel supply pump (C), if equipped. Inspect face of pump lever for wear. If worn flat or concave, replace supply pump.

9. Remove alternator, if desired. (See REMOVE AND INSTALL ALTERNATOR in Group 100.)

A—Final Fuel Filter B—Primary Fuel Filter/Water Separator C—Fuel Supply Pump

Fuel Filters

RG7745A –UN–07NOV97

RG10379 –UN–19OCT99

Fuel Filter and Supply Pump

RG,05,DT7373 –19–07NOV03–4/12

10. Remove thermostat housing-to-coolant pump tube

(D).

D—Thermostat Housing-to-Coolant Pump Tube

CTM104 (27JAN06)

Continued on next page

02-020-9

Thermostat Housing-to-Coolant Pump Tube

RG,05,DT7373 –19–07NOV03–5/12

PowerTech Plus 4.5L & 6.8L Diesel Engines

RG7412 –UN–03NOV97

013006

PN=91

Cylinder Head and Valves (Two-Valve Head Engines)

11. Remove fuel leakoff line (A) and fuel delivery lines (B) as an assembly. Remove fuel injection nozzles (C). See appropriate procedure:

020

• REMOVE FUEL INJECTION NOZZLES in Section

02, Group 090 of CTM207—Mechanical Fuel Systems.

• REMOVE FUEL INJECTION NOZZLES in Section

02, Group 090 of CTM170—Level 4 Electronic Fuel Systems with Bosch VP44 Pump.

• REMOVE FUEL INJECTION NOZZLES in Section

02, Group 090 of CTM331—Level 12 Electronic Fuel Systems with Stanadyne DE10 Pump.

• REMOVE FUEL INJECTION NOZZLES in Section

02, Group 090 of CTM284—Level 1 Electronic Fuel Systems with Delphi/Lucas DP201 Pump.

NOTE: Loosen all rocker arm adjusting screws prior to

removing assembly.

12. Remove rocker arm assembly.

Fuel Lines and Injection Nozzles

RG9095 –UN–27MAR98

A—Fuel Leakoff Line B—Fuel Delivery Lines C—Injection Nozzles

RG,05,DT7373 –19–07NOV03–6/12

CTM104 (27JAN06)

Continued on next page

02-020-10

Rocker Arm Assembly

RG,05,DT7373 –19–07NOV03–7/12

PowerTech Plus 4.5L & 6.8L Diesel Engines

RG7413 –UN–23NOV97

013006

PN=92

Cylinder Head and Valves (Two-Valve Head Engines)

13. Disconnect coolant temperature connector (A) from injection pump wiring harness.

A—Coolant Temperature Connector

02 020 11

14. Remove all push rods and identify for reassembly in the same location. Clean and inspect push rods.

Coolant Temperature Connector

RG7793 –UN–11NOV97

RG,05,DT7373 –19–07NOV03–8/12

RG7414 –UN–23NOV97

Valve Push Rods

CTM104 (27JAN06)

Continued on next page

02-020-11

RG,05,DT7373 –19–07NOV03–9/12

PowerTech Plus 4.5L & 6.8L Diesel Engines

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PN=93

Cylinder Head and Valves (Two-Valve Head Engines)

15. If a cylinder head gasket failure has occurred, check and record torque on each cylinder head cap screw before removing.

020

To check cylinder head cap screw torque: a. Make a reference mark (in-line) on socket (A) and

cylinder head surface (B). b. Loosen cap screw at least 1/2 turn. c. Retighten cap screw (using a torque wrench) until

reference marks align and record torque.

16. Remove all cylinder head cap screws and discard. Do not reuse cylinder head cap screws.

IMPORTANT: DO NOT use screwdrivers or pry bars

between cylinder block and head to loosen head gasket seal. Screwdrivers or pry bars can damage cylinder head and block gasket surfaces.

17. Lift cylinder head (A) from block using JDG23 Engine Lifting Sling, or heavy-duty chains, and a hoist. If cylinder head sticks, use a soft hammer to tap cylinder head.

Cylinder Head Cap Screws

RG6310 –UN–03NOV97

A—Mark on Socket B—Mark on Head Surface

RG,05,DT7373 –19–07NOV03–10/12

A—Cylinder Head

CTM104 (27JAN06)

Continued on next page

02-020-12

Cylinder Head

RG,05,DT7373 –19–07NOV03–11/12

PowerTech Plus 4.5L & 6.8L Diesel Engines

RG7415A –UN–03NOV97

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Cylinder Head and Valves (Two-Valve Head Engines)

18. Remove cylinder head gasket (B). Inspect for possible oil, coolant, or combustion chamber leaks. Also, check for evidence of incorrect head gasket being used.

NOTE: Do not rotate crankshaft with cylinder head

removed unless cylinder liners are secured with cap screws and large flat washers. (See CHECK CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK), later in this group.)

B—Head Gasket

02 020 13

RG7416 –UN–03NOV97

Cylinder Head Gasket

RG,05,DT7373 –19–07NOV03–12/12

CTM104 (27JAN06)

02-020-13

PowerTech Plus 4.5L & 6.8L Diesel Engines

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Cylinder Head and Valves (Two-Valve Head Engines)

Disassemble and Inspect Rocker Arm Shaft Assembly

NOTE: Note location of parts as rocker arms are

020

1. Remove plugs (A) and bowed washers (B) from rocker

2. Disassemble and inspect all parts for wear or damage.

46 mm (1.81 in.) Compressed

Height—Spring Tension 18—27 N (4—6 lb-force).....................................

Spring—Compressed Height 46 mm @ 18—27 N

Shaft—OD 19.99—20.02 mm

Wear Limit 19.94 mm (0.785 in.)................................................................

Shaft Support—Maximum ID 20.17 mm (0.794 in.)....................................

Bore—ID 20.07—20.12 mm

Wear Limit 20.17 mm (0.794 in.)................................................................

disassembled, to aid in assembly.

arm shaft.

Replace any parts that are damaged or not within specifications.

Rocker Arm Assembly—Specification

......................................

(1.81 in. @ 4—6 lb-force)

.....................................................................

(0.787—0.788 in.)

........................................................................

(0.790—0.792 in.)

A—Plug B—Washer

Rocker Arm Shaft

RG7417 –UN–03NOV97

RG7418 –UN–23NOV97

Rocker Arm Shaft OD

CTM104 (27JAN06)

02-020-14

Rocker Shaft Support ID

Rocker Arm Bore ID

RG,05,DT7372 –19–11NOV97–1/1

PowerTech Plus 4.5L & 6.8L Diesel Engines

RG7419 –UN–23NOV97

RG7420 –UN–23NOV97

013006

PN=96

john deere POWERTECH 4.5L Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual