John Deere POWERTECH 8.1 L Technical Manual

PowerTech 8.1L

Diesel Engines

Mechanical Fuel

Systems

COMPONENT TECHNICAL MANUAL

Diesel models 6081

CTM243 18 FEB 05 (ENGLISH)

For complete service information also see:

PowerTech 8.1 L Diesel Engines Base
Engine

Alternators and Starting Motors CTM77

OEM Engine Accessories CTM67

CTM106819 - Application List CTM106819

CTM86

John Deere Power Systems

CTM243-COMPONENT TECHNICAL MANUAL

FORWARD
Section 01 - GENERAL

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

Section 02 - REPAIR AND ADJUSTMENT

Group 090 - Mechanical Fuel System Repair and Adjustments

Section 03 - THEORY OF OPERATION

Group 130 - Mechanical Fuel Systems Operation

Section 04 - DIAGNOSTICS

Group 150 - Observable Diagnostics and Tests

Section 05 - TOOLS

Group 170 - Repair Tools
Group 180 - Diagnostic Service Tools

Section 6 - SPECIFICATIONS

Group 200 - Repair and General OEM Specifications

(g) by Belgreen v2.1

Table of contents

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<- Go to Global Table of contents CTM243-COMPONENT TECHNICAL MANUAL

GENERAL

(g) by Belgreen v2.0

Forward

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 (CTM243) covers only the mechanical fuel system. It is one of five volumes on the 8.1L engine. The following four
companion manuals cover the base engine and electronic fuel system repair, operation and diagnostics:

CTM68—Electronic Fuel Injection Systems
CTM86—Base Engine
CTM134—John Deere Level 3 Electronic Fuel Systems with Bosch In-Line Pump.
CTM255—John Deere Level 9 Electronic Fuel Systems with Denso In-Line Pump.

This new CTM covers information formerly in Group 35 of CTM86 dated 06JUL99 and Group 115 of CTM134 dated 22FEB99.

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

A complete set of all manuals covering the 8.1L engines, excluding CTM68, can be procured by ordering 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.

CAUTION:

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 Section 01,
Group 001 identifies product-model/component type-model relationship. See the machine technical manual for information on
component removal and installation, and gaining access to the components.

Information is organized in sections and groups for the various components requiring service instruction.

Before beginning repair on an engine, clean the engine.

This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware
on these engines is metric sized.

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

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

California Proposition 65 Warning

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.

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Section 01 page 1

CTM243-COMPONENT TECHNICAL MANUAL

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL

Table of contents

Group 000 - Safety 1 ...................................................................................................................................

Handle Fluids Safely—Avoid Fires 1 .........................................................................................................

Handle Starting Fluid Safely 1 .................................................................................................................

Handling Batteries Safely 1 .....................................................................................................................

Prepare for Emergencies 4 ......................................................................................................................

Avoid High-Pressure Fluids 4 ...................................................................................................................

Wear Protective Clothing 5 ......................................................................................................................

Service Machines Safely 5 .......................................................................................................................

Work In Ventilated Area 6 ........................................................................................................................

Work in Clean Area 6 ...............................................................................................................................

Remove Paint Before Welding or Heating 6 .............................................................................................

Avoid Heating Near Pressurized Fluid Lines 8 ..........................................................................................

Illuminate Work Area Safely 8 .................................................................................................................

Use Proper Lifting Equipment 8 ...............................................................................................................

Construct Dealer-Made Tools Safely 9 .....................................................................................................

Practice Safe Maintenance 10 .................................................................................................................

Use Proper Tools 10 .................................................................................................................................

Dispose of Waste Properly 11 ..................................................................................................................

Live With Safety 11 .................................................................................................................................

Group 001 - Engine Identification 13 .......................................................................................................

Engine Model Designation 13 ..................................................................................................................

Engine Serial Number Plate Information 13 .............................................................................................

Engine Option Code Label 14 ..................................................................................................................

Group 002 - Fuels, Lubricants and Coolant 15 .......................................................................................

Diesel Fuel 15 ..........................................................................................................................................

Bio-Diesel Fuel 16 ....................................................................................................................................

Lubricity of Diesel Fuel 17 .......................................................................................................................

Testing Diesel Fuel 17 .............................................................................................................................

Diesel Engine Break-In Oil 18 ..................................................................................................................

Diesel Engine Oil 19 ................................................................................................................................

Extended Diesel Engine Oil Service Intervals 20 .....................................................................................

Alternative and Synthetic Lubricants 20 ..................................................................................................

Mixing of Lubricants 20 ...........................................................................................................................

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

registered trademark of Deere & Company. 20 ................................................................................

Grease 21 ................................................................................................................................................

Heavy Duty Diesel Engine Coolant 22 .....................................................................................................

Diesel Engine Coolants, Supplemental Additive Information 24 ..............................................................

Testing Diesel Engine Coolant 25 ............................................................................................................

Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes 26 .............................

Operating in Warm Temperature Climates 27 .........................................................................................

Flush and Service Cooling System 27 ......................................................................................................

Disposing of Coolant 29 ...........................................................................................................................

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Section 01 - GENERAL Group 000: Safety

Group 000 - Safety

Handle Fluids Safely—Avoid Fires

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.

Handle Starting Fluid Safely

Store 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.

Handling Batteries Safely

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Section 01 page 1

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

CAUTION:

Explosion

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

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

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

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

CAUTION:

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Section 01 page 2

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Acid

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:

Filling batteries in a well-ventilated area.1.
Wearing eye protection and rubber gloves.2.
Avoiding breathing fumes when electrolyte is added.3.
Avoiding spilling or dripping electrolyte.4.
Use proper jump start procedure.5.

If you spill acid on yourself:

Flush your skin with water.1.
Apply baking soda or lime to help neutralize the acid.2.
Flush your eyes with water for 15—30 minutes. Get medical attention immediately.3.

If acid is swallowed:

Do not induce vomiting.1.
Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).2.
Get medical attention immediately.3.

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.

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Section 01 page 3

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Prepare for Emergencies

First Aid Kit

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.

Avoid High-Pressure Fluids

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 in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling
1-800-822-8262 or [phone].

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Section 01 page 4

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Wear Protective Clothing

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

Moving Parts

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Section 01 page 5

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

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.

Work In Ventilated Area

Engine exhaust fumes

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

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

Work in Clean Area

Clean Work 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.

Remove Paint Before Welding or Heating

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Section 01 page 6

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Toxic Fumes

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating:

Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an
approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or
heating.

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

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

Dispose of paint and solvent properly.

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Section 01 page 7

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Avoid Heating Near Pressurized Fluid Lines

Flammable Spray

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

Illuminate Work Area Safely

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.

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Section 01 page 8

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Use Proper Lifting Equipment

Proper Lifting Equipment

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

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

Construct Dealer-Made Tools Safely

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.

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Section 01 page 9

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

Practice Safe Maintenance

Keep Area Clean

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

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

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

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

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

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

Use Proper Tools

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Section 01 page 10

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 000: Safety

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

Recycle Waste

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.

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Section 01 page 11

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 001: Engine Identification

Live With Safety

Safety Systems

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

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Section 01 page 12

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 001: Engine Identification

Group 001 - Engine Identification

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:

Engine Model Designation

6081 HRW01 Engine

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

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

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

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

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

Aspiration Code

T .......... Turbocharged, not aftercooled

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

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

User Code

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

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

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

FF .......... Kernersville 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 Application Manual, CTM106819.

Engine Serial Number Plate Information

Engine Serial Number Plate

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Section 01 page 13

LEGEND:

A Engine Serial Number
B Engine Application Data

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

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 Serial Numbers

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. See
Application Manual, CTM106819.

Engine Option Code Label

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

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Section 01 page 14

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Group 002 - Fuels, Lubricants and Coolant

Diesel Fuel

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

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 ORCloud Point at least 5°C (9°F) below the
expected low temperature.

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

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.

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Section 01 page 15

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

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.

DIN 51606 Specification

Bio-Diesel Property List for DIN 51606

Property Unit DIN 51606 Sept 1997

Density at 15° C (59° F)

Viscosity at 40° C (104° F)

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, 122° F) Degree of Corrosion 1

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

g/cm 3 (lb/ft 3 )

mm 2 /s (cST)

0.875—0.900 (55—56)

3.5—5.0

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Section 01 page 16

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Bio-Diesel Property List for DIN 51606

Property Unit DIN 51606 Sept 1997

Total Glycerine % Mass Max. 0.25

Iodine Number — Max. 115

Phosphorus % Mass Max. 0.001

Alkali Content (Na + K) % Mass Max. 0.0005

Lubricity of Diesel Fuel

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

IMPORTANT:

Make sure the diesel fuel used in your machine demonstrates good lubricity characteristics.

Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

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

Lubricity of Biodiesel Fuel

Significant improvement in lubricity can occur with biodiesel blends up to B20. The gain in lubricity above a 20% blend is
limited.

Testing Diesel Fuel

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

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

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Section 01 page 17

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Diesel Engine Break-In Oil

New engines are filled at the factory with either John Deere Break-In ™ or Break-In™ Plus Engine Oil. During the break-in
period, add John Deere Break-In™ or Break-In™ Plus Engine Oil, respectively, as needed to maintain the specified oil level.

Operate the engine under various conditions, particularly heavy loads with minimal idling, to help seat engine components
properly.

