John Deere POWERTECH 8.1 L Technical Manual

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POWERTECH 8.1 L

Diesel Engines

Base Engine

COMPONENT

TECHNICAL

MANUAL

For complete service information also see:

Deere Power Systems Group

CTM86 (20MAR01)

LITHO IN U.S.A.

ENGLISH

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 (CTM86) covers only the base engine. It is one of five volumes on 8.1 L engines. The following four companion manuals cover fuel system repair and diagnostics:

• CTM243—Mechanical Fuel Systems

• CTM134—Level 3 Electronic Fuel Systems

• CTM255—Level 9 Electronic Fuel Systems

• CTM68—Electronic Injection Fuel Systems

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

A set of all manuals covering the 8.1 L engines, except CTM68, can be obtained by purchasing CTM450 Binder Set.

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

applicable essential tools, service equipment, and other materials needed to do the job, service parts kits, specifications, wear tolerance, and torque values.

Before beginning repair on an engine, clean the engine and mount on a repair stand. (See CLEAN ENGINE in Group 010 and see MOUNT ENGINE ON REPAIR STAND in 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 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.

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.

Use this component technical manual in conjunction with the machine technical manual. An application listing in the introduction identifies engine-models/applications. See the machine technical manual for information on engine removal and installation, and gaining access to engine components.

Information is organized in sections and groups for the various components requiring service instruction. At the end of the book are summary listings of all

Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic types of failures and their causes.

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.

CTM86 (20MAR01) P

OWERTECH

DPSG,OUO1004,912 –19–15JUN99–1/1

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8.1 L Diesel Engines — Base Engine

032001

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John Deere Dealers

Introduction

The changes listed below make your CTM obsolete. Repair, operation, and diagnostics are now covered in five manuals. Discard CTM86 dated 06JUL99 and

replace with the following new manuals:

• CTM86—Base Engine

• CTM243—Mechanical Fuel Systems

• CTM134—Level 3 Electronic Fuel Systems

• CTM255—Level 9 Electronic Fuel Systems

• CTM68—Electronic Fuel Injection Systems

Also, copy these pages and route through your Service Department.

SECTION 01, GROUP 001 (Engine Identification)

• Updated engine model designation chart.

• Updated engine application charts.

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

• Updated engine oil and coolant application guidelines.

SECTION 02, GROUP 050 (Camshaft and Timing Gear Train Repair and Adjustment)

• Eliminated procedure to check valve lift. Use appropriate procedure from Group 020 or Group

021.

• Revised specifications for installation of crankshaft gear-driven auxiliary drive.

• Revised procedure for installation of thrust washer and timing gear cover.

SECTION 02, GROUP 060 (Lubrication System Repair and Adjustment)

• Added information for top-load oil filter.

SECTION 02, GROUP 070 (Cooling System Repair and Adjustment)

• Added belt routing diagrams.

• Revised procedure for installation of coolant pump.

SECTION 02, GROUP 080 (Air Intake and Exhaust System Repair and Adjustments)

SECTION 02, GROUP 010 (Engine Rebuild)

• Updated engine disassembly sequence.

• Updated engine assembly sequence.

• Updated sealant application guidelines.

SECTION 02, GROUP 020 (Cylinder Head and Valves Repair and Adjustment Serial Number ( —199,999)

• Repair procedures for cylinder head and valves on engines with serial number ( —199,999) are covered in this group.

SECTION 02, GROUP 021 (Cylinder Head and Valves Repair and Adjustment Serial Number (200,000— )

• Repair procedures for cylinder head and valves on engines with serial number (200,000— ) are covered in this group.

• Revised procedure for turbocharger inspection techniques.

• Eliminated procedure for adjusting turbocharger wastegate actuator.

• Revised specifications for installing turbocharger.

SECTION 02, GROUP 090 (Fuel System Repair and Adjustments)

NOTE: Repair procedures for fuel systems have been

have been moved to Section 02, Group 090 in the three following technical manuals:

•

CTM243—Mechanical Fuel Systems

•

CTM134—Level 3 Electronic Fuel Systems

•

CTM255—Level 9 Electronic Fuel Systems

SECTION 02, GROUP 100 (OEM Starting and Charging Systems)

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Introduction

• Starting and charging systems are covered in this new group.

SECTION 03, GROUP 120 (Base Engine Operation)

• Base engine theory of operation is covered in this new group.

NOTE: Fuel system theory of operation has been

moved to Section 03 in the three following technical manuals:

•

CTM243—Mechanical Fuel Systems

•

CTM134—Level 3 Electronic Fuel Systems

•

CTM255—Level 9 Electronic Fuel Systems

SECTION 04, GROUP 150 (Observable Diagnostics and Tests)

• Base engine observable diagnostics and tests are covered in this new section/group.

NOTE: Fuel system diagnostics and testing has been

moved to Section 04 in the three following technical manuals:

•

CTM243—Mechanical Fuel Systems

•

CTM134—Level 3 Electronic Fuel Systems

•

CTM255—Level 9 Electronic Fuel Systems

SECTION 05 (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 06 (Specifications)

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

• Updated bolt and cap screw torque values.

• Updated General OEM specifications.

• Updated dynamometer specifications.

• Updated turbocharger boost specifications

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About this Manual

Introduction

This component technical manual (CTM) covers the base engine for P

OWERTECH



8.1 L (494 cu. in.) diesel engines

produced in Waterloo, Iowa.

This manual is a complete revision of CTM86 (06JUL99). Replace earlier manual with the following new

manuals:

• CTM86 — P

OWERTECH



8.1 L Diesel Engines—Base

Engine

• CTM243 — P

OWERTECH



8.1 L Diesel Engines—

Mechanical Fuel Systems

• CTM134 — P

OWERTECH



6.8 L & 8.1 L Diesel Engines—Level 3 Electronic Fuel Systems with Bosch In-Line Pump

• CTM255 — 8.1 L Diesel Engines—Level 9 Electronic Fuel Systems with Denso In-Line Pump

• CTM68 —Electronic Fuel Injection Systems

Direction of engine crankshaft rotation in this manual is referenced facing the flywheel looking toward the fan. Front of engine is fan drive end.

Read each procedure completely before performing any service.

IMPORTANT: For repair, diagnostics, and testing

procedures on the fuel system, refer to the companion manuals:

• CTM243 — P

OWERTECH



8.1 L Diesel

Engines—Mechanical Fuel Systems

• CTM134 — P

OWERTECH



6.8 L & 8.1 L Diesel Engines—Level 3 Electronic Fuel Systems with Bosch In-Line Pump

• CTM255 — 8.1 L Diesel Engines—

Level 9 Electronic Fuel Systems with Denso In-Line Pump

• CTM68 —Electronic Fuel Injection

Systems

OWERTECH

is a registered trademark of Deere & Company

CTM86 (20MAR01) P

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Introduction

Identification Views Serial Number ( —199,999)

8.1 L Diesel Engine Right Front View (Engines —199,999)

RG7362 –UN–05JAN98

8.1 L Diesel Engines Left Front View (Engines —199,999)

RG7363 –UN–05JAN98

8.1 L Diesel Engines Right Side View (Engines —199,999)

RG7385 –UN–05JAN98

8.1 L Diesel Engines Left Side View (Engines —199,999)

CTM86 (20MAR01) P

OWERTECH

RG7387 –UN–05JAN98

RG,RG34710,4001 –19–14DEC00–1/2

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Introduction

8.1 L Diesel Engine Right Front View (Engines —199,999)

RG7388 –UN–20JUN00

8.1 L Diesel Engine Left Front View (Engines —199,999)

RG7386 –UN–20JUN00

8.1 L Diesel Engine Front View (Engines —199,999)

RG7383 –UN–05JAN98

8.1 L Diesel Engine Rear View (Engines —199,999)

CTM86 (20MAR01) P

OWERTECH

RG7384 –UN–05JAN98

RG,RG34710,4001 –19–14DEC00–2/2

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Introduction

Identification Views Serial Number (200,000— )

8.1 L Diesel Engine Right Front View (Engines 200,000— )

8.1 L Diesel Engine Front View (Engines 200,000— )

RG11511 –UN–13DEC00

RG11513 –UN–31OCT00

8.1 L Diesel Engines Left Front View (Engines 200,000— )

RG11512 –UN–31OCT00

RG11514 –UN–31OCT00

8.1 L Diesel Engine Rear View (Engines 200,000— )

CTM86 (20MAR01) P

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SECTION 01—General

Group 000—Safety Group 001—Engine Identification Group 002—Fuels, Lubricants and Coolant

SECTION 02—Repair and Adjustments

Group 010—Engine Rebuild Group 020—Cylinder Head and Valves Repair and

Adjustment S. N. ( —199,999)

Group 021—Cylinder Head and Valves Repair and

Adjustment S. N. (200,000— )

Group 030—Cylinder Block, Liners, Pistons, and

Rods Repair and Adjustment

Group 040—Crankshaft, Main Bearings and

Flywheel Repair and Adjustment

Group 050—Camshaft and Timing Gear Train

Repair and Adjustment

Group 060—Lubrication System Repair and

Adjustment Group 070—Cooling System Repair and Adjustment Group 080—Air Intake and Exhaust System Repair

and Adjustment Group 100—OEM Starting and Charging Systems

Repair and Adjustment

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.

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

Previous Editions

INDX

CTM86 (20MAR01)

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Contents

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Page

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

Group 001—Engine Identification

Engine Model Designation................01-001-1

Engine Serial Number Plate Information .....01-001-2

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

Engine Application Chart (John Deere

Agricultural Equipment) ................01-001-4

Engine Application Chart (John Deere

Construction Equipment) ...............01-001-5

Engine Application Chart (OEM) (Outside

Equipment Manufacturers)..............01-001-5

Group 002—Fuels, Lubricants and Coolant

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

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

Lubricity of Diesel Fuel ..................01-002-4

Dieselscan Fuel Analysis.................01-002-4

Diesel Engine Break-In Oil ...............01-002-5

Diesel Engine Oil ......................01-002-6

Extended Diesel Engine Oil Service

Intervals............................01-002-6

Alternative and Synthetic Lubricants ........01-002-7

Mixing of Lubricants ....................01-002-7

Oilscan and Coolscan ...................01-002-8

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

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

Diesel Engine Coolants, Supplemental

Additive Information..................01-002-11

Testing Diesel Engine Coolant ...........01-002-12

Replenishing Supplemental Coolant

Additives (SCAs) Between Coolant

Changes ..........................01-002-13

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

Contents

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Contents

CTM86 (20MAR01)

01-2

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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

Avoid Fires

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.

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

CTM86 (20MAR01)

01-000-1

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8.1 L Diesel Engines — Base Engine

PN=13

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000

Handling Batteries Safely

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.

Safety

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

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.

TS204 –UN–23AUG88TS203 –UN–23AUG88

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.

CTM86 (20MAR01)

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8.1 L Diesel Engines — Base Engine

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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

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.

First Aid Kit

TS291 –UN–23AUG88

DX,FIRE2 –19–03MAR93–1/1

X9811 –UN–23AUG88

High-Pressure Fluids

CTM86 (20MAR01)

01-000-3

OWERTECH

DX,FLUID –19–03MAR93–1/1



8.1 L Diesel Engines — Base Engine

PN=15

032001

000

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.

Service Machines Safely

Safety

TS206 –UN–23AUG88

Protective Clothing

DX,WEAR –19–10SEP90–1/1

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.

Moving Parts

TS228 –UN–23AUG88

DX,LOOSE –19–04JUN90–1/1

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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

01 000 5

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.

Engine exhaust fumes

TS220 –UN–23AUG88

DX,AIR –19–17FEB99–1/1

T6642EJ –UN–18OCT88

Clean Work Area

CTM86 (20MAR01)

01-000-5

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DX,CLEAN –19–04JUN90–1/1



8.1 L Diesel Engines — Base Engine

PN=17

032001

000

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 76 mm (3 in.) from area to be affected by heating.

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

Safety

TS220 –UN–23AUG88

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 be accidentally cut when heat goes beyond the immediate flame area.

DX,PAINT –19–22OCT99–1/1

TS953 –UN–15MAY90

Flammable Spray

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Safety

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.

01 000 7

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.

Work Area Safely

TS223 –UN–23AUG88

DX,LIGHT –19–04JUN90–1/1

TS226 –UN–23AUG88

Proper Lifting Equipment

CTM86 (20MAR01)

01-000-7

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DX,LIFT –19–04JUN90–1/1

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PN=19

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000

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.

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.

Construct Dealer-Made Tools Safely

LX1016749 –UN–01JUL97

DPSG,OUO1004,899 –19–19MAY99–1/1

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.

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

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01-000-8

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Keep Area Clean

DX,SERV –19–17FEB99–1/1



8.1 L Diesel Engines — Base Engine

PN=20

TS218 –UN–23AUG88

032001

Safety

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.

Use only service parts meeting John Deere specifications.

Dispose of Waste Properly

01 000 9

TS779 –UN–08NOV89

Proper Tools

DX,REPAIR –19–17FEB99–1/1

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.

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.

Recycle Waste

TS1133 –UN–26NOV90

DX,DRAIN –19–03MAR93–1/1

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000

Live With Safety

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

Safety

Safety Systems

TS231 –19–07OCT88

DX,LIVE –19–25SEP92–1/1

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Engine Model Designation

JOHN DEERE ENGINE MODEL—6081 John Deere engine model designation includes number of

cylinders, displacement in liters, aspiration, user code, and application code. For example:

6081 HRW01 Engine

6 ............................................................................ Number of cylinders

8.1 ............................................................................... Liter designation

H .................................................................................... Aspiration code

RW ........................................................................................ User code

01 ............................................................................... Application Code

Aspiration Code

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

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

H ............................................. Turbocharged and air-to-air aftercooled

User Code

CQ ................................................................ S.L.C. Horizontina (Brazil)

DW ........................................................................................ Davenport

F .................................................................................................... OEM

FF ........................................ Kernersvill Deere-Hitachi (North Carolina)

H ............................................................................................. Harvester

N ......................................................................................... Des Moines

RW ......................................................................... Waterloo (Tractors)

T .............................................................................................. Dubuque

TJ ............................................................................... Ontario (Canada)

........................................................................... Bessemer (Alabama)

Z ........................................................................................ Zweibrucken

Application Code

001, etc. ..... See ENGINE APPLICATION CHART, later in this Group

Group 001

Engine Identification

01 001 1

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001

Engine Serial Number Plate Information

IMPORTANT: The engine serial number plate can be

easily destroyed. Remove the plate or record the information elsewhere, before “hot tank” cleaning the block.

Engine Serial Number (A)

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:

Engine Identification

RG7010 –UN–26NOV97

Engine Serial Number Plate

RG6081H000000

RG ........................................................ Factory code producing engine

6081H ........................................................... Engine model designation

000000 .......................................................... Sequential serial number

Factory Code

RG ............................................................... Waterloo Engine Works

Engine Model Designation

6801H .................................... (See ENGINE MODEL DESIGNATION.)