Change the oil and filter at 100 hours maximum for Break-In™ Oil or 500 hours maximum for Break-In™ Plus Oil during the
initial operation of a new or rebuilt engine.

After engine overhaul, fill the engine with either John Deere Break-In™ or Break-In™ Plus Engine Oil.

If John Deere Break-In™ or Break-In™ Plus Engine Oil is not available, use a 10W-30 diesel engine oil meeting one of the
following during the first 100 hours of operation:

API Service Classification CE
API Service Classification CD
API Service Classification CC
ACEA Oil Sequence E2
ACEA Oil Sequence E1

IMPORTANT:

Do not use Plus-50™ II, Plus-50 or engine oils meeting any of the following for the initial break-in of a
new or rebuilt engine:

Oils

API CJ-4 ACEA E9

API CI-4 PLUS ACEA E7

API CI-4 ACEA E6

API CH-4 ACEA E5

API CG-4 ACEA E4

API CF-4 ACEA E3

API CF-2

API CF

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

John Deere Break-In™ Plus Engine Oil can be used for all John Deere diesel engines at all emission certification levels.

After the break-in period, use John Deere Plus-50 ™ II, John Deere Plus-50, or other diesel engine oil as recommended in this
manual.

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Section 01 page 18

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Diesel Engine Oil

Oil Viscosities for Air Temperature Ranges

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

John Deere Plus-50 ™ II oil is preferred.

John Deere Plus-50™ is also recommended.

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

John Deere Torq-Gard Supreme ™
API Service Category CJ-4
API Service Category CI-4 PLUS
API Service Category CI-4
API Service Category CH-4
API Service Category CG-4
API Service Category CF-4
ACEA Oil Sequence E9
ACEA Oil Sequence E7
ACEA Oil Sequence E6
ACEA Oil Sequence E5
ACEA Oil Sequence E4
ACEA Oil Sequence E3
ACEA Oil Sequence E2

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

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Section 01 page 19

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Multi-viscosity diesel engine oils are preferred.

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

If diesel fuel with sulfur content greater than 0.50% (5000 mg/kg) is used, reduce the service interval by 50%.

DO NOT use diesel fuel with sulfur content greater than 1.00% (10 000 mg/kg).

Extended Diesel Engine Oil Service Intervals

When John Deere Plus-50 ™ II or John Deere Plus-50™ oil is used with the specified John Deere filter, the service interval for
engine oil and filter changes may be increased by 50% but not to exceed a maximum of 500 hours.

When ACEA E9, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 oils are used with specified John Deere filter, use engine oil analysis to
determine if the service interval for engine oil and filter changes may be increased by a maximum of 50% but not to exceed
500 hours.

If John Deere Plus-50™ II or John Deere Plus-50™, ACEA E9, ACEA E7, ACEA E6, ACEA E5, or ACEA E4 oils are used with other
than the specified John Deere filter, change the engine oil and filter at the normal service interval.

If John Deere Torq-Gard Supreme ™ , API CJ-4, API CI-4 PLUS, API CI-4, API CH-4, or ACEA E3 oils are used, change the engine oil
and filter at the normal service interval.

If API CG-4, API CF-4, or ACEA E2 oils are used, change the engine oil and filter at 50% of the normal service interval.

IMPORTANT:

When using biodiesel blends greater than B20, reduce the oil and filter service interval by 50% or
monitor engine oil based on test results from Oilscan.

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.

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.

Avoid mixing different brands or types of oils. Oil manufacturers blend base stock and additives to create their oils and to meet
certain specifications and performance requirements. Mixing different oils can interfere with proper functioning of these
formulations and degrade lubricant performance.

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

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.

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

OILSCAN ™ and CoolScan ™

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Section 01 page 20

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Sampling Programs

Recommended Change Interval

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.

Grease

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Section 01 page 21

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Grease

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

John Deere SD POLYUREA GREASE is preferred.

The following greases are also recommended

John Deere HD LITHIUM COMPLEX GREASE
John Deere HD WATER RESISTANT GREASE
John Deere GREASE-GARD ™

Other greases may be used if they meet the following:

NLGI Performance Classification GC-LB

IMPORTANT:

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

Heavy Duty Diesel Engine Coolant

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

John Deere COOL-GARD ™ II Premix Coolant is preferred.

John Deere COOL-GARD II Premix is available in a concentration of 50% ethylene glycol.

Additional Recommended Coolants

The following engine coolants are also recommended:

John Deere COOL-GARD II Concentrate in a 40% to 60% mixture of concentrate with quality water.
John Deere COOL-GARD Premix (available in a concentration of 50% ethylene glycol).
John Deere COOL-GARD Concentrate in a 40% to 60% mixture of concentrate with quality water.
John Deere COOL-GARD PG Premix (available in a concentration of 55% propylene glycol).

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Section 01 page 22

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

John Deere COOL-GARD II Premix and COOL-GARD II Concentrate coolants do not require use of supplemental coolant
additives.

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

Use John Deere COOL-GARD PG Premix when a non-toxic coolant formulation is required.

Other Coolants

It is possible that John Deere COOL-GARD II, COOL-GARD, and COOL-GARD PG coolants are unavailable in the geographical area
where service is performed.

If these coolants are unavailable, use a coolant concentrate or prediluted coolant intended for use with heavy duty diesel
engines and with a minimum of the following chemical and physical properties:

Is formulated with a quality nitrite-free additive package.
Provides cylinder liner cavitation protection according to either the John Deere Cavitation Test Method or a fleet study run
at or above 60% load capacity.
Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion.

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

ethylene glycol or propylene glycol base prediluted (40% to 60%) heavy duty coolant
ethylene glycol or propylene glycol base heavy duty coolant concentrate in a 40% to 60% mixture of concentrate with
quality water

Water Quality

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

IMPORTANT:

Do not use cooling system sealing additives or antifreeze that contains sealing additives.

Do not mix ethylene glycol and propylene glycol base coolants.

Do not use coolants that contain nitrites.

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Section 01 page 23

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: 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 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.

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

Avoid Automotive-Type Coolants

Never use automotive-type coolants (such as those meeting ASTM D3306 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:

Water 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

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Section 01 page 24

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Freeze Protection

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.

Freeze Protection

Ethylene Glycol Freeze Protection Limit

40% -24°C (-12°F)

50% -37°C (-34°F)

60% -52°C (-62°F)

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

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.

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.

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Section 01 page 25

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes

Radiator Coolant Check

JT07298 Coolant/Battery Tester

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.

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Section 01 page 26

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

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.

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.

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 AND 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.

John Deere COOL-GARD ™ II Premix is available in a concentration of 50% ethylene glycol. However, there are situations in
warm temperature climates where a coolant with lower glycol concentration (approximately 20% ethylene glycol) has been
approved. In these cases, the low glycol formulation has been modified to provide the same level of corrosion inhibitor as John
Deere COOL-GARD II Premix (50/50).

IMPORTANT:

Water may be used as coolantin 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.

Flush and Service Cooling System

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Section 01 page 27

CTM243-COMPONENT TECHNICAL MANUAL

Section 01 - GENERAL Group 002: Fuels, Lubricants and Coolant

CAUTION:

Cooling System Safety

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.

→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 ENGINE COOLANT SPECIFICATIONS , earlier in this group.

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.

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Section 01 page 28

CTM243-COMPONENT TECHNICAL MANUAL

REPAIR AND ADJUSTMENT

(g) by Belgreen v2.0

Disposing of Coolant

Waste Disposal

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.

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Section 02 page 29

CTM243-COMPONENT TECHNICAL MANUAL

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT

Table of contents

Group 090 - Mechanical Fuel System Repair and Adjustments 1 ........................................................

Relieve Fuel System Pressure 1 ...............................................................................................................

Replace Rectangular Fuel Filter Element 1 ..............................................................................................

Replace Fuel Filter Check Valve 2 ...........................................................................................................

Replace Primary (Round) Fuel Filter/Water Separator 3 ..........................................................................

Identification of Fuel Supply Pumps 5 ......................................................................................................

Remove Fuel Supply Pump (Bosch and Nippondenso) 5 .........................................................................

Inspect Fuel Supply Pump 5 ....................................................................................................................

Install Fuel Supply Pump (Bosch and Nippondenso) 6 .............................................................................

Install Fuel Supply Pump (Motorpal) 7 .....................................................................................................

Repair Injection Pump Aneroid (Bosch and Nippondenso)—If Equipped 8 ...............................................

Remove Hydraulic Aneroid Activator (Bosch and Nippondenso)—If Equipped 8 ......................................

Disassemble, Clean, Assemble and Install Hydraulic Aneroid Activator Parts (Bosch and

Nippondenso)—If Equipped 8 ...........................................................................................................

Service Injection Pump Overflow Valve (Bosch and Nippondenso) 9 .......................................................

Service Injection Pump Overflow Valve (Bosch and Nippondenso) 10 .....................................................

Remove and Install Fuel Shut-off Solenoid (Bosch and Nippondenso)—If Equipped 13 ...........................

Remove and Install Fuel Shut-off Solenoid (Motorpal)—If Equipped 14 ...................................................

Identification of In-Line Fuel Injection Pumps 15 .....................................................................................

Service of Fuel Injection Pumps 16 ..........................................................................................................

Replace Motorpal Fuel Injection Pump Delivery Valve O-Rings 16 ..........................................................

Remove Fuel Injection Pump (Bosch and Nippondenso) 19 .....................................................................

Remove Fuel Injection Pump (Motorpal) 24 .............................................................................................

Install Fuel Injection Pump (Bosch and Nippondenso) 28 ........................................................................

Install Fuel Injection Pump (Motorpal) 34 ................................................................................................

Remove Fuel Injection Nozzles 39 ...........................................................................................................

Diagnose Injection Nozzle Malfunction 43 ...............................................................................................

Test Fuel Injection Nozzles 43 .................................................................................................................

Perform Opening Pressure Test 44 ..........................................................................................................

Injection Nozzle Opening Pressure Specifications 46 ...............................................................................

Perform Nozzle Leakage Test 47 .............................................................................................................

Perform Chatter and Spray Pattern Test 48 .............................................................................................

Disassemble Fuel Injection Nozzle 49 ......................................................................................................

Clean and Inspect Fuel Injection Nozzle Assembly 51 .............................................................................

Perform Nozzle Slide Test 52 ...................................................................................................................

Clean Spray Orifices 53 ...........................................................................................................................

Inspect Nozzle Holder 55 .........................................................................................................................

Inspect Gland Nut 57 ...............................................................................................................................

Assemble Fuel Injection Nozzle 59 ..........................................................................................................

Test and Adjust Injection Nozzle Opening Pressure 61 ............................................................................

Inspect and Clean Cylinder Head Nozzle Bore 62 ....................................................................................

Inspect and Clean Nozzle Seating Surface 64 .........................................................................................

Install Fuel Injection Nozzles 65 ...............................................................................................................

(g) by Belgreen v2.1

<- Go to Global Table of contents CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Group 090 - Mechanical Fuel System Repair and Adjustments

Relieve Fuel System Pressure

CAUTION:

Avoid High-Pressure Fluids

Escaping diesel fuel under pressure can have sufficient force to penetrate the skin, causing serious
injury. Before disconnecting lines, be sure to relieve pressure. Before applying pressure to the system,
be sure ALL connections are tight and lines, pipes and hoses are not damaged. Keep hands and body
away from pinholes and nozzles which eject fluid under pressure. Use a piece of cardboard or wood,
rather than hands, to search for suspected leaks.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type injury or gangrene may result. Doctors unfamiliar with this type of injury may call the
Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed
air from the system.

Replace Rectangular Fuel Filter Element

LEGEND:

A Guide Pins
B Drain Plug
C Bleed Plug

Replacing Rectangular Fuel Filter Element

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Section 02 page 1

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

→NOTE:

Refer to your operator′s manual for proper servicing and replacement (hourly) intervals.

[1] - Close fuel shut-off valve at bottom of fuel tank (not illustrated).

[2] - Loosen bleed plug (C) and remove drain plug (B). Drain fuel from filter.

[3] - With fuel filter held firmly against base, lift up on top retaining spring and pull down on bottom retaining spring. Pull fuel

filter off guide pins (A) of fuel filter base and discard filter.

[4] -

Installing Fuel Filter Element

Install fuel filter onto guide pins on fuel filter base. Hold filter against base.

[5] - Secure bottom retaining spring first, then secure top retaining spring. (See arrows.)

[6] - Apply LOCTITE ™ 592 Pipe Sealant with TEFLON ™ to drain plug and bleed plug. Install drain plug, shown installed.

Tighten bleed plug and drain plug securely. Do not overtighten.

Number Name Use

• TY9375 (us)

• TY9480 (canadian)

Pipe Sealant Apply to rectangular fuel filter bleed plug and drain plug.

• 592 LOCTITE ™ (loctite)

[7] - Open fuel shut-off valve and bleed fuel system.

[8] - If fuel filter base was removed from engine, reinstall and tighten cap screws to specifications.

Item Measurement Specification

Fuel Filter Base-to-Block Mounting Cap Screws Torque 35 N˙m (25 lb-ft)

Replace Fuel Filter Check Valve

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Section 02 page 2

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

LEGEND:

A Fuel Filter Inlet Line
B Chick Valve Assembly
C Fuel Filter

Replacing Fuel Filter Check Valve

[1] - Drain and remove fuel filter (C) as described earlier in this group.

[2] - Remove fuel filter inlet line (A), (shown removed).

[3] - Inspect and clean fuel filter base (if needed).

[4] - Remove check valve assembly (B) from fuel filter base and discard.

[5] - Install new check valve assembly and tighten securely.

[6] - Install fuel inlet line and tighten connection to specifications.

Item Measurement Specification

Fuel Pipe Connections at Filter Base Maximum Torque 17 N˙m (12 lb-ft) (150 lb-in.) maximum

DO NOT overtighten.

[7] - Install fuel filter and bleed fuel system.

Replace Primary (Round) Fuel Filter/Water Separator

Fuel Filter/Water Separator

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Section 02 page 3

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

LEGEND:

A Retaining Ring
B Seal Kit
C Filter Element
D Water Separator Bowl
E Seal
F Filter Head
G Bleed Screw
H O-Ring
I Plug
J Stem
K O-Ring
L Cap
M Retaining Ring
N Primer Assembly
O Cap Screw (2 used)
P Washer (2 used)
Q O-Ring
R Fitting

→NOTE:

Refer to operator′s manual for proper servicing and (hourly) replacement intervals. See LUBRICATION

AND MAINTENANCE SERVICE INTERVAL CHART in operator′s manual.)

[1] - Thoroughly clean fuel filter/water separator assembly and surrounding area, if not previously done.

[2] - Connect a drain line to filter drain adapters and drain all fuel from filters.

[3] -

→NOTE:

Lifting up on retaining ring (A) as it is rotated helps to get it past raised locators.

Firmly grasp the retaining ring and rotate it counterclockwise 1/4 turn. Remove ring with filter element (C).

[4] - Inspect filter mounting base for cleanliness. Clean as required.

[5] - Remove water separator bowl (D). Drain and clean separator bowl. Dry with compressed air.

[6] - Install water separator bowl onto new filter element. Tighten securely.

[7] - Thoroughly inspect filter and base seals (B). Replace as needed.

[8] -

→NOTE:

The primary fuel filter must be indexed properly and the key on canister must be oriented in slot of
mounting base for correct installation.

Install new filter element onto mounting base and position element using a slight rocking motion. Be sure element is properly
indexed on mounting base.

<- Go to Section TOC

Section 02 page 4

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[9] - Install retaining ring onto mounting base and tighten about 1/3 turn until ring “snaps” into the detent. DO NOT
overtighten the retaining ring.

[10] - If removed, install fuel filter base and tighten cap screws to specifications.

Item Measurement Specification

Fuel Filter Base-to-Oil Filter Base Cap Screws Torque 61 N˙m (45 lb-ft)

[11] - Bleed fuel system.

Identification of Fuel Supply Pumps

6081 Engines are equipped with a mechanical fuel supply pump mounted on the outside of the injection pump (Bosch,
Nippondenso or Motorpal).

A tappet on the final supply pump is actuated by the injection pump rotating cam during engine revolution. The tappet on the
supply pump may be either a flat plunger type (Bosch or Motorpal) or a roller tappet type (Nippondenso). (The Nippondenso
pump is an option on 6081T engines only.)

Fuel supply pumps are furnished as complete assemblies for repair. Only the primer, washers, and fittings are available as
separate parts.

Remove Fuel Supply Pump (Bosch and Nippondenso)

Removing Fuel Supply Pump

Thoroughly clean exterior of supply pump. Also clean around supply pump mounting area on injection pump housing.

[1] - Disconnect fuel inlet line and outlet line, shown disconnected. Cap all line openings so contaminants do not enter fuel
system.

[2] - Remove three supply pump mounting nuts and pull fuel supply pump straight out from mounting studs as shown.

[3] - Cover supply pump mounting bore so debris cannot enter injection pump housing.

Inspect Fuel Supply Pump

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Section 02 page 5

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

LEGEND:

A Inlet Elbow Fitting
B Outlet Elbow Fitting
C Hand Primer Pump
D Copper Washer
E Pump Housing
F Plunger (Roller Tappet on Nippondenso)

Fuel Supply Pump (Bosch Shown)

[1] -

→NOTE:

Bosch fuel supply pump shown. Inspection procedures similar for all supply pumps.

Inspect supply pump housing (E) for cracks and wear. Be sure plunger or roller tappet bore is not worn or scored. Check
condition of threads for inlet and outlet fittings (A and B), hand primer pump (C) and spindle guide plug.

[2] - Inspect plunger (F) or roller tappet for wear, scoring on O.D. and burrs. Check lands that contact plunger and fuel pump
cam lobe to be sure they are flat and undamaged, or that roller tappet is not worn. Remove any deposits with a suitable
solvent.

[3] - If pump housing or plunger/roller tappet mechanism is worn or damaged, replace pump assembly (E). Use new O-rings on
fittings and new copper washer (D) on primer.

Install Fuel Supply Pump (Bosch and Nippondenso)

Installing Fuel Supply Pump

IMPORTANT:

Before installing supply pump, test pump to make sure fuel will not leak around plunger (or roller tappet)
and seal. See CHECK FUEL SUPPLY PUMP OPERATION in Group 150.

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Section 02 page 6

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[1] - On Bosch pumps, install a new gasket on supply pump mounting face and position pump over mounting studs.

On Nippondenso pumps, place a new O-ring in counterbore of injection pump housing at supply pump mounting face.

[2] - Position supply pump on mounting studs as shown.

[3] - Tighten mounting stud nuts to specifications.