Sequential Number

000000 .......................................................... 6-digit sequential number

The engine serial number plate is located either on the right-hand side of engine between the oil filter base and fuel injection pump (viewed from flywheel end) or on the left-hand side of the engine directly above the starter motor.

Engine Application Data (B)

The second line of information on the engine serial number plate identifies the engine/Deere machine or OEM relationship. SeeENGINE APPLICATION CHART later in this group.

A—Engine Serial Number B—Engine Application Data

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RG,RG34710,1022 –19–19MAY99–1/1

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032001

Engine Option Code Label

Engine Identification

01 001 3

Option Code Label

In addition to the serial number plate, later OEM engines have an engine option code label affixed to the rocker arm cover. These codes indicate which of the engine options were installed on your engine at the

RG11074 –UN–14AUG00

factory. When in need of parts or service, furnish your authorized servicing dealer or engine distributor with these numbers.

DPSG,OUO1004,900 –19–19MAY99–1/1

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01-001-3

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001

Engine Application Chart (John Deere

Agricultural Equipment)

Machine Model Engine Model DES MOINES—COTTON PICKERS

9970 Cotton Picker ............................................................. 6081AN001

9976 Cotton Picker .................................................... 6081HN001, 003

HARVESTER—COMBINES

9510 Low Power Combine ................................................. 6081HH001

9510 High Power Combine ................................................ 6081HH002

9550 Low Power Combine ................................................. 6081HH008

9550 High Power Combine ................................................ 6081HH009

9610 Combine .................................................................... 6081HH003

9650 and 9650CTS Combine ............................................ 6081HH010

9650 CTS-(Europe) Combine ............................................ 6081HH011

9650 STS Combine ............................................................ 6081HH006

9750 STS Combine ............................................................ 6081HH005

CTS II Combine (Europe-1998 Model Year ...................... 6081HH003

CTS II Combine (Europe-1999 Model Year) ..................... 6081HH004

CTS II Combine (North America) ....................................... 6081HH003

Amadus Peanut Combine .................................................. 6081HH007

WATERLOO—TRACTORS

7710 Tractor .............................................. 6081TRW01, 03, 05, 07, 09

7810 Tractor ....................................... 6081TRW02, 04, 06, 08, 10, 11

8100 Tractor ...................................................................... 6081HRW06

8200 Tractor ...................................................................... 6081HRW07

8300 Tractor ...................................................................... 6081HRW08

8400 Tractor ................................................................ 6081HRW01, 04

8100T (Tracks) Tractor ..................................................... 6081HRW10

8200T (Tracks) Tractor ..................................................... 6081HRW02

8300T (Tracks) Tractor ..................................................... 6081HRW09

8400T (Tracks) Tractor ..................................................... 6081HRW03

8110 Tractor ...................................................................... 6081HRW11

8210 Tractor ...................................................................... 6081HRW13

8310 Tractor ...................................................................... 6081HRW15

8410 Tractor ...................................................................... 6081HRW17

8110T (Tracks) Tractor ..................................................... 6081HRW12

8210T (Tracks) Tractor ..................................................... 6081HRW14

8310T (Tracks) Tractor ..................................................... 6081HRW16

8410T (Tracks) Tractor ..................................................... 6081HRW18

9100 4-Wheel Drive Tractor .............................................. 6081HRW05

ZWEIBRUCKEN—COMBINES/FORAGE HARVESTERS

2256 Combine ............................................................. 6081HZ003, 007

2258 Combine ............................................................... 6081HZ002, 05

2264 Combine ..................................................................... 6081HZ002

2266 Combine ..................................................................... 6081HZ001

2268 Combine ..................................................................... 6081HZ006

6650 Self-Propelled Forage Harvester ............................... 6081HZ004

S.L.C. HORIZONTINA (BRAZIL)—COMBINES

1185A Combine ................................................................. 6081ACQ01

Engine Identification

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8.1 L Diesel Engines — Base Engine

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Engine Identification

Engine Application Chart (John Deere Construction Equipment)

Machine Model Engine Model DAVENPORT

644G Loader ..................................................................... 6081HDW04

644H Loader ..................................................................... 6081HDW05

644H-MH Loader ............................................................... 6081HDW06

740G/748G/748G II/748G III Skidder ............................... 6081TDW01

770C (Late)/770CH/772CH Motor Grader ........................ 6081HDW01

770C Motor Grader (Early) ............................................... 6081HDW03

DUBUQUE

762B Series II Scraper ........................................................ 6081AT001

850C Series II Crawler Dozer (822868— ) ........................ 6081AT002

KERNERSVILLE (DEERE-HITACHI)

330LC/370 Excavator .......................................................... 6081HT001

BESSEMER

530B/535 Log Loader ......................................................... 6081ATJ01

WOODSTOCK, ON

660D Skidder ...................................................................... 6081ATJ02

01 001 5

Engine Application Chart (OEM) (Outside Equipment Manufacturers)

Application Engine Model

OEM Engine (Tier I Emissions Certified) ........................ 6081TF001

OEM Engine (Tier I Emissions Certified) ............................ 6081AF001

OEM Engine (Tier I Emissions Certified) ............................ 6081HF001

Marine Engine .................................................................... 6081AFM01

OEM Engine (Tier II Emissions Certified) ........................... 6081HF070

RG41183,0000024 –19–25JAN01–1/1

RG41183,000003A –19–28FEB01–1/1

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001

Engine Identification

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8.1 L Diesel Engines — Base Engine

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Diesel Fuel

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

Group 002

Fuels, Lubricants and Coolant

01 002 1

Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test.

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.

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

Cetane number of 40 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.

Sulfur content:

• Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred.

• If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the service interval for engine oil and filter by 50%.

• DO NOT use diesel fuel with sulfur content greater than 1.0%.

DO NOT mix used engine oil or any other type of lubricant with diesel fuel.

RG41165,0000071 –19–13MAR01–1/1

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Fuels, Lubricants and Coolant

002

Bio-Diesel Fuel

Bio-diesel fuels may be used ONLY if the fuel properties meet DIN 51606 or equivalent specification. It has been shown that bio-diesel fuels have been found to improve lubricity in concentrations up to 5% blend in petroleum diesel fuel.

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

IMPORTANT: Raw pressed vegetable oils are NOT

acceptable for use for fuel in any concentration in John Deere engines. These oils do not burn completely, and will cause engine failure by leaving deposits on injectors and in the combustion chamber.

Users of bio-diesel fuel should always remember that a major selling merit is its ability to biodegrade, so the storage and handling of this fuel is very important. This importance can be seen in the following areas of concern:

• The quality of the fresh 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/blocked injector nozzles, leading to poor

atomization of fuel,

• Filter plugging,

• Lacquering/seizure of internal components,

• Sludge and sediments,

• Reduced service life.

CTM86 (20MAR01)

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01-002-2

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

8.1 L Diesel Engines — Base Engine

PN=30

032001

Fuels, Lubricants and Coolant

Bio-Diesel Property List for DIN 51606

Property Unit DIN 51606 Sept 1997

Density at 15° C(59° F) g/cm3(lb/ft3) 0.875—0.900 (55—56) Viscosity at 40° C(104° F) mm2/s (cST) 3.5—5.0 Flash Point °C(°F) Min. 110 (230) Cold Filter Plugging Point—Summer °C(°F) Max. 0 (32) Cold Filter Plugging Point—Winter °C(°F) Max. -20 (-4) Total Sulfur % Mass 0.01 Conradson (CCR) at 100% % Mass Max. 0.05 Cetane Number — Min. 49 Ash Content % Mass Max. 0.03 Water Content % Mass Max. 0.03 Total Contamination % Mass Max. 0.002 Copper Corrosion (3 hours, 50° C) (3 hours, Degree of Corrosion 1

122° F) Neutralization Value mg KOH/g Max. 0.5 Methanol Content % Mass Max. 0.3 Monoglycerides % Mass Max. 0.8 Diglycerides % Mass Max. 0.4 Trigycerides % Mass Max. 0.4 Free Glycerine % Mass Max. 0.02 Total Glycerine % Mass Max. 0.25 Iodine Number — Max. 115 Phosphorus % Mass Max. 0.001 Alkali Content (Na + K) % Mass Max. 0.0005

01 002 3

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Fuels, Lubricants and Coolant

002

Lubricity of Diesel Fuel

Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components.

Diesel fuels for highway use in the United States and Canada require sulfur content less than 0.05%.

Diesel fuel in the European Union requires sulfur content less than 0.05%.

Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components. The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks.

Use of low lubricity diesel fuels may also cause accelerated wear, injection nozzle erosion or corrosion, engine speed instability, hard starting, low power, and engine smoke.

Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test.

ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test.

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

Dieselscan Fuel Analysis

DIESELSCAN is a John Deere fuel sampling program to help you monitor the quality of your fuel source. It verifies fuel type, cleanliness, water content, suitability for cold weather operation, and if fuel is within ASTM specifications. Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

DX,FUEL5 –19–24JAN00–1/1

DX,FUEL6 –19–06DEC00–1/1

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8.1 L Diesel Engines — Base Engine

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Fuels, Lubricants and Coolant

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.

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

01 002 5

• ACEA Specification 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 API CH-4, API CG4, API CF4, ACEA E3, or ACEA E2 performance levels during the first 100 hours of operation of a new or rebuilt engine. These oils will not allow the engine to break-in properly.

PLUS-50 is a registered trademark of Deere & Company.

DX,ENOIL4 –19–24JAN00–1/1

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8.1 L Diesel Engines — Base Engine

PN=33

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Fuels, Lubricants and Coolant

002

Diesel Engine Oil

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

The following oil is preferred:

• John Deere PLUS-50



The following oil is also recommended:

• John Deere TORQ-GARD SUPREME



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

• API Service Classification CH-4

• API Service Classification CG-4

• API Service Classification CF-4

• ACEA Specification E3

• ACEA Specification E2

Multi-viscosity diesel engine oils are preferred.

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

Extended service intervals may apply when John Deere preferred engine oils are used. Consult your John Deere dealer for more information.

TS1661 –UN–10OCT97

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

Extended Diesel Engine Oil Service Intervals

When John Deere PLUS-50oil and the specified John Deere filter are used, the service interval for engine oil and filter changes may be increased by 50%.

If other than PLUS-50oil and the specified John Deere filter are used, change the engine oil and filter at the normal service interval.

PLUS-50 is a trademark of Deere & Company

CTM86 (20MAR01)

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DX,ENOIL6 –19–10OCT97–1/1



8.1 L Diesel Engines — Base Engine

PN=34

032001

Fuels, Lubricants and Coolant

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual.

Some John Deere brand coolants and lubricants may not be available in your location.

Consult your John Deere dealer to obtain information and recommendations.

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils.

Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

01 002 7

Mixing of Lubricants

In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements.

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

DX,ALTER –19–15JUN00–1/1

Consult your John Deere dealer to obtain specific information and recommendations.

DX,LUBMIX –19–18MAR96–1/1

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8.1 L Diesel Engines — Base Engine

PN=35

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Fuels, Lubricants and Coolant

002

OILSCANand CoolScan



OILSCANand CoolScanare John Deere sampling programs to help you monitor machine performance and identify potential problems before they cause serious damage.

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

Check with your John Deere dealer for the availability of OILSCANand CoolScankits.

T6828AB –UN–15JUN89T6829AB –UN–18OCT88

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

DPSG,OUOD002,1824 –19–02AUG00–1/1

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8.1 L Diesel Engines — Base Engine

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Fuels, Lubricants and Coolant

Grease

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

The following greases are preferred:

• John Deere SD POLYUREA GREASE The following greases are also recommended:

• John Deere HD MOLY GREASE

• 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 thickener are not

compatible with others. Consult your grease supplier before mixing different types of grease.

01 002 9

TS1667 –UN–30JUN99

CTM86 (20MAR01)

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

8.1 L Diesel Engines — Base Engine

PN=37

032001

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).

The following engine coolant is preferred for service:

• John Deere COOL-GARD Prediluted Coolant The following engine coolant is also recommended:

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

Fuels, Lubricants and Coolant

protection at lower temperatures is required, consult your John Deere dealer for recommendations.

Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol base engine coolant concentrate.

IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains sealing additives.

Coolant Drain Intervals

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

• ASTM D5345 (prediluted coolant)

• ASTM D4985 (coolant concentrate) in a 40 to 60%

mixture of concentrate with quality water

Coolants meeting these specifications require use of supplemental coolant additives, formulated for heavy-duty diesel engines, for protection against corrosion and cylinder liner erosion and pitting.

A 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -37°C (-34°F). If

Drain the factory fill engine coolant, flush the cooling system, and refill with new coolant after the first 3 years or 3000 hours of operation. Subsequent drain intervals are determined by the coolant used for service. At each interval, drain the coolant, flush the cooling system, and refill with new coolant.

When John Deere COOL-GARD is used, the drain interval may be extended to 5 years or 5000 hours of operation, provided that the coolant is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive.

If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation.

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

8.1 L Diesel Engines — Base Engine

PN=38

032001

Fuels, Lubricants and Coolant

Diesel Engine Coolants, Supplemental Additive Information

Engine coolants are a combination of three chemical components: ethylene 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.

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

Coolants meeting ASTM D5345 (prediluted coolant) or ASTM D4985 (coolant concentrate) require an initial charge of supplemental coolant additives.

Replenish Coolant Additives

The concentration of coolant additives is gradually depleted during engine operation. Periodic replenishment of inhibitors is required, even when John Deere COOL-GARD 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 simple mixture of ethylene glycol and water will not give adequate protection.

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 or ASTM D4656). 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.

Non-Aqueous Propylene Glycol

Non-aqueous propylene glycol should not be used with John Deere diesel engines. This coolant works best with coolant temperatures above the acceptable engine operating range. This could decrease engine life due to lower engine oil viscosity. In addition, electronically controlled engines could experience premature power de-rate due to high coolant temperature.

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 base engine coolant concentrate. All water used in the cooling system should meet the following minimum specifications for quality:

Chlorides 40 mg/L or less Sulfates 100 mg/L or less Total Dissolved Solids 340 mg/L or less Total Hardness 170 mg/L or less pH Level 5.5 to 9.0

Freeze Protection

01 002 11

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.

CTM86 (20MAR01)

The relative concentrations of ethylene glycol and water in the engine coolant determine its freeze protection limit. Refer to the chart on the following page.

Continued on next page

01-002-11

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

8.1 L Diesel Engines — Base Engine

PN=39

032001

Fuels, Lubricants and Coolant

002

Ethylene Glycol Freeze Protection Limit

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

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

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

DPSG,OUOD002,1835 –19–03AUG00–2/2

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

For a more thorough evaluation of your coolant, perform a CoolScan analysis. See your John Deere dealer for information about CoolScan.