Item Measurement Specification

Bosch and Nippondenso Fuel Supply Pump Mounting Stud Nuts Torque 5—7 N˙m (4—5 lb-ft) (45—60 lb-in.)

[4] - Install fuel inlet and outlet lines and tighten to specifications.

Item Measurement Specification

Fuel Supply Pump Inlet and Outlet Lines Torque 10 N˙m (7 lb-ft)

Item Measurement Specification

Bosch and Nippondenso Fuel Supply Pump Elbow Lock Nuts Torque 35 N˙m (26 lb-ft)

[5] - Bleed fuel system. See BLEED THE FUEL SYSTEM in Group 150.

Install Fuel Supply Pump (Motorpal)

LEGEND:

A O-Ring
B Bracket (2 used)
C Cap Screw (2 used)
D Fuel Supply Pump
E O-Rings (2 used)
F Fittings (2 used)
G Copper Washer
H Hand Primer Pump

Install Fuel Supply Pump

IMPORTANT:

Before installing supply pump, test pump to make sure fuel will not leak around plunger (or roller tappet)
and seal. See CHECK FUEL SUPPLY PUMP OPERATION in Group 150.

[1] - Install new O-rings (A and E) and copper washer (G) as required.

[2] - Install fuel supply pump in injection pump bore. Pump should be oriented as shown, with inlet and outlet ports pointing

down. Install clamps (B) over flange of supply pump and install cap screws (C). Tighten cap screws to specifications.

Item Measurement Specification

Motorpal Fuel Supply Pump Mounting Cap Screws Torque 8 N˙m (6 lb-ft) (72 lb-in.)

[3] - Install fuel inlet and outlet lines and tighten to specifications.

Item Measurement Specification

Fuel Supply Pump Inlet and Outlet Lines Torque 10 N˙m (7 lb-ft)

<- Go to Section TOC

Section 02 page 7

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[4] - Bleed fuel system. See BLEED THE FUEL SYSTEM in Group 150.

Repair Injection Pump Aneroid (Bosch and Nippondenso)—If Equipped

For aneroid repair and adjustment, have an authorized diesel repair station perform the work.

The aneroid controls fuel delivery to pump when intake manifold pressure is about 100 kPa (1.00 bar) (15 psi) or less.
Therefore, all final adjustments are to be made on the test stand with aneroid mounted on injection pump.

IMPORTANT:

Correct aneroid adjustments are essential for satisfactory engine performance. Whenever aneroid has
been disassembled or adjustments have been altered, injection pump (including aneroid) must be
calibrated on test stand before releasing pump for service.

Remove Hydraulic Aneroid Activator (Bosch and Nippondenso)—If Equipped

LEGEND:

A Special Screw
B Copper Washer
C Banjo Connector
D Spring
E Restrictor Wire
F Capillary Valve
G Activator Housing (2 Used)

Removing Hydraulic Aneroid Activator

→NOTE:

The hydraulic aneroid activator is located on back side of pump governor housing next to cylinder block.

[1] - Remove injection pump as described later in this group.

[2] - Remove special screw (A), copper washers (B) and banjo connector (C). Discard copper washers.

[3] -

→NOTE:

Do not bend restrictor wire or other activator parts.

Remove spring (D), restrictor wire (E) and capillary valve (F) from activator housing (G). Remove activator housing.

Disassemble, Clean, Assemble and Install Hydraulic Aneroid Activator

<- Go to Section TOC

Section 02 page 8

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Parts (Bosch and Nippondenso)—If Equipped

LEGEND:

A Starting Fuel Control Shaft
B Return Spring
C Washer
D Retainer Ring
E Piston Spring
F Piston
G Gasket
H Activator Housing
I Mounting Screw (2 Used)
J Capillary Valve Spring
K Restrictor Wire
L Capillary Valve
M Washers
N Special Screw

Inspecting Hydraulic Aneroid Activator

[1] - Remove gasket (G), piston (F) and piston spring (E).

[2] - Wash all parts in clean solvent and dry with compressed air. Blow out all openings to make sure they are open.

[3] - Check piston (F) and activator housing (H) for general condition. Piston must move freely in its bore.

[4] - Inspect piston spring (E) and capillary valve spring (L). Replace if weak or broken.

[5] - Inspect condition of restrictor wire (K). Wire must not be bent or broken and must fit loosely in capillary valve (J).

[6] - Check condition of return spring (B), washer (C) and retaining ring (D) on starting fuel control shaft (A). Replace spring if

weak or broken. Be sure retaining ring is secure on shaft.

[7] - To assemble and install activator, reverse disassembly procedure using new gaskets.

Tighten special screw (N) to specifications.

Item Measurement Specification

Aneroid Activator Special Screw Torque 14 N˙m (10 lb-ft)

Service Injection Pump Overflow Valve (Bosch and Nippondenso)

LEGEND:

A Leak-Off Line
B Elbow
C Overflow Valve Assembly

Removing Injection Pump Overflow Valve

<- Go to Section TOC

Section 02 page 9

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

→NOTE:

Overflow valve can be serviced with injection pump installed.

[1] - Remove leak-off line (A) from elbow (B). Remove elbow from overflow valve assembly (C).

[2] - Remove valve assembly from pump.

[3] -

LEGEND:

A Reducer
B Washer
C Valve Body
D Spring Seat
E Spring
F Valve
G Washer

Inspecting Injection Pump Overflow Valve

Remove reducer (A) and copper washer (B) from valve body (C). Discard copper washer.

[4] - Unscrew for spring seat (D); then remove spring (E) and valve (F).

[5] - Inspect for foreign material imbedded in seat of nylon valve.

[6] - Check spring to see that it is not weak or broken.

[7] - Wash all parts in solvent and air dry.

[8] -

→NOTE:

There is no adjustment on valve to regulate housing pressure. If suspected that valve is malfunctioning,
replace valve to restore proper operation.

Item Measurement Specification

Fuel Injection Pump Overflow Valve Opening Pressure 130—180 kPa (1.3—1.8 bar) (19—26 psi)

Reverse order of removal for reassembly of overflow valve. Install new copper washers.

Service Injection Pump Overflow Valve (Bosch and Nippondenso)

<- Go to Section TOC

Section 02 page 10

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

LEGEND:

A Leak-Off Line
B Elbow
C Overflow Valve Assembly

Removing Injection Pump Overflow Valve

→NOTE:

Overflow valve can be serviced with injection pump installed.

[1] - Remove leak-off line (A) from elbow (B). Remove elbow from overflow valve assembly (C).

[2] - Remove valve assembly from pump.

[3] -

LEGEND:

A Reducer
B Washer
C Valve Body
D Spring Seat
E Spring
F Valve
G Washer

Inspecting Injection Pump Overflow Valve

Remove reducer (A) and copper washer (B) from valve body (C). Discard copper washer.

[4] - Unscrew for spring seat (D); then remove spring (E) and valve (F).

[5] - Inspect for foreign material imbedded in seat of nylon valve.

[6] - Check spring to see that it is not weak or broken.

[7] - Wash all parts in solvent and air dry.

[8] -

<- Go to Section TOC

Section 02 page 11

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

→NOTE:

There is no adjustment on valve to regulate housing pressure. If suspected that valve is malfunctioning,
replace valve to restore proper operation.

Item Measurement Specification

Fuel Injection Pump Overflow Valve Opening Pressure 130—180 kPa (1.3—1.8 bar) (19—26 psi)

Reverse order of removal for reassembly of overflow valve. Install new copper washers.

<- Go to Section TOC

Section 02 page 12

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Remove and Install Fuel Shut-off Solenoid (Bosch and Nippondenso)—If
Equipped

Fuel Shut-off Solenoid

LEGEND:

A Wiring Connector
B Fuel Shut-off Solenoid
C Solenoid Shaft
D Lever Cap Screw
E Washer
F Fuel Shut-off Lever
G Lock Washer and Screws
H Hex Nuts
I Cap Screws
J Solenoid Mounting Bracket

[1] - Disconnect electrical wiring connector (A) in solenoid lead.

[2] - Remove cap screw (D), and detach solenoid shaft (C) from fuel shut-off lever (F).

[3] - Remove fuel shut-off solenoid (B) from solenoid mounting bracket (J) by removing hex nuts (H) and machine screws (G).

[4] - If solenoid mounting bracket is to be removed, remove cap screws (I) and washers (E) that fasten the bracket to oil filter

base.

[5] - Inspect condition of solenoid and replace parts as necessary. (A repair kit is available from parts for this solenoid
assembly.)

[6] -

<- Go to Section TOC

Section 02 page 13

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

IMPORTANT:

Fuel shut-off solenoid linkage should move freely back and forth. On “A” pumps if linkage is binding,
check pump for proper alignment. See INSTALL FUEL INJECTION PUMP (BOSCH AND NIPPONDENSO) , later
in this group.

→NOTE:

Electric fuel shut-off solenoids are factory adjusted to a specified length and should not require
additional adjustment. See CHECK FUEL SHUT-OFF SOLENOID OPERATION in Group 150.

To install fuel shut-off solenoid, reverse removal procedure. Tighten cap screws and hex nuts to specifications.

Item Measurement Specification

Fuel Shut-off Solenoid Mounting Cap Screw Torque 23 N˙m (17 lb-ft)

Fuel Shut-off Solenoid Mounting Hex Nut Torque 7 N˙m (5 lb-ft)

Remove and Install Fuel Shut-off Solenoid (Motorpal)—If Equipped

LEGEND:

A Connector
B Cap Screw (4 used)
C Fuel Shut-Off Solenoid
D Washer
E Cotter Pin
F Fuel Shut-Off Lever
G Cap Screw
H Mounting Bracket

Remove and Install Fuel Shut-off Solenoid

[1] - Disconnect wiring connector (A) in solenoid lead.