DPSG,OUOD002,1825 –19–02AUG00–1/1

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

8.1 L Diesel Engines — Base Engine

PN=40

032001

Fuels, Lubricants and Coolant

Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes

01 002 13

IMPORTANT: Do not add supplemental coolant

additives when the cooling system is drained and refilled with John Deere ANTIFREEZE/SUMMER COOLANT or John Deere COOL-GARD.

NOTE: If a system is to be filled with coolant that does

not contain SCAs, the coolant must be precharged. Determine the total system capacity and premix with 3% John Deere Coolant Conditioner.

Through time and use, the concentration of coolant additives is gradually depleted during engine operation. Periodic replenishment of inhibitors is required, even when John Deere ANTIFREEZE/SUMMER COOLANT is used. The cooling system must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner.

RG6261 –UN–08DEC97

Maintaining the correct coolant conditioner concentration (SCAs) and freeze point is essential in your cooling system to protect against rust, liner pitting and corrosion, and freeze-ups due to incorrect coolant dilution.

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

DO NOT mix one brand of SCA with a different brand.

Test the coolant solution at 600 hours or 12 months of operation using either John Deere coolant test strips or a COOLSCANanalysis. If a COOLSCANanalysis is not available, recharge system per instructions printed on label of John Deere Liquid Coolant Conditioner.

RG6262 –UN–05DEC97

COOL-GARD is a registered trademark of Deere & Company COOLSCAN is a registered trademark of Deere & Company.

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RG,01,DT7035 –19–14NOV00–1/2



8.1 L Diesel Engines — Base Engine

PN=41

032001

Fuels, Lubricants and Coolant

002

IMPORTANT: ALWAYS maintain coolant at correct

level and concentration. DO NOT operate engine without coolant for even a few minutes.

If frequent coolant makeup is required, the glycol concentration should be checked with JT07298 Coolant/Battery Tester to ensure that the desired freeze point is maintained. Follow manufacturer’s instructions provided with Coolant/Battery Tester.

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

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

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

See DIESEL ENGINE COOLANTS, SUPPLEMENTAL ADDITIVE INFORMATION earlier in this group for proper mixing of coolant ingredients before adding to the cooling system.

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.

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,DT7035 –19–14NOV00–2/2

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

8.1 L Diesel Engines — Base Engine

PN=42

032001

Fuels, Lubricants and Coolant

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. See CHECKING COOLING SYSTEM in operator’s manual.

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 with in 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.

01 002 15

TS281 –UN–23AUG88

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

service interval. See LUBRICATION AND MAINTENANCE SERVICE INTERVAL CHART in operator’s manual.

Flush cooling system as described in your operator’s manual. See FLUSHING COOLING SYSTEM in operator’s manual. Clean cooling system with clean water and TY15979 John Deere Heavy-Duty Cooling System Cleaner or an equivalent 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.

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

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PN=43

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Fuels, Lubricants and Coolant

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

CTM86 (20MAR01)

01-002-16

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=44

032001

Section 02

Repair and Adjustments

Contents

Page Page

Group 010—Engine Rebuild

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

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

Safety Precautions .....................02-010-2

Install Adapters on Engine Repair Stand.....02-010-2

Engine Lifting Procedure.................02-010-3

Clean Engine .........................02-010-4

Disconnect Turbocharger Oil Inlet Line ......02-010-5

Mount Engine on Repair Stand ............02-010-6

Engine Disassembly Sequence for

Overhaul ...........................02-010-8

Sealant Application Guidelines ............02-010-9

6081 Engine Assembly Sequence After

Overhaul ..........................02-010-11

Engine Break-In Guidelines..............02-010-13

Perform Engine Break-In................02-010-14

Check Crankcase Ventilation System ......02-010-16

Check Air Intake System................02-010-16

Check Exhaust System.................02-010-17

Check and Service Cooling System .......02-010-17

Check Electrical System ................02-010-19

General Tune-Up Recommendations ......02-010-21

Group 020—Cylinder Head and Valves Repair and

Adjustment S. N. ( —199,999)

Check and Adjust Valve Clearance Serial

Number ( —199,999)..................02-020-1

Check Valve Lift Serial Number

( —199,999) ........................02-020-5

Remove Cylinder Head Serial Number

( —199,999) ........................02-020-6

Head Gasket Inspection and Repair

Sequence Serial Number ( —199,999) ....02-020-9

Disassemble and Inspect Rocker Arm Shaft

Assembly Serial Number

( —199,999) .......................02-020-11

Assemble Rocker Arm Shaft Assembly

Serial Number ( —199,999)............02-020-12

Measure Valve Recess Serial Number

( —199,999) .......................02-020-13

Preliminary Cylinder Head and Valve

Checks Serial Number ( —199,999) .....02-020-14

Remove Valve Assembly Serial Number

( —199,999) .......................02-020-15 ( —199,999) .......................02-020-32

Inspect and Measure Valve Springs Serial

Number ( —199,999).................02-020-16

CTM86 (20MAR01)

Inspect Valve Spring Caps, Wear Caps, and

Retainer Locks Serial Number

( —199,999) .......................02-020-17

Clean Valves Serial Number ( —199,999). . .02-020-17 Inspect and Measure Valves Serial Number

( —199,999) .......................02-020-18

Grind (Reface) Valves Serial Number

( —199,999) .......................02-020-19

Inspect and Clean Cylinder Head Serial

Number ( —199,999).................02-020-19

Check Cylinder Head Combustion Face

Flatness Serial Number ( —199,999).....02-020-20

Measure Cylinder Head Thickness Serial

Number ( —199,999).................02-020-21

Clean Valve Guides Serial Number

( —199,999) .......................02-020-22

Measure Valve Guides Serial Number

( —199,999) .......................02-020-22

Knurl Valve Guides Serial Number

( —199,999) .......................02-020-23

Clean and Inspect Valve Seats Serial

Number ( —199,999).................02-020-23

Measure Valve Sears Serial Number

( —199,999) .......................02-020-24

Grind Valve Seats Serial Number

( —199,999) .......................02-020-25

Remove Valve Seat Inserts Serial Number

( —199,999) .......................02-020-26

Install Valve Seat Inserts Serial Number

( —199,999) .......................02-020-27

Inspect and Clean Cylinder Head Nozzle

Bore Serial Number ( —199,999)........02-020-27

Clean and Inspect Push Rods Serial Number

( —199,999) .......................02-020-29

Inspect and Clean Ventilator Outlet Hose

Serial Number ( —199,999)............02-020-29

Clean and Inspect Top Deck of Cylinder

Block Serial Number ( —199,999) .......02-020-30

Measure Cylinder Liner Standout (Height

Above Block) Serial Number

( —199,999) .......................02-020-31

Assemble Valve Assembly Serial Number

Continued on next page

02-1

OWERTECH



8.1 L Diesel Engines — Base Engine

032001

PN=1

Contents

Page Page

Install Cylinder Head and Cap Screws Grind (Reface) Valves Serial Number

Serial Number ( —199,999)............02-020-33

Torque-to-Yield Flanged-Head Cap Screws—

Grade 180 Marked “SPECIAL” Serial

Number ( —199,999).................02-020-35

Install Rocker Arm Assembly Serial Number

( —199,999) .......................02-020-36

Inspect and Clean Ventilator Outlet Hose

Serial Number ( —199,999)............02-020-37

Complete Final Assembly of Injection Pump

Side of Engine Serial Number

( —199,999) .......................02-020-38

Complete Final Assembly on Exhaust

Manifold Side of Engine Serial Number

( —199,999) .......................02-020-39

Perform Engine Break-In Serial Number

( —199,999) .......................02-020-40

(200,000— ) .......................02-021-22

Inspect and Clean Cylinder Head Serial

Number (200,000— ).................02-021-23

Check Cylinder Head Combustion Face

Flatness Serial Number (200,000— ).....02-021-24

Measure Cylinder Head Thickness Serial

Number (200,000— ).................02-021-25

Clean Valve Guides Serial Number

(200,000— ) .......................02-021-26

Measure Valve Guides Serial Number

(200,000— ) .......................02-021-26

Knurl Valve Guides Serial Number

(200,000— ) .......................02-021-27

Clean and Inspect Valve Seats Serial

Number (200,000— ).................02-021-27

Measure Valve Seats Serial Number

(200,000— ) .......................02-021-28

Group 021—Cylinder Head and Valves Repair and

Adjustment S. N. (200,000— )

Check Valve Clearance Serial Number

(200,000— ) ........................02-021-1

Adjust Valve Clearance Serial Number

(200,000— ) ........................02-021-4

Check Valve Lift Serial Number

(200,000— ) ........................02-021-8

Remove Cylinder Head Serial Number

(200,000— ) ........................02-021-9

Diagnosing Head Gasket Joint Failures

Serial Number (200,000— )............02-021-11

Head Gasket Diagnostic Charts Serial

Number (200,000— ).................02-021-13

Head Gasket Inspection and Repair

Sequence Serial Number (200,000— ) . . .02-021-14

Inspect Rocker Arm Assembly Serial Number

(200,000— ) .......................02-021-16

Disassemble and Assemble Rocker Arm

Assembly Serial Number (200,000— )....02-021-17

Measure Valve Recess Serial Number

(200,000— ) .......................02-021-17

Preliminary Cylinder Head and Valve

Checks Serial Number (200,000— ) .....02-021-18

Remove Valve Assembly Serial Number

(200,000— ) .......................02-021-19

Inspect and Measure Valve Springs Serial

Number (200,000— ).................02-021-20

Inspect Valve Spring Caps, Wear Caps, and

Retainer Locks Serial Number

(200,000— ) .......................02-021-20

Clean Valves Serial Number (200,000— ). . .02-021-21

Grind Valve Seats Serial Number

(200,000— ) .......................02-021-29

Remove Valve Seat Inserts and Measure

Bores in Cylinder Head Serial Number

(200,000— ) .......................02-021-30

Install Valve Seat Inserts Serial Number

(200,000— ) .......................02-021-31

Inspect and Clean Cylinder Head Nozzle

Bore Serial Number (200,000— )........02-021-31

Clean and Inspect Push Rods Serial Number

(200,000— ) .......................02-021-32

Clean and Inspect Top Deck of Cylinder

Block Serial Number (200,000— ) .......02-021-32

Measure Cylinder Liner Standout (Height

Above Block) Serial Number

(200,000— ) .......................02-021-33

Assemble Valve Assembly Serial Number

(200,000— ) .......................02-021-34

Install Cylinder Head and Cap Screws

Serial Number (200,000— )............02-021-35

Torque-to-Yield Flanged-Head Cap Screws—

Grade 180 Marked “SPECIAL” Serial

Number (200,000— ).................02-021-37

Install Rocker Arm Assembly Serial Number

(200,000— ) .......................02-021-39

Inspect and Clean Ventilator Outlet Hose

Serial Number (200,000— )............02-021-39

Complete Final Assembly of Fuel Pump Side

of Engine Serial Number

(200,000— ) .......................02-021-40

Complete Final Assembly on Exhaust

Manifold Side of Engine Serial Number

(200,000— ) .......................02-021-41

Inspect and Measure Valves Serial Number

(200,000— ) .......................02-021-21

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02-2

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

8.1 L Diesel Engines — Base Engine

Continued on next page

032001

PN=2

Contents

Page Page

Perform Engine Break-In Serial Number Group 040—Crankshaft, Main Bearings and

(200,000— ) .......................02-021-42

Flywheel Repair and Adjustment

Crankshaft and Main Bearing Failure

Group 030—Cylinder Block, Liners, Pistons, and

Rods Repair and Adjustment

Preliminary Liner, Piston, and Rod Checks . . .02-030-1

Connecting Rods—General Information .....02-030-2

Remove Pistons and Connecting Rod

Assemblies .........................02-030-3

Measure Cylinder Liner Standout (Height

Above Block) ........................02-030-7

Remove Cylinder Liners .................02-030-8

Deglaze Cylinder Liners .................02-030-9

Clean Cylinder Liners ..................02-030-10

Disassemble Piston and Rod Assembly ....02-030-11

Clean Pistons ........................02-030-12

Visually Inspect Pistons.................02-030-13

Check Piston Ring Groove Wear..........02-030-14

Inspect Piston Pin and Bore .............02-030-15

Visually Inspect Cylinder Liners...........02-030-16

Cylinder Liner Manufacturing Date Code

Explanation ........................02-030-18

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

Crankshaft Rear Oil Seal and Wear Sleeve

General Information...................02-040-2

Remove Crankshaft Rear Oil Seal and Wear

Sleeve .............................02-040-3

Crankshaft Rear Oil Seal and Wear Sleeve

Handling Precautions..................02-040-5

Install Crankshaft Rear Oil Seal and Wear

Sleeve .............................02-040-6

Inspect Vibration Damper ................02-040-7

Check Crankshaft End Play ..............02-040-8

Remove Crankshaft Vibration Damper ......02-040-9

Remove Crankshaft Front Oil Seal and Wear

Sleeve ............................02-040-10

Remove and Install Timing Gear

Cover—Engine Installed in Vehicle (8000 Series

Tractors) ..........................02-040-12

Remove Timing Gear Cover—Engine

Removed..........................02-040-13

Inspect and Measure Flywheel ...........02-040-14

Check Flywheel Housing Face Runout .....02-040-14Determine Piston-to-Liner Clearance.......02-030-19

Inspect Rod and Cap ..................02-030-21

Inspect Piston Pins and Bushings .........02-030-23

Remove Piston Pin Bushing, Clean and

Inspect Pin Bore ....................02-030-25

Measure Liner Flange ..................02-030-26

Inspect and Measure Connecting Rod

Bearings ..........................02-030-27

Install Piston Pin Bushing in Connecting

Rod..............................02-030-29

Complete Disassembly of Cylinder Block (If

Required)..........................02-030-30

Remove and Clean Piston Cooling

Orifices ...........................02-030-30

Inspect and Clean Cylinder Block .........02-030-31

Measure Cylinder Block ................02-030-33

Install Piston Cooling Orifices and Gallery

Plugs.............................02-030-34

Recheck Cylinder Liner Standout .........02-030-34

Install Liner Shims—If Required ..........02-030-35

Install Packing on Cylinder Liner and O-Rings

in Block ...........................02-030-36

Install Cylinder Liner in Block ............02-030-37

Install Piston and Connecting Rod.........02-030-38

Torque-Turn Connecting Rod Cap

Screws............................02-030-43

Check Engine Rotation for Excessive

Check Flywheel Face Flatness ...........02-040-15

Check Pilot Bearing Bore Concentricity.....02-040-15

Remove Flywheel .....................02-040-16

Remove SAE 1 Flywheel Housing.........02-040-16

Remove SAE 2 and 3 Flywheel Housing....02-040-17

Replace Flywheel Ring Gear.............02-040-17

Remove and Install Rear Oil Seal

Housing—Engine Installed in Vehicle (8000 Series

Tractors) ..........................02-040-18

Remove Rear Oil Seal Housing—Engine

Removed..........................02-040-19

Remove Main Bearing Caps .............02-040-20

Check Main Bearing Oil Clearance ........02-040-22

Remove Connecting Rod Caps and Remove

Crankshaft.........................02-040-23

Inspect Crankshaft ....................02-040-24

Measure Assembled I.D. of Bearings and

O.D. of Crankshaft Journals............02-040-25

Main Bearing Cap Line Bore

Specifications.......................02-040-27

Thrust Bearing New Part Specifications ....02-040-28

Crankshaft Grinding Guidelines...........02-040-29

Crankshaft Grinding Specifications ........02-040-31

Replace (Crankshaft) Oil Pump Drive

Gear .............................02-040-32

Replace Crankshaft Gear ...............02-040-33

Inspect Thrust Bearings ................02-040-34

Tightness..........................02-030-44

Complete Final Assembly ...............02-030-45

CTM86 (20MAR01)