[2] - Remove cotter pin (E) and washer (D) and detach solenoid shaft from fuel shut-off lever (F).

[3] - Remove cap screws (B) and remove shut-off solenoid (C) from bracket.

[4] - Inspect condition of solenoid and replace parts as necessary.

[5] -

IMPORTANT:

Fuel shut-off solenoid linkage should move freely back and forth.

→NOTE:

Electric fuel shut-off solenoids are factory adjusted to a specified length and should not require
additional adjustment. See CHECK FUEL SHUT-OFF SOLENOID OPERATION in Group 150.

To install fuel shut-off solenoid, reverse removal procedure.

<- Go to Section TOC

Section 02 page 14

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Identification of In-Line Fuel Injection Pumps

LEGEND:

A Bosch Pump Serial Number
B Bosch Part Number
C Bosch Identification Number
D John Deere Part Number (Bosch)
E Motorpal Identification Number
F Motorpal Pump Serial Number
G John Deere Part Number (Motorpal)

Bosch Fuel Injection Pump Identification Plate

Motorpal Fuel Injection Pump Identification Plate

The in-line fuel injection pumps used on 6081 engines are either P-Series Bosch pumps, A-Series Nippondenso pumps or Mf
Series Motorpal pumps. (The A-Series pump is optional on 6081T engines only.) The type of pump is easily determined by the
pump identification plate.

I.D. Numbers

BOSCH INJECTION PUMP IDENTIFICATION NUMBER

A–76417 00136 B .......... Pump Serial Number

B–0 402 796 813 .......... Bosch Part Number

C–PES6P120A720RS7356

PES .......... Injection Pump With Housing Flange

6 .......... Number of plungers

P .......... Type or Size of Pump

120 .......... Plunger Diameter in mm (120 is 12 mm)

A .......... Letter Designating Design Change

000 .......... Three Numbers Denoting an Assembly

R .......... Right-Hand Rotation (Viewed From Drive End)

S .......... Production Pump

0000 .......... Pump Identification Number

D–RE 61 658 .......... John Deere Part Number

<- Go to Section TOC

Section 02 page 15

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

I.D. Numbers

MOTORPAL INJECTION PUMP IDENTIFICATION NUMBER

E–PP6M10P1f3468

PP .......... Injection Pump With Flange Attachment

6 .......... Number of plungers

M .......... Type or Size of Pump

10 .......... Plunger Diameter in mm

P .......... Plunger Design Type

1 .......... Drive Direction and Injection Order

f .......... Basic Design Designation

3468 .......... Pump Identification Number

F–XX0000 .......... Pump Serial Number

G–RE501784 .......... John Deere Part Number

Pumps may have mechanical or electrical shut-off. Electronically controlled governors and hydraulic aneroids are an option on
Bosch pumps only.

To summarize pump applications:

Pump Applications

P-Series Bosch Pumps

A-Series Nippondenso Pumps A2500 optional on 6081T only.

Mf-Series Motorpal Pumps PPMf optional on 6081T

P3000 optional 6081T and A;
P7100 optional on 6081A;
standard on 6081H.

Service of Fuel Injection Pumps

Have an authorized diesel repair station perform any internal service or test stand calibration required on injection pumps.

For diagnostics and tests of electronic control systems, refer to the following:

Older Bosch ECU controls, see CTM68.
John Deere ECU controls with electronic fuel systems, see CTM134.
John Deere ECU controls with high pressure common rail (HPCR) fuel systems, see CTM255

→NOTE:

If no injection pump repair and testing stations are available locally complete remanufactured pumps are
available for Motorpal pumps. If a Motorpal injection pump fails, return it for a replacement pump. In the
U.S. and Canada, return the failed pump to:

ReGen Manufacturing Co.

4500 Mustard Way

Springfield, MO. 65803

Outside the U.S. and Canada, return pump to nearest Service Parts Depot.

Replace Motorpal Fuel Injection Pump Delivery Valve O-Rings

<- Go to Section TOC

Section 02 page 16

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

LEGEND:

A Delivery Valve
B O-Ring

Delivery Valve

Delivery Valve O-Rings

[1] -

IMPORTANT:

ALWAYS clean area around injection pump and fuel delivery lines with a steam cleaner and/or
compressed air as needed so that no dirt or debris is allowed to enter injection pump. Never steam clean
or pour cold water on an injection pump while pump is running or while pump is warm. This could cause
seizure of internal pump parts.

→NOTE:

Delivery valve O-rings (B) may be replaced with pump removed or installed on engine.

Clean area around injection pump and delivery lines as needed.

[2] - Remove delivery valve (A) using a 17 mm deep well socket.

[3] - Remove O-ring (B) from delivery valve and discard.

[4] - Clean delivery valve in diesel fuel and dry with compressed air.

[5] - Lightly lubricate new O-ring with clean engine oil or dip in clean diesel fuel. Install O-ring against shoulder of delivery

valve as shown.

[6] - Carefully install delivery valve and tighten to the following specification.

<- Go to Section TOC

Section 02 page 17

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Item Measurement Specification

Fuel Injection Pump Delivery Valve (Motorpal) Torque 47 N˙m (35 lb-ft)

[7] - After installation, cover delivery valve with a clean cap to keep dirt out of fuel system.

[8] - Repeat procedure on remaining delivery valves as needed.

<- Go to Section TOC

Section 02 page 18

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Remove Fuel Injection Pump (Bosch and Nippondenso)

LEGEND:

A Timing Hole Plug

Injection Pump Timing Access Hole

IMPORTANT:

Never steam clean or pour cold water on an injection pump while pump is running, or while it is still
warm. To do so may cause seizure of pump parts.

[1] - Clean injection lines and area around the injection pump with cleaning solvent or a steam cleaner.

[2] - Remove timing hole plug (A).

[3] - Rotate engine flywheel (in normal running direction) with JDG820 Flywheel Turning Tool until No. 1 piston is at “TDC” of

its compression stroke.

Flywheel Turning Tool

JDG820

JDG820

Used to rotate flywheel on engine to check damper radial runout and time engine. JDE81-1 may be used also if JDG820 is not
available.

At this point, JDE81-4 Timing Pin should enter hole in flywheel.

Timing Pin

JDE81-4

JDE81-4

<- Go to Section TOC

Section 02 page 19

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Lock engine at TDC when timing valve train, adjusting valve clearance, and installing fuel injection pump. Use with JDG820 and
JDE81-1 Flywheel Turning Tools.

[4] - Timing marks on injection pump drive hub and fixed timing pointer should be aligned.

[5] -

LEGEND:

A Timing Pin
B Cap Screw
C Adapter

Installing Timing Pin and Removing Pump Gear

Remove injection pump drive gear cover (shown removed), remove and discard all gasket material or O-ring.

[6] -

→NOTE:

If removal of pump drive gear cap screw is difficult due to interference from the radiator, fan or fan belt,
perform the following step:

Remove JDG81-4 Timing Pin from flywheel and rotate engine until cap screw (B) at 5 o′clock position is clearly accessible.
Remove cap screw using a T45 TORX ™ adapter.

Rotate engine with JDG820 Flywheel Turning Tool until JDE81-4 Timing Pin enters flywheel at No. 1 cylinder′s compression
stroke.

[7] -

IMPORTANT:

To assure that accurate injection pump timing is maintained when pump is removed and reinstalled, is it
recommended that JDG886 Injection Pump Timing Pin (A) is used prior to removal and installation of
injection pump. If injection pump will be serviced at an authorized repair station, remove timing pin prior
to shipping for service.

→NOTE:

It may be necessary to rotate injection pump drive hub slightly to install timing pin.

Install JDG886 Timing Pin (A) through hole in injection pump drive gear.

Injection Pump Timing Pin

JDG886

<- Go to Section TOC

Section 02 page 20

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

JDG886

Used to set Bosch and Nippondenso fuel injection pump timing prior to removal of pump.

Thread timing pin into injection pump hub until it bottoms.

[8] - Remove remaining injection pump drive gear cap screws using a T45 TORX ™ adapter (C) and remove drive gear from
pump drive hub.

Adapter

TORX ™ T45

Injection pump drive gear-to-hub cap screws.

[9] -

LEGEND:

A Governor Pigtail Connectors
B Oil Filter
C Injection Pump Lube Line
D Fuel Inlet Line
E Leak-off Line Assembly
F Fuel Supply Pump Lines

Removing Injection Pump

Remove engine oil filter (B) from filter base.

[10] - Disconnect governor pigtail connectors (A) from main wiring harness. Disconnect fuel shut-off solenoid wiring lead
(shown disconnected and capped).

[11] - Remove injection pump lube line (C) from elbow fitting.

[12] - Remove fuel inlet (D) from shut-off solenoid. Remove fuel leak-off line assembly (E).

[13] - Disconnect fuel supply pump lines (F). (Photo shows outlet line only.)

Cap all openings on pump and line connections so contaminants do not enter fuel system.