02-3

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

8.1 L Diesel Engines — Base Engine

Continued on next page

032001

PN=3

Contents

Page Page

Remove and Clean Piston Cooling Remove and Install Oil Filter Base and Oil

Orifices ...........................02-040-34

Install Main Bearings and Crankshaft ......02-040-35

Install Crankshaft Rear Oil Seal Housing....02-040-38

Check Crankshaft Rear Oil Seal Housing

Runout............................02-040-40

Crankshaft Rear Oil Seal and Wear Sleeve

Handling Precautions.................02-040-41

Install Crankshaft Rear Oil Seal and Wear

Sleeve Assembly....................02-040-42

Install Timing Gear Cover ...............02-040-44

Install Front Wear Sleeve ...............02-040-45

Install Crankshaft Front Oil Seal ..........02-040-46

Install Vibration Damper ................02-040-47

Install SAE 2 and 3 Flywheel Housing......02-040-48

Install Flywheel .......................02-040-49

Install SAE 1 Flywheel Housing...........02-040-50

Complete Final Assembly ...............02-040-50

Pressure Regulating Valve Housing.......02-060-5

Engine Oil Cooler Assembly ..............02-060-7

Remove, Inspect, and Install Engine Oil

Cooler .............................02-060-8

Remove, Inspect, and Install Oil Pressure

Regulating Valve, Oil Filter Bypass

Valve, and Oil Cooler Bypass Valve .....02-060-10

Remove Engine from 8000 Tractors for

Access to Engine Oil Pump ............02-060-11

Remove Oil Pan ......................02-060-11

Check Crankshaft Gear-to-Oil Pump Drive

Gear Backlash......................02-060-12

Remove Engine Oil Pump...............02-060-12

Inspect and Clean Oil Pump .............02-060-13

Check Drive Shaft End Play .............02-060-14

Check Drive Shaft Side Movement ........02-060-14

Check Pumping Gear Backlash...........02-060-15

Inspect Oil Pump Drive Gear.............02-060-15

Group 050—Camshaft and Timing Gear Train

Repair and Adjustment

Check Camshaft End Play and Measure Gear

Backlash ...........................02-050-1

Remove Vibration Damper and Timing

Gear Cover .........................02-050-2

Remove, Inspect, and Install Crankshaft

Gear-Driven Auxiliary Drive—If Equipped . .02-050-3

Remove Camshaft......................02-050-8

Remove Camshaft Gears ...............02-050-10

Measure Thrust Washer Thickness........02-050-11

Adjust Oil Pump Set Screw..............02-060-16

Install Engine Oil Pump.................02-060-16

Remove and Install Oil Pump Outlet Tube

and Oil Cooler Crossover Tube

Adapter ...........................02-060-18

Remove, Inspect, and Install Oil Pump

Pickup Tube .......................02-060-19

Install Engine Oil Pan ..................02-060-20

Tighten Cap Screws on Front Frame/Oil

Sump (8000 Series Tractors)...........02-060-22

Inspect and Measure Camshaft Followers. . .02-050-11

Visually Inspect Camshaft...............02-050-12

Measure Camshaft Journal O.D. and

Bushing I.D.........................02-050-12

Measure Camshaft Lobe Lift .............02-050-13

Install Camshaft Gears .................02-050-14

Service Camshaft Bushings Using JDG602

Adapter Set ........................02-050-15

Service Camshaft Bushings Using JDG606

Adapter Set ........................02-050-17

Install Camshaft ......................02-050-19

Install Thrust Washer and Timing Gear

Cover.............................02-050-20

Complete Final Assembly ...............02-050-21

Group 070—Cooling System Repair and

Adjustment

Replace Bearings in Heavy-Duty,

Adjustable Fan Drive Assembly ..........02-070-1

Replace Bearings in Coolant

Manifold-Mounted, Fixed Fan Drive

Assembly...........................02-070-4

Fan Drive Assembly ....................02-070-5

Checking Belt Tensioner Spring Tension and

Belt Wear..........................02-070-10

Inspect and Install Fan Assembly .........02-070-12

Visually Inspect Coolant Pump ...........02-070-13

Remove Coolant Pump Assembly.........02-070-14

Install Coolant Pump Assembly...........02-070-16

Group 060—Lubrication System Repair and

Adjustment

Diagnosing Lubrication System

Malfunctions ........................02-060-1

Oil Filter Base and Oil Pressure

Replace Bypass Tube Seal in Coolant

Pump Cover .......................02-070-17

Remove and Test Thermostats ...........02-070-17

Remove Coolant Manifold...............02-070-18

Install Thermostats ....................02-070-19

Regulating Valve Housing Assembly ......02-060-2 Install Coolant Manifold.................02-070-20

Top-Load Oil Filter Assembly .............02-060-3

Changing Top-Load Oil Filter .............02-060-4

CTM86 (20MAR01)

02-4

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

8.1 L Diesel Engines — Base Engine

Continued on next page

032001

PN=4

Page

Remove and Install Coolant Temperature

Switch ............................02-070-20

Servicing of Engine Coolant Heater........02-070-21

Complete Final Assembly ...............02-070-21

Group 080—Air Intake and Exhaust System Repair

and Adjustment

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

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

Turbocharger Failure Analysis.............02-080-4

Turbocharger Inspection .................02-080-6

Repair Turbocharger ...................02-080-12

Prelube Turbocharger ..................02-080-12

Install Turbocharger ...................02-080-13

Remove, Inspect, and Install Exhaust

Manifold...........................02-080-15

Remove, Inspect, and Install Intake

Manifold (6081T and 6081H Engines) ....02-080-17

Remove Vertically-Mounted Aftercooler

and Intake Manifold (6081A Engines) ....02-080-18

Remove and Disassemble

Horizontally-Mounted Aftercooler (6081A

Engines) ..........................02-080-19

Inspect and Repair Aftercooler (6081A

Engines) ..........................02-080-20

Inspect and Repair Intake Manifold and

Air Intake Cover (6081A Engines) .......02-080-21

Install Intake Manifold and

Vertically-Mounted Aftercooler (6081A

Engines) ..........................02-080-22

Assemble and Install Horizontally-Mounted

Aftercooler Assembly (6081A Engines) . . .02-080-25

Servicing of Air Heater (If Equipped).......02-080-26

Contents

Group 100—OEM Starting and Charging Systems

Repair and Adjustment

Remove and Install Alternator (OEM

Engines) ...........................02-100-1

Remove and Install Starter Motor (OEM

Engines) ...........................02-100-2

CTM86 (20MAR01)

02-5

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

8.1 L Diesel Engines — Base Engine

032001

PN=5

Contents

CTM86 (20MAR01)

02-6

OWERTECH



8.1 L Diesel Engines — Base Engine

032001

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 procedure 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 measure to avoid high-cost repairs

and costly downtime.

Group 010

Engine Rebuild

02 010 1

John Deere overhaul kits have a 1500-hour or 12-month warranty, whichever comes first. Installation labor is covered by warranty if an authorized John Deere dealer installed the overhaul kit and the replacement parts.

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 before installing it on repair stand.

A—Engine Repair Stand

DPSG,OUO1032,3410 –19–15JUN00–1/1

CTM86 (20MAR01)

02-010-1

OWERTECH

Engine Repair Stand

RG,RG34710,1043 –19–23OCT97–1/1



8.1 L Diesel Engines — Base Engine

PN=47

RG4929 –UN–05DEC97

032001

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

SAE Grade 8 or higher socket head cap screws must be used to mount adapters or engine. Use LOCTITE 242 Thread Lock and Sealer on cap screws when installing lifting straps on engine. Tighten cap screws to 170 N•m (125 lb-ft).

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.

To avoid an unsafe off-balance load condition, 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 low and the possibility of tipping low.

To prevent possible personal injury due to sudden engine movement, lower 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.

Install Adapters on Engine Repair Stand

Attach the No. 205466 Engine Adapter (A) to mounting hub of the engine repair stand using SAE Grade 8 socket-head screws. Tighten screws to 135 N•m (100 lb-ft).

A—Engine Adapter

CTM86 (20MAR01)

02-010-2

Adapter for Engine Repair Stand

OWERTECH



8.1 L Diesel Engines — Base Engine

RG,RG34710,1044 –19–23OCT97–1/1

RG8183A –UN–08DEC00

RG,RG34710,1045 –19–23OCT97–1/1

032001

PN=48

Engine Rebuild

Engine Lifting Procedure

CAUTION: The only recommended method for lifting the 6081 engine is with JDG23 Engine Lifting 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.

Lift engine with longitudinal loading on lift sling and lifting brackets only. Angular loading greatly reduces lifting capacity of sling and brackets.

1. Install lift straps provided with engine and torque to the

following specifications.

Specification

Engine Lift Straps (Provided with

engine from factory)—Torque 197 N•m (145 lb-ft).....................................

02 010 3

RG10053 –UN–23JUN99

Engine Lifting Sling and Straps

A—Engine Lifting Sling B—Engine Lifting Straps

2. Attach JDG23 Engine Lifting Sling (A) to engine lifting

straps (B) and to overhead hoist or floor crane.

Continued on next page

DPSG,OUO1004,902 –19–13DEC00–1/2

CTM86 (20MAR01)

02-010-3

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

8.1 L Diesel Engines — Base Engine

PN=49

032001

NOTE: If engine lifting straps are misplaced, they should

be procured through service parts or SERVICEGARD. Use of an engine lifting sling (as shown) is the ONLY APPROVED method for

010

IMPORTANT: Lifting straps are designed to lift the

lifting engine.

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 PTO’s, transmissions, generators or air compressors, are attached to other locations on the engine, the lift 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.

Engine Rebuild

3. Carefully lift engine to desired location.

SERVICEGARD is a trademark of Deere & Company

Clean Engine

1. Cap or plug all openings on engine. If electrical components (starter, alternator, etc.) are not removed prior to cleaning, cover with plastic and tape securely to prevent moisture from entering.

2. Steam-clean engine thoroughly.

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.

DPSG,OUO1004,902 –19–13DEC00–2/2

CTM86 (20MAR01)

02-010-4

OWERTECH

RG,RG34710,1047 –19–23OCT97–1/1



8.1 L Diesel Engines — Base Engine

PN=50

032001

Engine Rebuild

Disconnect Turbocharger Oil Inlet Line

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

IMPORTANT: When servicing turbocharged engines

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.

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

02 010 5

RG7407 –UN–03NOV97

Turbocharger Oil Inlet Line

A—Turbocharger Oil Inlet Line

CTM86 (20MAR01)

02-010-5

OWERTECH

RG,RG34710,1048 –19–23OCT97–1/1



8.1 L Diesel Engines — Base Engine

PN=51

032001

Mount Engine on Repair Stand

010

Engine Rebuild

CTM86 (20MAR01)

Mounting Engine on Repair Stand

Continued on next page

02-010-6

OWERTECH

RG,RG34710,1049 –19–08JUN99–1/2



8.1 L Diesel Engines — Base Engine

PN=52

RG8770 –UN–08DEC97

032001

Engine Rebuild

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.

NOTE: If starter motor or crankshaft driven auxiliary drive

accessory is to be removed from engine, remove before mounting engine onto repair stand.

1. Mount the starter side of the engine to the engine adapter with four SAE Grade 8 (or higher grade) cap screws in the following sizes:

Engine-to-Stand Cap Screws

6081AT001 .................................. 5/8-11UNC x 2-1/2 in.

6081TDW01 ................................ 5/8-11UNC x 2-1/2 in.

6081TRW01 ................................ 5/8-11UNC x 2-1/2 in.

6081TRW02 ................................ 5/8-11UNC x 2-1/2 in.

6081TRW09 ................................ 5/8-11UNC x 2-1/2 in.

6081TRW10 ................................ 5/8-11UNC x 2-1/2 in.

6081TRW11 ................................ 5/8-11UNC x 2-1/2 in.

All Other 6081 Engines ............... 5/8-11UNC x 3-1/2 in.

02 010 7

RG10054 –UN–23JUN99

Engine on Repair Stand

2. Tighten cap screws to 203 N•m (150 lb-ft).

3. Carefully remove lift sling from engine. To remove engine from repair stand, reverse the

installation procedure. To install engine in vehicle, refer to machine technical

manual.

RG,RG34710,1049 –19–08JUN99–2/2

CTM86 (20MAR01)

02-010-7

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=53

032001

Engine Rebuild

Engine Disassembly Sequence for Overhaul

The following sequence is suggested when complete disassembly for overhaul is required. Refer to the appropriate repair group when removing individual

engine components.

010

1. Drain all coolant and engine oil. Check engine oil for metal contaminates.

2. Remove turbocharger oil inlet line and oil return line. Remove turbocharger.

3. Remove fan pulley and coolant manifold assembly.

4. Remove coolant pump assembly from timing gear cover.

NOTE: DO NOT damage option code label (if

equipped), when removing rocker arm cover.

5. Remove breather hose from rocker arm cover. Remove rocker arm cover. Remove carrier, if equipped.

6. Remove rocker arm assembly(ies) and push rods. Identify parts for reassembly.

7. Remove front crankshaft pulley and damper assembly.

8. Remove fuel injection lines, fuel connectors, and injection nozzles.

9. Remove engine oil filter, filter base, and valve housing.

14. Remove air intake manifold.

NOTE: ALWAYS bolt down liners when rotating

engine flywheel with cylinder head removed.

15. Remove cylinder head with assembly. Remove head gasket.

16. Revolve engine on repair stand and remove engine oil pump assembly.

17. Remove front timing gear cover.

18. Revolve engine to vertical position. Remove pistons and connecting rods. Identify for reassembly. Perform bearing-to-journal wear checks with PLASTIGAGE.

19. On SAE No. 3 flywheel housings, remove flywheel housing and then remove flywheel.

20. On SAE No. 1 and 2 flywheel housings, remove flywheel and then remove flywheel housing.

21. Remove main bearing caps and remove crankshaft. Perform bearing-to-journal wear checks with PLASTIGAGE.

22. Remove camshaft and cam followers. Identify for reassembly.

23. Revolve engine to horizontal position, remove liners, O-rings, and packings. Mark liners for reassembly in same bore from which removed.

10. Remove fuel filter and mounting base. Remove injection pump gear cover and remove injection pump. Remove all remaining fuel lines.