[14] -

<- Go to Section TOC

Section 02 page 21

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

IMPORTANT:

Removing Lines (Bosch “P” Pump Shown)

LEGEND:

A Injection Line Nuts
B Serrated Wrench
C Crowsfoot Wrench

DO NOT move delivery valve fittings while loosening line nuts. If a delivery valve and barrel housing
rotates while loosening or tightening a fuel line nut, injection pump must be recalibrated on a test stand.
Use a backup wrench. On Bosch “P” pumps, JDE90 Serrated Wrench (B) MUST BE used.

Remove injection line nuts (A) from injection pump delivery valves. On Bosch “P” pumps, use JDE90 Serrated Wrench (B) along
with either JDF22 Crowsfoot Wrench (C) or a standard 3/4-in. line wrench.

Serrated Wrench

JDE90

JDE90

Use to hold injection pump fuel outlet fittings on Bosch “P” pump from turning when loosening and tightening fuel pipe
connections.

Crowsfoot Wrench

JDF22

JDF22

Used to loosen and tighten fuel pipes at injection nozzles and at injection pump.

(On Nippondenso “A” pumps, use JDF22 Crowsfoot Wrench and a 22 mm open end wrench to hold valve fittings.)

[15] - Disconnect throttle linkage from pump.

<- Go to Section TOC

Section 02 page 22

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[16] - Remove four injection pump mounting stud nuts.

[17] - Carefully remove injection pump and place it on a clean flat surface.

[18] - Cap all delivery valve fittings.

<- Go to Section TOC

Section 02 page 23

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Remove Fuel Injection Pump (Motorpal)

LEGEND:

A Timing Hole Plug
B JDG820 Flywheel Turning Tool
C JDE81-4 Timing Pin

Timing Hole Plug

Flywheel Turning/Locking Tools

IMPORTANT:

Never steam clean or pour cold water on an injection pump while pump is running, or while it is still
warm. To do so may cause seizure of pump parts.

[1] - Clean injection lines and area around the injection pump with cleaning solvent or a steam cleaner.

[2] - Drain enough coolant form radiator to remove heater hose and upper radiator hose from water pump inlet elbow (shown

removed) for access to injection pump drive gear cover.

[3] - Remove timing hole plug (A) to view drive hub timing mark.

[4] - Rotate engine flywheel (in normal running direction) with JDG820 Flywheel Turning Tool until No. 1 piston is at “TDC” of

its compression stroke.

Flywheel Turning Tool

JDG820

JDG820

<- Go to Section TOC

Section 02 page 24

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Used to rotate flywheel on engine to check damper radial runout and time engine. JDE81-1 may be used also if JDG820 is not
available.

At this point, JDE81-4 Timing Pin should enter hole in flywheel.

Timing Pin

JDE81-4

JDE81-4

Lock engine at TDC when timing valve train, adjusting valve clearance, and installing fuel injection pump. Use with JDG820 and
JDE81-1 Flywheel Turning Tools.

Timing mark on injection pump drive hub should be visible.

[5] - If timing mark is not visible, remove timing pin from flywheel and rotate flywheel one full revolution until timing pin enters
hole in flywheel and timing mark on injection pump drive hub is visible.

[6] - Reinstall timing hole plug using LOCTITE ™ 242 (TY9370) Thread Lock and Sealer. Tighten plug securely.

Number Name Use

• T43512 (us)

• TY9473 (canadian)

Thread Lock and Sealer (Medium Strength) Injection pump timing hole plug.

• 242 LOCTITE ™ (loctite)

[7] -

→NOTE:

Use a thin-wall 17 mm open-end crowsfoot wrench to keep delivery valve fittings from turning when
loosening line nuts at injection pump.

If delivery valves are disturbed when loosening lines, valves are retorqued to 47N˙m (35 lb-ft).

O-rings on delivery valves are available for service.

<- Go to Section TOC

LEGEND:

A Throttle Bracket
B Aneroid Line
C Aneroid Connector
D Oil Fill Plug
E Injection Line
F Leak-Off Line
G Lube Line
H Supply Pump Inlet Line
I Supply Pump Outlet Line
J Fuel Inlet Line
K Throttle Cable
L Fuel Shut-Off Solenoid Connector

Section 02 page 25

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Remove Injection Pump

Remove all fuel delivery lines (E) from injection pump using JDF22 Crowsfoot Wrench and an open end wrench. Cap all delivery
valves and lines to keep debris out.

Crowsfoot Wrench

JDF22

JDF22

Used to loosen and tighten fuel pipes at injection nozzles and at injection pump.

[8] - Disconnect leak-off line (F), supply pump inlet line (H), supply pump outlet line (I) and fuel inlet line (J). Cap lines and
fittings.

[9] - Disconnect throttle cable (K) from injection pump throttle lever and bracket (A).

[10] - Disconnect injection pump lube line (G).

[11] - Disconnect line (B) and harness connector (C) from aneroid.

[12] - Disconnect fuel shut-off solenoid harness connector (L) (shown disconnected).

[13] - Disconnect fuel shut-off solenoid with bracket from oil filter base.

→NOTE:

Injection pump will be removed with shut-off solenoid and bracket attached.

[14] -

LEGEND:

A Timing Pin
B Spring
C Cap

Remove V-belt and remove injection pump drive gear cover (shown removed). Remove and discard all gasket material.

[15] -

<- Go to Section TOC

Section 02 page 26

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

IMPORTANT:

To ensure that accurate injection pump timing is maintained when pump is removed and reinstalled,
perform the following step:

Remove cap (C), pin (A) and spring (B) from pump. Reinstall parts as show, with pin first, then spring and cap. Tighten cap by
hand. This will lock injection pump timing.

[16] - Remove four injection pump drive gear-to-pump hub cap screws using a T45 TORX ™ adapter.

Adapter

TORX ™ T45

Injection pump drive gear-to-hub cap screws.

[17] - Remove four injection pump mounting stud nuts.

[18] - Carefully remove injection pump and shut-off solenoid with bracket from mounting studs.

[19] - Remove injection pump drive gear from timing gear cover.

<- Go to Section TOC

Section 02 page 27

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Install Fuel Injection Pump (Bosch and Nippondenso)

LEGEND:

A Pointer
B Drive Hub
C O-Ring
D Bearing Plate
E JDG886 Timing Pin

Preparing Injection Pump for Installation

[1] - If engine was rotated after injection pump was removed, rotate flywheel until timing pin enters flywheel at No. 1 cylinder′s
“TDC” compression stroke.

→NOTE:

When No.1 cylinder is at “TDC” compression stroke, intake and exhaust valves for No. 1 cylinder will be
closed and both rocker arms will be loose.

[2] - Rotate injection pump drive hub until marks on drive hub (B) and pointer (A) are aligned.

[3] -

→NOTE:

It may be necessary to rotate pump hub slightly to get timing pin (E) to enter bearing plate.

Thread JDG886 Timing Pin (E) into drive hub, as shown, and tighten until it bottoms against bearing plate (D).

Injection Pump Timing Pin

JDG886

JDG886

Used to set in-line fuel injection pump timing prior to removal of pump.

[4] - Install a new O-ring (C) on pump mounting hub. Lightly lubricate O-ring with AR54749 Soap Lubricant to aid in pump
installation and prevent O-ring damage.

Number Name Use

• AR54749 (us) Soap Lubricant Injection pump mounting flange O-ring.

<- Go to Section TOC

Section 02 page 28

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

→NOTE:

Place injection pump drive gear in timing gear housing (if previously removed) with chamfered side of
gear toward injection pump. Chamfer is at outer edge of bore for easier installation of gear to pump drive
hub.

[5] -

IMPORTANT:

Nippondenso “A” injection pumps must be installed straight (upright) on the engine to assure correct
alignment of fuel shut-off solenoid linkage. Misaligned linkage will bind and not allow shut-off solenoid to
operate properly, if pump is incorrectly installed. Pump is correctly aligned if linkage can be moved freely
back and forth.

LEGEND:

A Timing Pin
B Adapter

Installing Pump Drive Gear

Install injection pump using moderate forward pressure and slight rocking motion to work O-ring into mounting bore.

Injection pump flange should seat solidly against cylinder block and injection pump drive hub nut should be positioned in I.D. of
pump drive gear.

[6] - Install mounting stud nuts and tighten to specifications.

Item Measurement Specification

Bosch and Nippondenso Injection Pump-to-Cylinder Block Stud Nuts Torque 47 N˙m (35 lb-ft)

[7] - Carefully install drive gear on pump drive hub, position gear so mounting cap screws are approximately centered in
mounting slots. This will allow for minor adjustment of pump timing, should the need arise.

[8] - Install four drive gear-to-pump hub cap screws and tighten to specifications using a T45 TORX ™ adapter (B).

Item Measurement Specification

Bosch and Nippondenso Injection Pump Drive Gear-to-Pump Hub Cap Screw Torque 61 N˙m (45 lb-ft)

Adapter

TORX ™ T45

Used to install injection pump drive gear-to-hub cap screws.

[9] - Remove JDG886 Timing Pin (A) from injection pump hub. Install timing hole plug using LOCTITE ™ 242 (TY9370) Thread
Lock and Sealer, tighten plug securely.

<- Go to Section TOC

Section 02 page 29

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Number Name Use

• T43512 (us)

• TY9473 (canadian)

Thread Lock and Sealer (Medium Strength) Injection pump timing hole plug.

• 242 LOCTITE ™ (loctite)

→NOTE:

Also remove timing pin from engine flywheel (if installed).

[10] - Install injection pump drive gear cover using a new gasket or O-ring. Tighten cap screws to specifications.

Item Measurement Specification

Injection Pump Drive Gear Cover Cap Screws Torque 27 N˙m (20 lb-ft)

[11] -

→NOTE:

Remove protective caps and plugs that were installed on fuel system components during injection pump
removal.

LEGEND:

A Fuel Delivery Line Nuts
B Serrated Wrench
C Crowsfoot Wrench

Installing Lines (Bosch “P” Pump Shown)

Connect fuel delivery line nuts (A) to injection pump delivery valve fittings using two wrenches as shown. On Bosch “P” pumps,
use JDE90 Serrated Wrench (B) and JDF22 Crowsfoot Wrench (C).

Serrated Wrench

JDE90

JDE90

Use to hold injection pump fuel outlet fittings on Bosch “P” pump from turning when loosening and tightening fuel pipe
connections.

Crowsfoot Wrench

JDF22

<- Go to Section TOC

Section 02 page 30

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

JDF22

Used to loosen and tighten fuel pipes at injection nozzles and at injection pump.

(On Nippondenso “A” pumps, use JDF22 Crowsfoot Wrench and a 22 mm open end wrench to hold valve fittings.) Tighten line
nuts to specifications.

Item Measurement Specification

Fuel Delivery Line Connectors @ Delivery Valves and Nozzles Torque 27 N˙m (20 lb-ft)

IMPORTANT:

DO NOT move delivery valve fittings while tightening line nuts. If delivery valve and barrel housing
rotates while tightening a fuel line nut, injection pump fuel delivery will be altered. The injection pump
will have to be recalibrated on a test stand by an authorized diesel repair station.

[12] -

IMPORTANT:

Tighten all fuel system connections securely to avoid leakage and air entering system.

LEGEND:

A Governor Pigtail Connectors
B Oil Filter
C Injection Pump Lube Line
D Fuel Inlet Line
E Leak-off Line Assembly
F Supply Pump Lines

Installing Injection Pump

Install fuel leak-off line assembly (E) onto pump connectors and tighten all connections

to specifications.

Item Measurement Specification

Bosch and Nippondenso Fuel Leak-Off Lines-to-Injection Pump Connectors Torque 13 N˙m (10 lb-ft)

[13] - Connect fuel supply pump lines (F) and fuel inlet line (D) at fuel shut-off solenoid.

Item Measurement Specification

Fuel Supply Pump Lines-to-Injection Pump Torque 10 N˙m (7 lb-ft)

<- Go to Section TOC

Section 02 page 31

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Item Measurement Specification

Fuel Inlet Line-to-Injection Pump Torque 10 N˙m (7 lb-ft)

[14] - Connect injection pump lube line (C) to cylinder block fitting.

Item Measurement Specification

Injection Pump Lube Line Torque 4.5 N˙m (3 lb-ft) (36 lb-in.)

[15] - Connect governor pigtail connectors (A) to wiring harness.

[16] - Install engine oil filter (B).

[17] -

IMPORTANT:

NEVER operate injection pump without engine lubricating oil in pump housing. Doing so may cause
damage to internal pump rotating parts.

LEGEND:

A Oil Fill Plug
B Governor Oil Fill Plug

Adding Oil to Pump Housings

Remove oil fill plug (A) and add enough clean engine oil until oil comes out fill hole. Engine should be level when checking oil
level. Tighten plug to specifications.

Item Measurement Specification

Nippondenso and Bosch Injection Pump Housing Oil Fill Plug Torque 25 N˙m (18 lb-ft)

→NOTE:

On Nippondenso “A” pumps, oil fill plug is on top of pump housing. Add 1/2 pint of clean engine oil.

[18] - Also add clean engine oil to pump rear governor housing by removing plug (B) at top. Add 0.1 Liter (1/5 quart). Tighten

plug to specifications.

Item Measurement Specification

Nippondenso and Bosch Injection Pump Governor Housing Oil Fill Plug Torque 40 N˙m (30 lb-ft)

[19] - Service fuel filter and water separator as needed.

[20] - Bleed fuel system. See BLEED THE FUEL SYSTEM in Group 150.

[21] - Connect throttle linkage to pump. To check fast and slow idle speeds, refer to Group 105 of CTM134. See CHECK AND

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Section 02 page 32

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

ADJUST SLOW IDLE SPEED in Group 150. See CHECK FAST IDLE SPEED in Group 150.

<- Go to Section TOC

Section 02 page 33

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Install Fuel Injection Pump (Motorpal)

LEGEND:

A Timing Pin
B Spring
C Cap

Install Pump Timing Pin

[1] -

→NOTE:

If missing, timing pin assembly is available through John Deere Service Parts.

If engine was rotated after injection pump was removed, rotate flywheel until timing pin enters flywheel at No. 1 cylinder′s
“TDC” compression stroke.

→NOTE:

When No.1 cylinder is at “TDC” compression stroke, intake and exhaust valves for No. 1 cylinder will be
closed and both rocker arms will be loose.

[2] - Check to make sure that injection pump timing pin (A) is fully engaged in pump timing slot with spring (B) on the

outboard side of pin.

[3] - Reinstall spring and tighten cap (C) finger tight.

Applying a light turning force, attempt to rotate pump by hand to verify pump is locked.

[4] -

→NOTE:

Fuel shut-off solenoid and bracket assembly MUST BE installed onto injection pump before installing
pump on engine.

<- Go to Section TOC

LEGEND:

A Shut-Off Solenoid
B Washer
C Cotter Pin
D O-ring
E Solenoid Rod Offset

Section 02 page 34

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Install Fuel Shut-Off Solenoid

Install fuel shut-off solenoid (A) and bracket assembly onto shut-off lever using washer (B) and cotter pin (C). Offset (E) in rod
should face away from pump as shown.

[5] - Install new O-ring (D) in groove of pump mounting hub. Lubricate O-ring with AR54749 Soap Lubricant to aid in pump
installation and prevent damage to O-ring.

Number Name Use

• AR54749 (us) Soap Lubricant Injection pump mounting flange O-ring.

[6] - Install injection pump drive gear in timing gear cover with part number facing front of engine. Four slots in gear should be
at 3, 6, 9 and 12 o′clock positions.

→NOTE:

It may be necessary to reposition drive gear in timing gear cover so that mounting slots align with
threaded holes in pump drive hub.

[7] - Install injection pump with shut-off solenoid and bracket onto mounting studs as O-ring seats in mounting bore using

moderate forward pressure and a slight rocking motion. Injection pump flange should seat solidly against cylinder block and
injection pump drive hub nut should be positioned in I.D. of pump drive gear.

[8] - If necessary, rotate and reposition pump drive gear so that four threaded holes in drive hub line up in the middle of gear
slots.

[9] - Install four mounting stud nuts and tighten to specifications.

Item Measurement Specification

Motorpal Injection Pump-to-Cylinder Block Stud Nuts Torque 47 N˙m (35 lb-ft)

[10] - Using a T45 TORX ™ adapter, install four drive gear-to-pump hub cap screws and tighten to the following specifications.

Item Measurement Specification

Motorpal Injection Pump Drive Gear-to-Pump Hub Cap Screws Torque 61 N˙m (45 lb-ft)

Adapter

TORX ™ T45

Used to install injection pump drive gear-to-hub cap screws.

[11] -

Pump Timing Pin

<- Go to Section TOC

LEGEND:

A Cap
B Spring
C Timing Pin

Section 02 page 35

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Remove timing cap (A), spring (B) and pin (C). Place spring (B) over pin as shown. Reinstall pin with spring into hole.This
installs timing pin in disengaged position. Make sure sealing washer is installed in cap. Install cap and tighten to specifications.

Item Measurement Specification

Motorpal Injection Pump Timing Pin Cap Torque 70 N.m (52 lb-ft)

[12] - Install injection pump drive gear cover and new gasket. Tighten cover cap screws to specifications.

Item Measurement Specification

Injection Pump Drive Gear Cover Cap Screws Torque 27 N˙m (20 lb-ft)

[13] - Install fan belt.

[14] - Remove timing pin and flywheel turning tool from engine and install plugs in respective locations.

[15] -

LEGEND:

A Throttle Bracket
B Aneroid Line
C Aneroid Connector
D Oil Fill Plug
E Injection Line
F Leak-Off Line
G Lube Line
H Supply Pump Inlet Line
I Supply Pump Outlet Line
J Fuel Inlet Line
K Throttle Cable
L Fuel Shut-Off Solenoid Connector

Remove Injection Pump

Connect fuel shut-off solenoid with bracket to oil filter base and tight hardware to specifications.

Item Measurement Specification

Fuel Shut-Off Solenoid Bracket to Oil Filter Base Cap Screws Torque 27 N˙m (20 lb-ft)

Item Measurement Specification

Throttle Bracket to Oil Filter Base Cap Screws Torque 27 N˙m (20 lb-ft)

[16] -

IMPORTANT:

Use a thin-wall crowsfoot open-end wrench to keep delivery valve fittings from turning when tightening
line nuts at injection pump.

IMPORTANT:

Tighten all fuel system connections securely to avoid leakage and air entering system.

Connect all fuel injection pump delivery lines (E) to pump delivery valves using JDF22 Crowsfoot Wrench and an open end
wrench. Tighten line nuts to specifications.

Item Measurement Specification

Fuel Delivery Line Connectors @ Delivery Valves and Nozzles Torque 27 N˙m (20 lb-ft)

Crowsfoot Wrench

<- Go to Section TOC

Section 02 page 36

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

JDF22

JDF22

Used to loosen and tighten fuel pipes at injection nozzles and at injection pump.