11. Remove high pressure common rail, if equipped.

12. Remove engine oil cooler assembly.

13. Remove front and rear exhaust manifolds.

PLASTIGAGE is a registered trademark of DANA Corp.

CTM86 (20MAR01)

24. Remove piston cooling orifices from cylinder block.

25. Remove any sensors/gauges, cylinder block plugs

26. Refer to appropriate group for inspection and

02-010-8

and engine serial number plate, if block is to be put in a “hot tank”.

repair of engine components.

RG,RG34710,1050 –19–19MAY99–1/1

OWERTECH



8.1 L Diesel Engines — Base Engine

032001

PN=54

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 assure hardware retention. ALWAYS use the following recommended sealants when assembling your John Deere Diesel Engine to assure 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 exists, clean with solvent. Refer to John Deere Merchandise and Parts Sales Manual for ordering information.

AR31790 SCOTCH-GRIPEC1099 Plastic Adhesive:

• AR31790 118 ml (4 oz) Rocker arm cover gasket

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

• TY9370 6 ml (0.2 oz) tube

• T43512 50 ml (1.7 oz) bottle

Pipe plugs: cylinder block (coolant manifold), thermostat housing, air intake manifold, and coolant pump.

Coolant pump and block coolant drain valves Injection pump governor cover fitting (fuel return) Fuel filter drain and bleed plugs Threaded nipples and elbows in coolant pump housing Temperature sending unit and switch Oil pan (drain hose, drain valve and elbow) Connectors: turbo line and turbo drain Adapter fitting for turbo oil inlet line

LOCTITE680 Retaining Compound (Green):

• TY15969 50 ml. (1.7 oz) bottle Expansion (frost) plugs in cylinder block

02 010 9

Plugs and fittings: fuel filter base, intake manifold, cylinder block (oil galley).

Injection pump timing hole plug. Cap screws: injection pump access cover, electronic

tachometer cover, oil filler inlet, oil filter adapter, flywheel, coolant manifold.

Oil pressure sending unit.

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

• TY9374 6 ml. (0.2 oz) tube

• TY9375 50 ml. (1.7 oz) bottle

LOCTITE is a registered trademark of Loctite Corp. SCOTCH-GRIP is a registered trademark of 3M Co. TEFLON is a registered trademark of Du Pont Co. NEVER-SEEZ is a registered trademark of Emhart Chemical Group.

CTM86 (20MAR01)

Wear sleeve-to-crankshaft

PERMATEX Aviation (Form-A-Gasket No. 3):

• TY6299 227 g (8oz) container Rear camshaft bore steel cap plug Oil pan gasket surfaces

PT569 NEVER-SEEZCompound:

• PT569 227 g (8 oz) Brush

• PT506 453 g (16 oz) Spray

Continued on next page

02-010-9

OWERTECH

RG,RG34710,1051 –19–23OCT97–1/2



8.1 L Diesel Engines — Base Engine

PN=55

032001

Engine Rebuild

Cap Screws: turbocharger mounting and aftercooler cover.

Cap Screws: reinstallation of special 12-point flange head cap screws on exhaust manifold of 8000 Series

010

tractors.

Injection nozzle gland nut threads and barrel

LOCTITE is a registered trademark of Loctite Corp.

Special 12-point flange head cap screws have pre-applied

anti-sieze compound. Apply additional compound for reuse only.

LOCTITE51048 Moly Paste

Camshaft nose (gear installation)

RG,RG34710,1051 –19–23OCT97–2/2

CTM86 (20MAR01)

02-010-10

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=56

032001

Engine Rebuild

6081 Engine Assembly Sequence After Overhaul

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.

6081 Engine Assembly Sequence After Overhaul Serial Number ( —199,999)

1. Install all plugs in cylinder block that were removed to service block. Install engine serial number plate.

2. Install piston cooling orifices.

3. Install cylinder liners without O-rings and measure liner stand-out. Install liner O-rings in block and packings on liners. Install liners.

NOTE: If new piston and liner kit assemblies are being

installed, install the crankshaft first.

4. Install main bearings and crankshaft. Rotate crankshaft to assure correct assembly. Check crankshaft end play.

NOTE: ALWAYS bolt liners down before rotating

engine with cylinder head removed.

If installing new piston/liner kits, assemble kits onto the respective connecting rods using NEW snap rings. Bolt liners down as each kit is installed.

5. Install engine flywheel and housing, if applicable:

• SAE 3: Flywheel goes on before housing.

• SAE 1 and SAE 2: Housing goes on before

flywheel.

8. Install cam followers in hole from which originally removed.

9. Install camshaft. Align timing marks (camshaft-to-crankshaft gears) with No. 1 piston at “TDC” compression stroke.

10. Install engine oil pump assembly.

11. Install fuel injection pump and drive gear.

12. Install engine oil cooler assembly.

13. Install filter base, valve housing, and new oil filter.

14. Install cylinder head, push rods, and rocker arm

assembly. Measure valve lift and adjust valve clearance.

15. Install rocker arm cover. Install breather hose.

16. Install air intake manifold.

17. Install front and rear exhaust manifolds.

18. Install timing gear cover. Install front crankshaft

wear sleeve and oil seal.

19. Install coolant pump assembly and coolant

manifold.

20. Install turbocharger. Install turbocharger oil inlet

line and oil return line.

21. Install fuel injection nozzles and delivery line

assembly.

22. Install fuel filter base, supply lines, and filter.

02 010 11

6. Install piston and rod assemblies. Bolt liners down after each piston assembly is installed.

7. Install crankshaft rear oil seal housing and check runout. Install rear oil seal and wear sleeve.

CTM86 (20MAR01)

23. Install front pulley and new damper as an

24. Install fan pulley assembly. Install starter motor.

Continued on next page

02-010-11

assembly.

OWERTECH

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

8.1 L Diesel Engines — Base Engine

PN=57

032001

Engine Rebuild

25. Fill engine with clean oil. Install dipstick.

26. Flush cooling system and refill with proper coolant.

27. Perform engine break-in and normal standard

010

performance checks. See ENGINE BREAK-IN GUIDELINES later in this group.

6081 Engine Assembly Sequence After Overhaul Serial Number (200,000— )

1. Install all plugs in cylinder block that were removed to service block. Install engine serial number plate.

2. Install piston cooling orifices.

3. Install cylinder liners without O-rings and measure liner stand-out. Install liner O-rings in block and packings on liners. Install liners.

NOTE: If new piston and liner kit assemblies are being

installed, install the crankshaft first.

4. Install main bearings and crankshaft. Rotate crankshaft to assure correct assembly. Check crankshaft end play.

NOTE: ALWAYS bolt liners down before rotating

engine with cylinder head removed.

If installing new piston/liner kits, assemble kits onto the respective connecting rods using NEW snap rings. Bolt liners down as each kit is installed.

9. Install camshaft. Align timing marks (camshaft-to-crankshaft gears) with No. 1 piston at “TDC” compression stroke.

10. Install engine oil pump assembly.

11. Install high pressure common rail.

12. Install fuel injection pump and drive gear.

13. Install engine oil cooler assembly.

14. Install fuel filter base, supply lines, and filter.

15. Install oil filter base, valve housing, and new oil

filter.

16. Install cylinder head, push rods, rocker arm

assemblies, electronic injectors, and fuel connectors.

17. Install carrier, rocker arm cover, and breather

hose.

18. Install air intake manifold.

19. Install front and rear exhaust manifolds.

20. Install timing gear cover. Install front crankshaft

wear sleeve and oil seal.

21. Install coolant pump assembly and coolant

manifold.

5. Install engine flywheel and housing, if applicable:

• SAE 3: Flywheel goes on before housing.

• SAE 1 and SAE 2: Housing goes on before

flywheel.

6. Install piston and rod assemblies. Bolt liners down after each piston assembly is installed.

7. Install crankshaft rear oil seal housing and check runout. Install rear oil seal and wear sleeve.

8. Install cam followers in hole from which originally removed.

CTM86 (20MAR01)

22. Install turbocharger. Install turbocharger oil inlet

23. Install fuel leak-off lines and high pressure fuel

24. Install front pulley and new damper as an

25. Install fan pulley assembly. Install starter motor.

26. Fill engine with clean oil. Install dipstick.

27. Flush cooling system and refill with proper coolant.

Continued on next page

02-010-12

line and oil return line.

delivery lines.

assembly.

OWERTECH



8.1 L Diesel Engines — Base Engine

RG,RG34710,1052 –19–08JUN99–2/3

032001

PN=58

28. Perform engine break-in and normal standard performance checks. See ENGINE BREAK-IN GUIDELINES later in this group.

Engine Rebuild

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. (Check and reset valve

clearance.) Injection pump has been removed or critical adjustments

have been made while it is on the engine. (Primary objective is to check power).

RG,RG34710,1052 –19–08JUN99–3/3

02 010 13

CTM86 (20MAR01)

02-010-13

OWERTECH

RG,RG34710,1053 –19–23OCT97–1/1



8.1 L Diesel Engines — Base Engine

PN=59

032001

Perform Engine Break-In

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.

010

IMPORTANT: DO NOT use John Deere PLUS-50 oil or

engine oils meeting API CG4, API CF4, ACEA E3 or ACEA E2, 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.

Do not add makeup oil until the oil level is BELOW the add mark. John Deere Break-In Oil should be used to make up any oil consumed during break-in period.

Engine Rebuild

RG7359 –UN–20JUN00

Check Engine Oil Level

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.

If John Deere Engine Break-In Oil is not available, use diesel engine oil meeting API Service Classification CE or ACEA Specification E1.

IMPORTANT: During preliminary break-in, periodically

check engine oil pressure and coolant temperature. Also check for signs of fuel, oil, or coolant leaks.

2. Start engine, run at loads and speeds shown in following chart for time limits given.

Engine Oil Level Dipstick

RG5895 –UN–13AUG91

CTM86 (20MAR01)

Continued on next page

02-010-14

OWERTECH

RG,100,JW7645 –19–21NOV97–1/3



8.1 L Diesel Engines — Base Engine

PN=60

032001

Engine Rebuild

PRELIMINARY ENGINE BREAK-IN AFTER MAJOR OVERHAUL Time Load Engine Speed

1 minute No load 850 rpm 2 minutes No load Fast Idle 15 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.

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.

02 010 15

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 TORQ-GARD SUPREMEOR PLUS-50or other heavy-duty diesel engine oil within the same service classification as recommended in this manual. See DIESEL ENGINE OIL in Group 002, Fuels, Lubricants, and Coolant.

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

CTM86 (20MAR01)

Continued on next page

02-010-15

OWERTECH

RG,100,JW7645 –19–21NOV97–2/3



8.1 L Diesel Engines — Base Engine

PN=61

032001

NOTE: Some increase in oil consumption may be

expected when low viscosity oils are used. Check oil levels more frequently.

Engine Rebuild

010

If air temperature is below -10°C (14°F), use an engine block heater.

Check Crankcase Ventilation System

1. Inspect crankcase ventilation system for restrictions. Lack of ventilation causes sludge to form in crankcase. This can lead to clogging of oil passages, filters, and screens, resulting in serious engine damage.

2. Clean crankcase vent tube (A) with solvent and compressed air if restricted. Install and tighten hose clamps securely.

A—Crankcase Vent Tube

RG,100,JW7645 –19–21NOV97–3/3

RG5797 –UN–26NOV97

Crankcase Vent Tube

Check Air Intake System

1. Replace air cleaner primary filter element. (See operator’s manual.) Replace secondary element if primary element has holes in it.

2. Check condition of air intake hose(s). Replace hoses that are cracked, split, or otherwise in poor condition.

3. Check hose clamps (A) for tightness. Replace clamps that cannot be properly tightened. This will help prevent dust from entering the air intake system which could cause serious engine damage.

A—Hose Clamps

CTM86 (20MAR01)

02-010-16

OWERTECH

RG,RG34710,1055 –19–23OCT97–1/1

Air Intake Hose Clamps

RG,RG34710,1056 –19–23OCT97–1/1



8.1 L Diesel Engines — Base Engine

RG4689 –UN–20DEC88

032001

PN=62

Engine Rebuild

Check Exhaust System

1. Inspect exhaust system for leaks or restrictions. Check manifold for cracks. Repair or replace as necessary.

2. Check that turbocharger-to-exhaust elbow adapter clamps are securely tightened and do not leak.

3. Check exhaust stack for evidence of oil leakage past valve stem seals.

Oil in exhaust stack may be caused by excessive valve stem-to-guide clearance or excessive light load engine idling.

Check and Service Cooling System

1. Remove trash that has accumulated on or near radiator.

2. Visually inspect entire cooling system and all components for leaks or damage. Repair or replace as necessary.

02 010 17

RG,RG34710,1057 –19–23OCT97–1/1

3. Remove the foam filter from weep hole (A, shown removed) located on the side of timing gear cover and discard filter. Inspect the weep hole for any restrictions.

4. Insert a heavy gauge wire deep into weep hole to make sure hole is open.

5. Install new foam filter flush with timing gear cover.

Cooling System Weep Hole with Foam Filter

A—Weep Hole

Continued on next page

RG7061 –UN–26NOV97

RG,RG34710,1058 –19–23OCT97–1/2

CTM86 (20MAR01)

02-010-17

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=63

032001

CAUTION: Do not drain coolant until the coolant temperature is below operating temperature. Always loosen coolant pump drain valve (A) and block drain valve (B) slowly to relieve any

010

excess pressure.

IMPORTANT: Both coolant pump drain valve and

block drain valve must be opened to completely drain the engine.

Engine Rebuild

6. Remove and check thermostat(s). See REMOVE AND TEST THERMOSTATS in Group 070.

7. Drain and flush cooling system. See FLUSH AND SERVICE COOLING SYSTEM in Group 002.

IMPORTANT: Air must be expelled from cooling

system when system is refilled. Loosen temperature sending unit fitting at rear of cylinder head, bleed plug at top front of cylinder head, or plug in thermostat housing to allow air to escape when filling system. Retighten fitting or plug when all the air has been expelled.

8. Fill cooling system with coolant. See DIESEL ENGINE COOLANT in Group 002.

9. Run engine until it reaches operating temperature. Check entire cooling system for leaks.

10. After engine cools, check coolant level.

NOTE: Coolant level should be even with bottom of

radiator filler neck.

Service Cooling System Safely

TS281 –UN–23AUG88

RG7044 –UN–26NOV97

Coolant Pump Drain Valve

11. Check system for holding pressure. See PRESSURE

TEST COOLING SYSTEM AND RADIATOR CAP in Group 150.

CTM86 (20MAR01)

02-010-18

Cylinder Block Coolant Drain Valve

A—Coolant Pump Drain Valve B—Block Drain Valve

OWERTECH



8.1 L Diesel Engines — Base Engine

RG7143 –UN–26NOV97

RG,RG34710,1058 –19–23OCT97–2/2

032001

PN=64

Check Electrical System

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.

Engine Rebuild

02 010 19

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

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.

1. Clean batteries and cables with damp cloth. If corrosion is present, remove it and wash terminals with a solution of ammonia or baking soda in water. Then flush area with clean water.

2. Coat battery terminals and connectors with petroleum jelly mixed with baking soda to retard corrosion.

3. Test batteries. If batteries are not near full charge, try to find out why.

4. On low-maintenance batteries, check level of electrolyte in each cell of each battery. Level should be to bottom of filler neck. If water is needed, use clean, mineral-free water.

If water must be added to batteries more often than every 250 hours, alternator may be overcharging.

Prevent Battery Explosions

TS204 –UN–23AUG88

NOTE: Water cannot be added to maintenance-free

batteries.

5. If batteries appear to be either undercharged or overcharged, check alternator and charging circuit.

6. Check tension of drive belts. See CHECKING BELT TENSIONER SPRING TENSION AND BELT WEAR in Group 070.

CTM86 (20MAR01)

Continued on next page

02-010-19

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RG,RG34710,1059 –19–23OCT97–1/2



8.1 L Diesel Engines — Base Engine

PN=65

032001

7. Check operation of starter motor and gauges.

NOTE: For test and repair of alternators and starter

motors, see CTM77, Alternators and Starting

010

Motors.

Engine Rebuild

RG,RG34710,1059 –19–23OCT97–2/2

CTM86 (20MAR01)

02-010-20

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=66

032001

Engine Rebuild

General Tune-Up Recommendations

As a general rule, an engine tune-up is not necessary if ALL recommended operator’s manual hourly service procedures are performed on schedule. If your engine performance is not within the rated application guidelines, the following service procedures are recommended to help restore engine to normal operating efficiency.

IMPORTANT: Engines that are equipped with

electronically-controlled governors have a diagnostic feature that will display detailed codes to alert operator of specific performance problems. Refer to CTM68, Electronic Fuel Injection Systems, for diagnostic code troubleshooting procedures on Bosch ECU control systems. Refer to CTM134 for John Deere Level 3 ECU controls. Refer to CTM255 for John Deere Level 9 ECU controls.

02 010 21

Operation Detailed Reference

Change engine oil and filters. ............................................................................................... Operator’s Manual

Lubricate PTO clutch internal levers and linkage, if equipped. ............................................ Operator’s Manual

Replace fuel filter. .................................................................................................................. CTM134/CTM243/CTM255/Operator’s Manual

Clean crankcase vent tube. ................................................................................................... This Group/Operator’s Manual

Check air intake system. Replace air cleaner elements. ...................................................... This Group/Operator’s Manual

Check exhaust system. ......................................................................................................... This Group

Check and service engine cooling system. ........................................................................... This Group/Operator’s Manual

Check and adjust fan and alternator belts. ........................................................................... Operator’s Manual

Check electrical system. ........................................................................................................ This Group

Check crankshaft vibration damper. ...................................................................................... Group 040/Operator’s Manual

Inspect turbocharger and check turbocharger boost pressure. ............................................ Group 150

Check fuel injection system: Check engine/injection pump timing: check ........................... CTM134/CTM243/CTM255

and adjust speed advance; clean injection nozzles, and adjust opening pressure.

Check engine oil pressure. Correct as necessary. ............................................................... Group 150

Check engine valve clearance. Adjust if necessary. ............................................................ Group 020/Group 021

Check engine speeds. Correct as necessary. ...................................................................... Authorized Servicing Dealer

Check engine performance on dynamometer. ...................................................................... This Group

CTM86 (20MAR01)

02-010-21

OWERTECH

RG,RG34710,1061 –19–08JUN99–1/1



8.1 L Diesel Engines — Base Engine

PN=67

032001

010

Engine Rebuild

CTM86 (20MAR01)

02-010-22

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=68

032001

Group 020

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Check and Adjust Valve Clearance Serial Number ( —199,999)

Too little valve clearance throws valves out of time. Valves open too early and close too late. This causes the valves to overheat due to hot combustion gases rushing past valves when out of time. Overheating lengthens valve stems which prevents proper seating of valves. The valves seat so briefly or poorly that normal heat transfer into the cooling system does not have time to take place, causing burned valves and low power.

Too much valve clearance causes a lag in valve timing causing engine valve train imbalance. The fuel-air mixture enters the cylinders late during intake stroke. The exhaust valve closes early and prevents waste gases from being completely removed from cylinders. Also, the valves close with a great deal of impact, which may crack or break the valves and scuff the camshaft and followers.

02 020 1

CAUTION: To prevent accidental starting of engine while performing valve adjustments, always disconnect NEGATIVE (—) battery terminal.

IMPORTANT: Valve clearance MUST BE checked and

adjusted with engine COLD.

1. Remove rocker arm cover with 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.

CTM86 (20MAR01)

Continued on next page

02-020-1

OWERTECH

DPSG,OUO1004,829 –19–13DEC00–1/4



8.1 L Diesel Engines — Base Engine

PN=69

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

2. Remove plastic plug from cylinder block bores and install JDE81-1 or JDG820 Flywheel Turning Tool (A) and JDE81-4 Timing Pin (B).

3. Rotate engine with the flywheel turning tool until timing

020

pin engages timing hole in flywheel.

If the rocker arms for No. 1 (front) cylinder are loose, the engine is at No. 1 “TDC-Compression.”

If the rocker arms for No. 6 (rear) cylinder are loose, the engine is at No. 6 “TDC-Compression.” Rotate the engine one full revolution (360°) to No. 1 “TDC-Compression.”

Flywheel Turning Tool and Timing Pin

RG7013 –UN–26NOV97

A—Flywheel Turning Tool B—Timing Pin

Continued on next page

DPSG,OUO1004,829 –19–13DEC00–2/4

CTM86 (20MAR01)

02-020-2

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=70

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

4. With engine lock-pinned at “TDC” of No. 1 piston’s compression stroke, check valve clearance on Nos. 1, 3, and 5 exhaust valves and Nos. 1, 2, and 4 intake valves.

Intake Valve Clearance Checking (Rocker Arm-to-Valve Tip With Engine Cold)—Clearance 0.41—0.51 mm

Exhaust Valve Clearance Checking (Rocker Arm-to-Valve Tip With Engine Cold)— Clearance 0.66—0.76 mm

..........................................................................

Specification

..................................................

(0.016—0.020 in.)

(0.026—0.030 in.)

5. Rotate flywheel 360° until No. 6 piston is at “TDC” of its compression stroke. Rocker arms for No. 6 piston should be loose.

6. Check valve clearance to the same specifications on Nos. 2, 4, and 6 exhaust and Nos. 3, 5, and 6 intake valves.

NOTE: Adjust valve clearance in the same sequence

used for checking clearance.

7. If valve clearance needs to be adjusted, loosen the lock nut 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 lock nut to specifications.

02 020 3

RG5241 –UN–06DEC88

Adjusting Valve Clearance

RG4295 –19–21AUG91

Valve Adjusting Sequence

Valve Adjusting Screw Lock

Specification

Nut—Torque 27 N•m (20 lb-ft)....................................................................

Recheck clearance again after tightening lock nut and compare to the following specifications. Readjust clearance as necessary.

Specification

Intake Valve Clearance Adjustment (Rocker Arm-to-Valve Tip With Engine Cold)—

Clearance 0.46 mm (0.018 in.)...................................................................

Exhaust Valve Clearance Adjustment (Rocker Arm-to-Valve Tip With Engine Cold)—

Clearance 0.71 mm (0.028 in.)...................................................................

CTM86 (20MAR01)

Continued on next page

02-020-3

OWERTECH

DPSG,OUO1004,829 –19–13DEC00–3/4



8.1 L Diesel Engines — Base Engine

PN=71

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

8. Install rocker arm cover and tighten cap screws to specifications.

Rocker Arm Cover-to-Cylinder

Head Cap Screws—Torque 8 N•m (6 lb-ft) (72 lb-in.)................................

020

Specification

DPSG,OUO1004,829 –19–13DEC00–4/4

CTM86 (20MAR01)

02-020-4

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=72

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Check Valve Lift Serial Number ( —199,999)

IMPORTANT: For a more accurate measurement, it is

recommended that valve lift be measured at 0.00 mm (in.) valve clearance and with engine COLD.

NOTE: Measuring valve lift can give an indication of wear

on camshaft lobes and cam followers or bent push rods.

1. Remove turbocharger oil inlet clamp and rocker arm cover. Loosen lock nut on rocker arm. Set valve clearance at 0.00 mm (in.) on valve being checked. Tighten lock nut.

2. Put dial indicator tip on valve rotator. Be sure that valve is fully closed.

02 020 5

3. Check pre-set on dial indicator. Set dial indicator pointer at zero.

4. Manually turn engine in running direction, using the engine rotation tools previously mentioned for checking valve clearance.

5. Observe dial indicator reading as valve is moved to fully open position. Record reading and valve number.

Intake Valve—Lift 13.53—13.71 mm

Wear Tolerance 12.65 mm (0.498 in.)

Exhaust Valve—Lift 14.52—14.70 mm

Wear Tolerance 13.64 mm (0.537 in.)

..........................................................

........................................................

.......................................................

........................................................

Specification

(0.533—0.540 in.)

at 0.00 mm (in.)

at 0.00 mm (in.) clearance

(0.572—0.579 in.)

at 0.00 mm (in.)

at 0.00 mm (in.) clearance

6. Repeat procedure on all remaining valves.

7. Reset valve clearance to specification after measuring lift. See CHECK AND ADJUST VALVE CLEARANCE SERIAL NUMBER ( —199,999) earlier in this group.

Checking Valve Lift

RG5789 –UN–09AUG91

CTM86 (20MAR01)

02-020-5

OWERTECH

DPSG,OUO1004,830 –19–27APR99–1/1



8.1 L Diesel Engines — Base Engine

PN=73

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Remove Cylinder Head Serial Number ( —199,999)

It is not necessary to remove engine from machine to service cylinder head on all applications. Refer to your

Machine Technical Manual for engine removal procedure,

020

if required.

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. Always loosen drain valve slowly to relieve any excess pressure.

1. Drain engine oil and coolant. Disconnect turbocharger oil inlet line at turbocharger or oil filter base. See DISCONNECT TURBOCHARGER OIL INLET LINE in Group 010.

NOTE: If cylinder head is being removed for piston and

liner repairs or any other service that does not require disassembly of head, cylinder head can be removed with coolant manifold (A), turbocharger (B), intake manifold (C), and exhaust manifold (D) installed.

2. Remove coolant manifold and all coolant piping. See REMOVE COOLANT MANIFOLD in Group 070.

3. Remove turbocharger. See REMOVE TURBOCHARGER in Group 080. Remove front and rear exhaust manifold (D). See REMOVE, INSPECT AND INSTALL EXHAUST MANIFOLD in Group 080.

4. Remove air intake manifold. See REMOVE, INSPECT AND INSTALL INTAKE MANIFOLD in Group 080.

5. Remove fuel injection delivery lines and injection nozzles. If mechanical fuel system, see REMOVE FUEL INJECTION NOZZLES in Group 090 of CTM243. If Level 3 Electronic fuel system, see REMOVE FUEL INJECTION NOZZLES in Group 090 of CTM134.

Service Cooling System Safely

TS218 –UN–23AUG88

RG7014 –UN–26NOV97

Removing Cylinder Head

A—Coolant Manifold B—Turbocharger C—Intake Manifold D—Exhaust Manifold Assembly

CTM86 (20MAR01)

Continued on next page

02-020-6

OWERTECH

DPSG,OUO1004,787 –19–27APR99–1/4



8.1 L Diesel Engines — Base Engine

PN=74

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

6. Remove rocker arm cover with ventilator outlet hose assembly.

7. Loosen all rocker arm adjusting screws before removing assembly.

8. Remove six cap screws and remove all four rocker arm shaft clamps (A). Lift rocker arm assembly (B) up and remove. Remove wear caps from valve stems.

9. Remove all 12 push rods and identify for reassembly.

NOTE: Clean and inspect push rods. See CLEAN AND

INSPECT PUSH RODS SERIAL NUMBER ( — 199,999) later in this group.

02 020 7

DPSG,OUO1004,787 –19–27APR99–2/4

A—Rocker Arm Shaft Clamps B—Rocker Arm Assembly

Removing Rocker Arm Assembly

Continued on next page

RG7017 –UN–26NOV97

RG7018 –UN–05DEC97

Removing Push Rods

DPSG,OUO1004,787 –19–27APR99–3/4

CTM86 (20MAR01)

02-020-7

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=75

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

10. Remove all 26 cylinder head cap screws. Discard cap screws, they are not reusable.

IMPORTANT: DO NOT use screwdrivers or pry bars

020

between cylinder block and cylinder head to loosen head-to-block gasket seal.

11. Lift cylinder head from block. If cylinder head sticks, use a soft hammer to tap the cylinder head.

12. Remove cylinder head gasket. Inspect for possible oil, coolant, or combustion chamber leaks. Also, check for evidence of incorrect or defective head gasket being used.

NOTE: Do not rotate crankshaft with cylinder head

removed unless all cylinder liners are secured with cap screws and large flat washers as described in Group 030. See REMOVE PISTONS AND CONNECTING ROD ASSEMBLIES in Group

030.

Lifting Cylinder Head From Block

RG5245 –UN–05DEC97

DPSG,OUO1004,787 –19–27APR99–4/4

CTM86 (20MAR01)

02-020-8

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=76

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Head Gasket Inspection and Repair Sequence Serial Number ( —199,999)

02 020 9

Inspecting Cylinder Head Gasket

A—Combustion Seals (Flange) C—Rocker Arm Oil Port D—Elastomer Beading Strips E—Front of Engine B—Gasket Body

The following inspection procedures are recommended whenever a head gasket joint failure occurs, or when joint disassembly takes place.

• Adjacent body area burned/eroded.

• Fire ring severed/displaced/missing.

• Flange sealing pattern eccentric/contains voids.

• Discoloration of flange and adjacent body areas.

1. Review historical data relating to machine

• Flange surfaces rough/abraded/channelled. operation, maintenance and repair, along with diagnostic observations. Note all areas requiring

Examine gasket body (B) for the following:

further inspection and analysis.

• Combustion gas erosion paths or soot deposits

2. Remove rocker arm cover and check for presence of coolant in the oil.

originating at combustion seals.

• Extreme discoloration/hardening/embrittlement in localized areas.

3. Record head cap screw torques prior to removal. Upon removal, check cap screw length differences.

• O-ring seal missing/damaged in port area (C).

• Elastomer missing/damaged in port area (D).

• Oil or coolant paths from port areas.

4. Remove cylinder head using appropriate lifting

• Localized areas of low compression. devices to prevent handling damage to head gasket. See REMOVE CYLINDER HEAD SERIAL NUMBER ( —199,999) in Group 020.

6. Before cleaning components, inspect head, block, and liners for evidence of combustion gas and fluid leakage. Inspect cylinders and valve ports for

5. Observe surfaces of removed head gasket.

unusual deposits.

RG6448 –UN–26NOV97

Examine combustion seals (A) for the following:

• Flange severed/expanded/cracked/deformed.

CTM86 (20MAR01)

7. Clean block, head, liners, and cap screws. (Groups

Continued on next page

02-020-9

020 and 030.)

OWERTECH

RG,RG34710,1074 –19–23OCT97–1/2



8.1 L Diesel Engines — Base Engine

PN=77

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

8. Proceed with the following dimensional checks and visual inspections:

Cylinder Head (Group 020.)

020

• Check surface flatness/finish.

• Inspect for surface damage.

• Check cylinder head thickness, if resurfacing.

Cylinder Block and Liners (assembled and clamped) (Group 020 or 030.)

• Check liner standout at four places on each liner.

• Check liner standout difference between

cylinders.

Cylinder Block (Group 030.)

• Check surface flatness/finish.

• Inspect for surface damage.

• Check liner counterbore depth (if liner is

removed).

• Check top deck to crankshaft centerline

dimension.

• Inspect cap screw bosses, must be clean/intact. Cylinder Liner (Group 030.)

• Check liner flange flatness/finish.

• Check liner flange thickness (if liner is removed).

• Inspect flange for damage.

Cylinder Head Cap Screws (Group 020.)

• Inspect for corrosion damage.

• Inspect condition of threads.

• Inspect for straightness.

• Check length.

9. When inspections and measurements have been completed, determine most probable causes of joint failure. Make all necessary repairs to joint components, cooling system, and fuel injection system.

10. Reassemble the engine according to procedures

and specifications in the repair groups of this manual.

CTM86 (20MAR01)

02-020-10

OWERTECH

RG,RG34710,1074 –19–23OCT97–2/2



8.1 L Diesel Engines — Base Engine

PN=78

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Disassemble and Inspect Rocker Arm Shaft Assembly Serial Number ( —199,999)

NOTE: Make preliminary inspection during disassembly.

Look for: —Worn or scored rocker arms, shaft, and shaft

support. —Weak or broken springs —Lube oil restriction

02 020 11

RG3801 –UN–04DEC97

Rocker Arm Shaft Assembly

1. Remove plugs (A) and washers (B) from ends of rocker arm shaft.

2. Slide springs, rocker arms, and rocker arm supports off rocker arm shaft identifying their parts for reassembly in the same sequence they were in before disassembly.

3. Inspect rocker arm shaft (A) for severe scratching, scoring, or excessive wear at points of rocker arm contact. Measure rocker arm and shaft. Compare with specifications given below.

Rocker Arm Assembly—I.D. 19.07—19.10 mm

Shaft O.D. 19.01—19.05 mm

......................................................................

Specification

..........................................

(0.7507—0.7520 in.)

(0.7484—0.7500 in.)

A—Plugs B—Washers

RG,RG34710,1075 –19–23OCT97–1/3

NOTE: Wear could indicate weak valve springs, bent

push rods, or loose rocker arm shaft clamps.

4. Check rocker arm adjusting nut (C) and screw (B) for damage. Visually inspect rocker arm for hairline cracks. Replace if necessary.

IMPORTANT: Be sure all oil holes in rocker arm shaft

are clean and open.

5. Clean all rocker arm parts with clean solvent. Dry with compressed air.

CTM86 (20MAR01)

02-020-11

A—Rocker Arm Shaft B—Screw C—Rocker Arm Adjusting Nut

Continued on next page

OWERTECH

Rocker Arm Parts

RG,RG34710,1075 –19–23OCT97–2/3



8.1 L Diesel Engines — Base Engine

PN=79

RG3802 –UN–04DEC97

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

6. Check for cups or concave wear (A) on ends of rocker arms where they contact wear caps.

7. Examine spacer springs on shaft between rocker arms.

020

Be sure they are strong enough to exert a positive pressure on rocker arms.

NOTE: If the rocker arm has been damaged by a valve

failure, replace it and the push rods when replacing valves.

8. Roll rocker arm shaft and push rods on a flat surface to check for bends or distortion. Replace parts as necessary.

Assemble Rocker Arm Shaft Assembly Serial Number ( —199,999)

Assemble parts on rocker arm shaft in reverse of removal procedure.

Make sure rocker arm shaft end plugs (A) are firmly seated against end of shaft, and washers (B) are installed on shaft.

A—Rocker Arm Shaft End Plugs B—Washers

Rocker Arm Wear Area

RGR26131 –UN–12JAN98

A—Wear Area

RG,RG34710,1075 –19–23OCT97–3/3

RG3801 –UN–04DEC97

Rocker Arm Shaft Assembly

CTM86 (20MAR01)

02-020-12

OWERTECH

RG,RG34710,1076 –19–23OCT97–1/1



8.1 L Diesel Engines — Base Engine

PN=80

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Measure Valve Recess Serial Number ( —199,999)

Measure and record valve recess dimensions for all valves using JDG451 Gauge with D17526CI (English, in.) or D17527CI (Metric, mm) Dial Indicator or KJD10123 Gauge. Compare measurements to specifications given below.

02 020 13

Exhaust Valve—Recess 1.19—1.70 mm (0.047—0.067 in.)

Maximum Recess 2.46 mm (0.097 in.) below

Intake Valve—Recess 3.35—3.86 mm (0.132—0.152 in.)

Maximum Recess 4.62 mm (0.182 in.) below

.............................................

Specification

......................

below cylinder head

cylinder head

.........................

below cylinder head

cylinder head

NOTE: Thoroughly clean all gasket material from cylinder

head combustion face before measuring. If measurement does not meet specifications,

check valve face angle and valve seat angle. If valve is recessed beyond the maximum specification, install either new valves, valve seat inserts, or both to obtain proper valve recess. See REMOVE VALVE SEAT INSERTS SERIAL NUMBER ( —199,999) later in this group.

Measuring Valve Recess

RG5250 –UN–07NOV97

CTM86 (20MAR01)

02-020-13

OWERTECH

RG,RG34710,1077 –19–27APR99–1/1



8.1 L Diesel Engines — Base Engine

PN=81

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Preliminary Cylinder Head and Valve Checks Serial Number ( —199,999)

Make preliminary inspection of cylinder head and valve assembly during disassembly.

Look for the following conditions:

020

Sticking Valves:

• Carbon deposits on valve stem.

• Worn valve guides.

• Scored valve stems.

• Warped valve stems.

• Misaligned or broken valve springs.

• Worn or distorted valve seats.

• Insufficient lubrication.

Warped, Worn, or Distorted Valve Guides:

• Lack of lubrication.

• Cylinder head distortion.

• Excessive heat.

• Unevenly tightened cylinder head cap screws.

Distorted Cylinder Head and Gasket Leakage:

• Loss of cylinder head cap screw torque.

• Broken cylinder head cap screw.

• Overheating from low coolant level operation.

• Insufficient liner standout.

• Coolant leakage into cylinder causing hydraulic

failure of gasket.

• Leaking aftercooler.

• Cracked cylinder head.

• Cracked cylinder liner.

• Damaged or incorrect gasket.

• Overpowering or overfueling.

• Damaged cylinder head or block surfaces.

• Improper surface finish on cylinder head.

• Improperly tightened cylinder head cap screws.

• Faulty gasket installation (misaligned)

Worn or Broken Valve Seats:

• Distorted cylinder head.

• Carbon deposits on seats due to incomplete

combustion.

• Valve spring tension too weak.

• Excessive heat.

• Improper valve clearance.

• Improper valve timing.

• Incorrect valve or seat installed.

Burned, Pitted, Worn, or Broken Valves:

• Worn or distorted valve seats.

• Loose valve seats.

• Worn valve guides.

• Insufficient cooling.

• Cocked or broken valve springs.

• Improper engine operation.

• Improper valve train timing.

• Faulty valve rotators.

• Warped or distorted valve stems.

• “Stretched” valves due to excessive spring tension.

• Warped cylinder head.

• Bent push rods.

• Carbon build-up on valve seats.

• Rocker arm failure.

• Incorrect valve or seat installed.

• Incorrect piston-to-valve clearance.

Improper Valve Clearance:

• Inefficient use of fuel.

• Engine starts harder.

• Maximum engine power will not be achieved.

• Shorter service life of valve train.

• Greater chance for engine to overheat.

Excessive Valve Recession:

• Worn valve guides.

• Bent valves.

• Debris passed through valve train.

• Misaligned valves.

CTM86 (20MAR01)

02-020-14

OWERTECH

RG,RG34710,1078 –19–27APR99–1/1



8.1 L Diesel Engines — Base Engine

PN=82

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Remove Valve Assembly Serial Number ( —199,999)

Refer to PRELIMINARY CYLINDER HEAD AND VALVE CHECKS SERIAL NUMBER ( —199,999), earlier in this group as valves are removed from head.

IMPORTANT: Identify all usable parts for correct

reassembly in same location as removed.

1. Compress valve spring using JDE138 Valve Spring Compressor (A) as shown.

2. Remove retaining locks (B) using a small magnet.

3. Remove valve spring compressor from head.

02 020 15

RG7228 –UN–05DEC97

Removing Valve Assemblies

4. Remove valve spring cap (D) and valve spring (C).

5. Remove oil shield (A) from exhaust valves. Remove valve (B) from cylinder head. Identify valve for reassembly, if valve is to be reused.

NOTE: Intake valves do not have stem seals.

6. Repeat procedure on remaining valves.

A—Oil Shield B—Valve

A—JDE138 Valve Spring Compressor B—Retainer Locks C—Valve Springs D—Valve Spring Caps

RG,RG34710,1079 –19–23OCT97–1/2

RG7229 –UN–05DEC97

Removing Valves

CTM86 (20MAR01)

02-020-15

OWERTECH

RG,RG34710,1079 –19–23OCT97–2/2



8.1 L Diesel Engines — Base Engine

PN=83

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Inspect and Measure Valve Springs Serial Number ( —199,999)

1. Inspect valve springs for alignment, wear, and damage.

2. Put springs on a flat surface to see that they are

020

square and parallel.

NOTE: Free spring length of 65 mm (2.56 in.) springs

differ slightly, but compressed height must be the same.

3. Check valve spring tension using D01168A Spring Compression Tester.

Valve Spring

RG2732 –UN–04DEC97

Intake Valve Spring—Height 38.1 mm (1.50 in.)@810—880 N

Height 52.5 mm (2.07 in.)@345—399 N

....................................................

Exhaust Valve Spring—Height 38.5 mm (1.52 in.)@797—867 N

Height 54.5 mm (2.15 in.)@284—338 N

....................................................

Specification

.................

(182—198 lb-force) with valve

open

(78—90 lb-force) with valve

closed

Specification

..............

(179—195 lb-force) with valve

open

(64—76 lb-force) with valve

closed

Checking Valve Spring Tension

T82054 –UN–08NOV88

CTM86 (20MAR01)

02-020-16

OWERTECH

RG,RG34710,1080 –19–27APR99–1/1



8.1 L Diesel Engines — Base Engine

PN=84

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Inspect Valve Spring Caps, Wear Caps, and Retainer Locks Serial Number ( —199,999)

1. Inspect valve spring caps (A) in area where valve springs and retaining locks seat for excessive wear. Replace as needed.

2. Inspect retainer locks (C) for excessive wear. Replace as needed.

02 020 17

3. Inspect valve wear cap (B) contact surfaces. Replace wear caps if pitted or worn.

Clean Valves Serial Number ( —199,999)

1. Hold each valve firmly against a soft wire wheel on a bench grinder.

2. Make sure all carbon is removed from valve head, face and stem. Polish valve stem with steel wool or crocus cloth to remove scratch marks left by wire brush.

IMPORTANT: Any carbon left on valve stem will affect

alignment in refacer if valves need to be refaced.

Inspecting Valve Parts

RG7230 –UN–05DEC97

A—Valve Spring Caps B—Valve Wear Cap C—Retainer Locks

RG,RG34710,1081 –19–23OCT97–1/1

CTM86 (20MAR01)

02-020-17

OWERTECH

RG,RG34710,1082 –19–23OCT97–1/1



8.1 L Diesel Engines — Base Engine

PN=85

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Inspect and Measure Valves Serial Number ( —199,999)

1. Thoroughly clean and inspect valves to help determine

020

if they can be restored to a serviceable condition. Replace valves that are burned, cracked, eroded, or chipped.

2. Inspect valve retainer lock groove (C) on valve stem for damage. Also inspect stems for signs of scuffing, which may indicate insufficient valve guide-to-valve stem clearance. Replace if defects are evident.

3. Measure valve head O.D. (A). Compare valve stem O.D. (B) with guide I.D. to determine clearance, as outlined later in this group.

Intake Valve Stem—OD 9.461—9.487 mm

Exhaust Valve Stem—OD 9.436—9.462 mm

Intake Valve Head—OD 50.87—51.13 mm

Exhaust Valve Head—OD 46.87—47.13 mm

Specification

................................................

(0.3725—0.3735 in.)

.............................................

(0.3715—0.3725 in.)

................................................

(2.002—2.012 in.)

.............................................

(1.845—1.856 in.)

Measuring Valves

RG5795 –UN–05DEC97

A—Valve Head OD B—Valve Stem OD C—Valve Retainer Lock Groove

4. Use D05058ST Valve Inspection Center to determine if valves are out of round, bent or warped.

Valve Face—Runout 0.05 mm (0.002 in.) maximum

..................................

CTM86 (20MAR01)

Specification

permissible

02-020-18

OWERTECH

DPSG,OUO1004,833 –19–27APR99–1/2

Valve Face Runout Check

DPSG,OUO1004,833 –19–27APR99–2/2



8.1 L Diesel Engines — Base Engine

RG4234 –UN–05DEC97

032001

PN=86

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Grind (Reface) Valves Serial Number ( —199,999)

IMPORTANT: Valve grinding should only be done by

experienced personnel familiar with equipment and capable of maintaining required specifications.

If necessary to reface valve, grind valve face angle (A) to following specification.

02 020 19

Valve Face (Intake and

Exhaust)—Angle 29.25°±0.25°..................................................................

Specification

A—Valve Face Angle

IMPORTANT: When valve faces are ground, it is

important not to nick valve head-to-stem radius with facing stone. A nick could cause the valve to break. Radius all sharp edges after grinding.

Inspect and Clean Cylinder Head Serial Number ( —199,999)

1. Inspect combustion face for evidence of physical damage, oil or coolant leakage, or gasket failure prior to cleaning the cylinder head. Repair or replace cylinder head if there is evidence of physical damage; such as cracking, abrasion, distortion, or valve seat “torching”. Inspect all cylinder head passages for restrictions.

3. Clean cylinder head in a chemical hot tank, or with solvent and a brush.

4. Dry with compressed air and blow out all passages.

Valve Face Angle

RG5247 –UN–05DEC97

RG,RG34710,1084 –19–27APR99–1/1

damaged or destroyed by hot tank solutions.

2. Scrape gasket material, oil, carbon, and rust from head. Use a powered brass or copper wire brush to clean sealing surfaces.

IMPORTANT: Be sure to remove all plugs before

cleaning head, as parts can be

CTM86 (20MAR01)

5. Reinstall plugs removed from cylinder head and

Cylinder Head Plugs—Torque 60 N•m (44 lb-ft)..................................

02-020-19

tighten to the following specifications.

Specification

RG,RG34710,1085 –19–27APR99–1/1

OWERTECH



8.1 L Diesel Engines — Base Engine

032001

PN=87

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Check Cylinder Head Combustion Face Flatness Serial Number ( —199,999)

Check cylinder head flatness using D05012ST Precision Straightedge and feeler gauge. Check lengthwise,

crosswise, and diagonally in several places.

020

If any measurement exceeds specification, the cylinder head must be either resurfaced or replaced. See MEASURE CYLINDER HEAD THICKNESS SERIAL NUMBER ( —199,999) later in this group.

Cylinder Head—Maximum Acceptable Out-of-Flat Over

Entire Length or Width 0.08 mm (0.003 in.)...............................................

Straightness Per Any 305 mm (12

in.) Length Within 0.025 mm (0.001 in.).....................................................

Specification

Checking Flatness of Cylinder Head (1)

RG7231 –UN–05DEC97

Checking Flatness of Cylinder Head (2)

Location to Check for Head Flatness

RG,RG34710,1086 –19–27APR99–1/1

RG7232 –UN–05DEC97

RG4629 –UN–05DEC97

CTM86 (20MAR01)

02-020-20

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=88

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Measure Cylinder Head Thickness Serial Number ( —199,999)

Measure head thickness (A) from valve cover gasket rail-to-combustion face.

Cylinder Head—Thickness 155.45—155.71 mm

Wear Limit 154.69 mm (6.09 in.)................................................................

Combustion Face Surface Finish (Surface Mill Only to AA Finish) 1.5—2.8 micrometers

.......................................................................

Maximum Wave Depth 0.012 mm (0.0005 in.)...........................................

If cylinder head thickness is less than wear limit, DO NOT attempt to resurface. Install a new cylinder head.

Specification

........................................

(6.120—6.130 in.)

(60—110 micro-in.)

02 020 21

RG4421 –UN–05DEC97

Cylinder Head Thickness

A—Head Thickness

Resurfacing Head—Maximum

Material Removal 0.762 mm (0.030 in.)......................................................

Specification

NOTE: If necessary to resurface cylinder head, a

MAXIMUM of 0.762 mm (0.030 in.) can be ground from new part dimension. Remove ONLY what is necessary to restore flatness.

IMPORTANT: After resurfacing, check flatness as

described earlier and check surface finish on combustion face of head.

Check valve recess after grinding. See MEASURE VALVE RECESS SERIAL NUMBER ( —199,999) earlier in this group. Valve face may be ground to bring this characteristic within specification.

CTM86 (20MAR01)

02-020-21

OWERTECH

RG,RG34710,1087 –19–27APR99–1/1



8.1 L Diesel Engines — Base Engine

PN=89

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Clean Valve Guides Serial Number ( —199,999)

Use a D17024BR End Brush to clean valve guides before inspection or repair.

020

NOTE: A few drops of light oil or kerosene will help to

fully clean the guide.

Measure Valve Guides Serial Number ( —199,999)

Measure valve guides (A) for wear using a telescope gauge (B) and micrometer.

Valve Guide—ID 9.51—9.54 mm (0.3745—0.3755

New Guide-to-Exhaust Valve Stem—Clearance 0.051—0.102 mm (0.002—0.004

New Guide-to-Intake Valve Stem—Clearance 0.025—0.076 mm (0.001—0.003

....................................

..................................

Specification

in.) in new head

in.)

Specification

in.)

Cleaning Valve Guides

RG5346 –UN–07NOV97

RG,RG34710,1088 –19–23OCT97–1/1

RGR23984 –UN–12JAN98

A—Valve Guides B—Telescope Gauge

NOTE: Worn guides can allow a clearance of 0.15 mm

(0.006 in.) and still be acceptable. Worn guides may be knurled to return them to specified clearance if valve-to-guide clearance is 0.25 mm (0.010 in.) or less. If clearance exceeds 0.25 mm (0.010 in.), install oversize valves.

IMPORTANT: ALWAYS knurl exhaust valve guides

before reaming to assure proper valve guide-to-stem clearance.

CTM86 (20MAR01)

02-020-22

OWERTECH

RG,RG34710,1089 –19–23OCT97–1/1



8.1 L Diesel Engines — Base Engine

PN=90

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Knurl Valve Guides Serial Number ( —199,999)

1. Use JT05949 (formerly D20002) Valve Guide Knurler Kit to knurl valve guides.

NOTE: Use tool set exactly as directed by the

manufacturer.

2. After knurling, ream valve guide to finished size to provide specified stem-to-guide clearance.

A—Knurler B—Reamer C—Speed Reducer D—Lubricant

02 020 23

Clean and Inspect Valve Seats Serial Number ( —199,999)

1. Use an electric hand drill with D17024BR Wire Cleaning Brush or equivalent brush to remove all carbon on valve seats.

2. Check seats for cracks, pits, or excessive wear.

3. Check entire combustion face for rust, scoring, pitting, or cracks.

Knurling Valve Guides

RGR26141 –UN–12JAN98

RG,RG34710,1090 –19–23OCT97–1/1

R26142N –UN–09DEC88

Cleaning Valve Seats

CTM86 (20MAR01)

02-020-23

OWERTECH

RG,RG34710,1091 –19–23OCT97–1/1



8.1 L Diesel Engines — Base Engine

PN=91

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Measure Valve Seats Serial Number ( —199,999)

1. Measure valve seats for proper specifications listed

020

below.

2. Using D11010KW Eccentrimeter, measure valve seat runout (D).

3. If valve seat is not within specification, recondition valve seat by grinding or replace valve seat inserts (A) if reconditioning is not possible. See GRIND VALVE SEATS SERIAL NUMBER ( —199,999) or see INSTALL VALVE SEAT INSERTS SERIAL NUMBER ( —199,999), later in this group.

Specification

Valve Seat—Angle 30°±0.50°...................................................................

Maximum Runout 0.051 mm (0.0020 in.)...................................................

Specification

Exhaust Valve Seat—Width 2.0—3.8 mm (0.079—0.150 in.)....................

Measuring Valve Seats

RG5248 –UN–05DEC97

A—Valve Seat Insert B—Valve Seat Angle C—Valve Seat Width D—Valve Seat Runout

Intake Valve Seat—Width 1.4—3.8 (0.055—0.150 in.)..............................

Specification

RG,RG34710,1092 –19–23OCT97–1/1

CTM86 (20MAR01)

02-020-24

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=92

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Grind Valve Seats Serial Number ( —199,999)

IMPORTANT: Valve seat grinding should only be

done by experienced personnel familiar with equipment and capable of maintaining required specifications. ALWAYS keep work area clean when grinding valve seats. A 120-grit stone MUST BE used for grinding both intake and exhaust valve seat inserts (A).

Using JT05893 Heavy-Duty Seat Grinder Set, grind valve seats to obtain correct valve recess in cylinder head. See MEASURE VALVE RECESS SERIAL NUMBER ( —199,999) earlier in this group. Be sure valve guide bores are clean before grinding valve seats. See CLEAN VALVE GUIDES SERIAL NUMBER ( —199,999) earlier in this group.

02 020 25

R26143N –UN–09DEC88

Grinding Valve Seats

If valve seats need grinding, only a few seconds are required to recondition the average valve seat. Avoid the tendency to grind off too much. Do not use excessive pressure on the grinding stone.

1. Check the seat width (C) and contact pattern between the seat and valve with bluing. Seat width MUST BE maintained within specification. Use a vernier caliper or scale to measure seat width. Thoroughly clean seat area after grinding and replace valves and valve seat inserts as necessary.

NOTE: Valve seat width can be reduced with a narrowing

stone. This will change the angle (B) at the top of the seat and increase the diameter. If valve seat width is too narrow, valve may burn or erode. Varying the width changes the fine contact between valve face and seat.

2. ALWAYS measure valve seat runout after grinding using D11010KW Eccentrimeter and check recess in cylinder head after grinding as described later.

Measuring Valve Seats

RG5248 –UN–05DEC97

A—Valve Seat Insert B—Valve Seat Angle C—Valve Seat Width D—Valve Seat Runout

CTM86 (20MAR01)

Continued on next page

02-020-25

OWERTECH

RG,RG34710,1093 –19–23OCT97–1/2



8.1 L Diesel Engines — Base Engine

PN=93

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Valve Seat Grinding—Angle 30°±0.50°....................................................

Specification

Exhaust Width 2.0—3.8 mm (0.079—0.150 in.).........................................

Intake Width 1.4—3.8 mm (0.055—0.150 in.)............................................

Maximum Seat Runout 0.051 mm (0.0020 in.)...........................................

020

Remove Valve Seat Inserts Serial Number ( —199,999)

In some cases the valve seat bore in the cylinder head may become damaged or oversized and will require machining. In this case, oversize inserts are available in

0.25 mm (0.010 in.) oversize only.

Specification

Oversize Inserts—Width 0.25 mm (0.010 in.).............................................

IMPORTANT: Be careful not to damage cylinder head

when removing seats.

1. Remove valve seat insert (if necessary) with JDE41296 Valve Seat Puller (A). Adjusting screw on puller may need to be retightened during removal of inserts.

RG,RG34710,1093 –19–23OCT97–2/2

RG5306 –UN–07NOV97

Removing Valve Seat Inserts

Valve seat inserts may be also removed using the following method:

• Carefully heat insert at four points around face until

insert becomes red hot. Allow seat to cool and carefully pry out the insert(s) with a screwdriver.

2. After removal of inserts, thoroughly clean area around valve seat bore and inspect for damage or cracks.

Heating Valve Seat Inserts

RG5605 –UN–05DEC97

A—Valve Seat Puller

RG,RG34710,1094 –19–23OCT97–1/1

CTM86 (20MAR01)

02-020-26

OWERTECH



8.1 L Diesel Engines — Base Engine

PN=94

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

Install Valve Seat Inserts Serial Number ( —199,999)

1. Use the JDE7 Driver (A) along with JDG605 Valve Seat Installer (B) to drive inserts into place. The larger end of JDG605 Installer is used to install intake valves and the smaller end is used to install exhaust valves.

2. Install new or refaced valves and check valve recess. See MEASURE VALVE RECESS SERIAL NUMBER ( —199,999) earlier in this group.

3. Grind valve seats as required to maintain correct valve recess and valve-to-seat seal. See GRIND VALVE SEATS SERIAL NUMBER ( —199,999) earlier in this group.

A—Driver B—Valve Seat Installer

02 020 27

RG5653 –UN–31OCT97

Installing Valve Seat Inserts

Inspect and Clean Cylinder Head Nozzle Bore Serial Number ( —199,999)

1. Inspect condition of threads for gland nut. Threads are metric (M28 x 1.5).

2. Inspect condition of nozzle seating surface in cylinder head.

Cylinder head threads and nozzle seating surface must be free of debris and carbon deposits.

IMPORTANT: If the injection nozzle gland nut threads

are not clean, a false torque reading may be obtained when the injection nozzle is installed. This may prevent the injection nozzle from seating properly in the cylinder head.

3. Clean threads which have light foreign deposits using a drill and the D17030BR Thread Cleaning Brush. Work brush up and down several times to clean threads.

RG,RG34710,1095 –19–23OCT97–1/1

RG5251 –UN–14DEC88

Cleaning Cylinder Head Nozzle Bores

CTM86 (20MAR01)

Continued on next page

02-020-27

OWERTECH

RG,RG34710,1096 –19–23OCT97–1/3



8.1 L Diesel Engines — Base Engine

PN=95

032001

Cylinder Head and Valves Repair and Adjustment S. N. ( —199,999)

4. Clean threads with heavy foreign deposits or clean up damaged threads using the JDF5 Tap (M28 x 1.5 mm) or an equivalent M28 x 1.5 mm (metric) tap (A). Be sure to start tap straight to avoid possible

020

cross-threading. A light coat of grease on tap will help collect foreign deposits on tap and prevent them from falling into the nozzle bore.

A—Tap

5. Clean nozzle seating surface by using the JDG609 Nozzle Seat Reamer (A) to remove carbon.

6. Blow out debris with compressed air and thoroughly clean all nozzle bores.

A—Nozzle Seat Reamer

Using Tap on Nozzle Bore Threads

RG5252 –UN–06DEC88

RG,RG34710,1096 –19–23OCT97–2/3

RG5253 –UN–06DEC88

Cleaning Nozzle Seating Surface

CTM86 (20MAR01)

02-020-28

OWERTECH

RG,RG34710,1096 –19–23OCT97–3/3



8.1 L Diesel Engines — Base Engine

PN=96

032001

John Deere POWERTECH 8.1 L Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Foreword

Introduction

John Deere Dealers

About this Manual

Identification Views Serial Number ( —199,999)

Identification Views Serial Number (200,000— )

Contents

Section 01

General

Handle Fluids Safely—Avoid Fires

Group 000

Safety

Handle Starting Fluid Safely

Handling Batteries Safely

Prepare for Emergencies

Avoid High-Pressure Fluids

Wear Protective Clothing

Service Machines Safely

Work In Ventilated Area

Work in Clean Area

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Illuminate Work Area Safely

Use Proper Lifting Equipment

Construct Dealer-Made Tools Safely

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Engine Model Designation

Group 001

Engine Identification

Engine Serial Number Plate Information

Engine Option Code Label

Engine Application Chart (John Deere Construction Equipment)

Engine Application Chart (OEM) (Outside Equipment Manufacturers)

Diesel Fuel

Group 002

Fuels, Lubricants and Coolant

Bio-Diesel Fuel

Lubricity of Diesel Fuel

Dieselscan Fuel Analysis

Diesel Engine Break-In Oil

Diesel Engine Oil

Extended Diesel Engine Oil Service Intervals

Alternative and Synthetic Lubricants

Mixing of Lubricants

Grease

Diesel Engine Coolant

Diesel Engine Coolants, Supplemental Additive Information

Testing Diesel Engine Coolant

Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes

Operating in Warm Temperature Climates

Flush and Service Cooling System

Disposing of Coolant

Section 02

Repair and Adjustments

Engine Overhaul Guidelines

Group 010

Engine Rebuild

Engine Repair Stand

Safety Precautions

Install Adapters on Engine Repair Stand

Engine Lifting Procedure

Clean Engine

Disconnect Turbocharger Oil Inlet Line

Mount Engine on Repair Stand

Engine Disassembly Sequence for Overhaul

Sealant Application Guidelines

6081 Engine Assembly Sequence After Overhaul

Engine Break-In Guidelines

Perform Engine Break-In

Check Crankcase Ventilation System

Check Air Intake System

Check Exhaust System

Check and Service Cooling System