[17] - Connect aneroid air line (B).

[18] - Connect injection pump inlet line (J) and tighten to specifications.

Item Measurement Specification

Fuel Inlet Line-to-Injection Pump Torque 10 N˙m (7 lb-ft)

[19] - Connect leak-off line (F) and tighten to specifications.

Item Measurement Specification

Motorpal Fuel Leak-Off Line-to-Injection Pump Torque 13 N˙m (10 lb-ft)

[20] - Connect injection pump lube line (G) and tighten to specifications.

Item Measurement Specification

Injection Pump Lube Line Torque 4.5 N˙m (3 lb-ft) (36 lb-in.)

[21] - Connect fuel supply pump lines (H and I) and tighten to specifications.

Item Measurement Specification

Fuel Supply Pump Lines-to-Injection Pump Torque 10 N˙m (7 lb-ft)

[22] -

IMPORTANT:

NEVER operate injection pump without engine lubricating oil in pump housing. Doing so may cause
damage to internal pump rotating parts.

Remove oil fill plug (D) and add 360 cc (12 oz.) of clean engine oil. Install plug and tighten to specifications.

Item Measurement Specification

Motorpal Injection Pump Housing Oil Fill Plug Torque 25 N˙m (18 lb-ft)

[23] -

IMPORTANT:

Aneroid deactivator solenoid wiring harness and connector (C) MUST BE routed straight up as shown to
avoid contact with throttle lever.

Connect vehicle wiring harness connector to aneroid deactivator solenoid connector (C).

[24] - Connect fuel shut-off solenoid harness connector (L) to vehicle harness connector.

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Section 02 page 37

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[25] - Connect throttle cable (K) to throttle bracket and to injection pump throttle lever.

[26] - Bleed fuel system. See BLEED THE FUEL SYSTEM in Group 150.

[27] - To check fast and slow idle speeds, refer to Group 105 of CTM134. See CHECK AND ADJUST SLOW IDLE SPEED in Group

150. See CHECK FAST IDLE SPEED in Group 150.

<- Go to Section TOC

Section 02 page 38

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Remove Fuel Injection Nozzles

Avoid High-Pressure Fluids

CAUTION:

Escaping diesel fuel under pressure can have sufficient force to penetrate the skin, causing serious
injury. Before disconnecting lines, be sure to relieve pressure. Before applying pressure to the system,
be sure ALL connections are tight and lines, pipes, and hoses are not damaged. Keep hands and body
away from pinholes and nozzles which eject fluid under pressure. Use a piece of cardboard or wood,
rather than hands, to search for suspected leaks.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type injury or gangrene may result. Doctors unfamiliar with this type of injury may call the
Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

IMPORTANT:

Cap or plug all fuel lines as they are disconnected to prevent dirt and debris from entering fuel system.
Debris in fuel system can plug injectors which affects engine performance.

Injection nozzles on 6081 engines may be either Bosch or Nippondenso. Both nozzles are of same basic design and procedures
are combined on the following pages. Nozzle types and size tips are as follows:

Item Measurement Specification

Fuel Injection Nozzle Type 21 mm with 7 mm tip

Item Measurement Specification

Fuel Injection Nozzle

[ Nozzle tips available in various ID hole sizes: 0.208, 0.220, 0.236, 0.240, 0.244 and 0.255 mm. ]

Tip Hole Sizes 7 hole x 0.208—0.255 mm ID x 148° Spray Angle

To test injection nozzles before removal, see Group 150. See CYLINDER MISFIRE TEST in Group 150.

[1] - Thoroughly clean area around injection pump and nozzles, including all line connections, using compressed air.

[2] -

<- Go to Section TOC

Section 02 page 39

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

IMPORTANT:

On Bosch “P” pumps, JDE90 Serrated Wrench (B) MUST BE used to keep delivery valve fittings stationary
while loosening line nuts. If a delivery valve and barrel housing rotates while loosening or tightening a
fuel line nut, injection pump must be recalibrated on a test stand. On Nippondenso “A” pumps, use an
open end wrench to avoid turning valve fittings.

LEGEND:

A Injection Line Nuts
B Serrated Wrench
C Crowsfoot Wrench

Disconnecting Injection Nozzle Line (Bosch “P” Pump
Shown)

Disconnect injection line nuts (A) from injection pump delivery valves as follows:

Use JD90 Serrated Wrench (B) and JDF22 Crowsfoot Wrench (C) or a standard 3/4-in. line wrench on Bosch “P” pumps.

Serrated Wrench

JDE90

JDE90

Use to hold injection pump fuel outlet fittings on Bosch “P” pump from turning when loosening and tightening fuel pipe
connections.

Use JDF22 Crowsfoot Wrench and 22 mm open end wrench on Nippondenso “A” pumps

Crowsfoot Wrench

JDF22

JDF22

Used to loosen and tighten fuel pipes at injection nozzles and at injection pump.

<- Go to Section TOC

Section 02 page 40

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Use JDF22 Crowsfoot Wrench and an open end wrench on Motorpal pumps.

[3] - Disconnect fuel delivery lines from injection nozzles. Lift injection line assembly from engine.

[4] - Disconnect fuel leak-off line from injection nozzle leak-off assembly.

[5] -

LEGEND:

A Leak-Off Connector
B Line Nuts
C Packing

Engine with Metal Leak-Off Lines Shown

Remove packing (C) (if equipped) and line nuts (B) from each leak-off connector. Discard packing.

[6] -

→NOTE:

Engines with metal leak-off lines have O-rings (C) between leak-off connector and nozzle. Engines with
nylon leak-off lines have O-rings in groove of connector body on line nut end.

Remove leak-off connector (A) and O-rings from each injection nozzle.

[7] -

→NOTE:

The socket portion of JDE92 Nozzle Wrench (A) may be used to remove nozzles from cylinder head.

LEGEND:

A JDE92 Nozzle Wrench

Removing Injection Nozzles

If JDE92 Nozzle Wrench is not used, use a 24 mm (15/16-in.) deep socket on nozzles gland nut to remove nozzles.

Nozzle Socket

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Section 02 page 41

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

JDE92

JDE92

Used to remove and install 21 mm injection nozzles.

Gland nut will act as a jack screw to raise nozzle out of cylinder head bore. Remove hardened steel washer from injection
nozzle bore if it does not come out with nozzle.

[8] - To prevent debris from entering combustion chamber after nozzles are removed, insert a 12.7 mm (1/2 in.) hardwood
dowel in nozzle bore.

<- Go to Section TOC

Section 02 page 42

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Diagnose Injection Nozzle Malfunction

Diagnosis

Problem Possible Cause Suggested Remedy

Failed Carbon Stop Seal Washer Nozzle replaced without using new seal or washer. Install new washer.

Incorrect Opening Pressure Improper adjustment. Adjust opening pressure.

Broken spring. Replace spring.

Nozzle Will Not Open Plugged orifices. Clean.

Chipped orifices. Replace nozzle.

Bottomed lift screw. Adjust lift screw.

Poor Spray Pattern Plugged orifices. Clean.

Chipped orifices. Replace nozzle.

Cracked nozzle tip. Replace nozzle.

Poor Atomization Plugged orifice. Clean.

Chipped orifice. Replace nozzle.

Cracked nozzle tip. Replace nozzle.

Valve not free. See “Inconsistent Chatter”.

Inconsistent Chatter Spring components misaligned. Adjust opening pressure.

Varnish on valve. Clean guide area.

Deposits in seat area. Clean seat.

Bent valve. Replace nozzle.

Distorted body. Replace nozzle.

No Chatter Spring components misaligned. Adjust opening pressure.

Varnish on valve. Clean guide area.

Deposits in seat area. Clean seat.

Bent valve. Replace nozzle.

Valve seat eroded or pitted. Lap valve to seat. Replace nozzle as necessary.

Tip seat pitted. Lap tip to seat. Replace nozzle as necessary.

Seat interference angle worn. Replace nozzle.

Distorted body. Replace nozzle.

Seat Leakage Deposits in seat area. Clean seat.

Valve seat eroded or pitted. Lap valve to seat. Replace nozzle as necessary.

Tip seat pitted. Lap tip to seat. Replace nozzle as necessary.

Valve not free.

Distorted body. Replace nozzle.

Cracked tip. Replace nozzle.

See “Inconsistent Chatter”.
See “No Chatter”.

High Leak-Off Wear or Scratched at Guide Lap valve to guide. Replace nozzle.

Low Leak-Off Varnish on valve. Clean guide area.

Insufficient clearance. Clean nozzle. Lap valve to guide. Replace nozzle as necessary.

Test Fuel Injection Nozzles

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Section 02 page 43

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

CAUTION:

Avoid High-Pressure Fluids

Nozzle tip should always be directed away from operator. Fuel from spray orifices can penetrate skin and
clothing, causing serious personal injury. Enclosing nozzle in a transparent cover, or glass beaker is
recommended.

Before applying pressure to nozzle tester, be sure all connections are tight and fittings are not damaged.
Fuel escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood rather
than your hands, to search for suspected leaks.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type injury or gangrene may result.

Before disassembling, test injection nozzles with clean filtered fuel to determine its condition.

Test for:

Opening Pressure
Leakage
Chatter
Spray Pattern

Perform Opening Pressure Test

<- Go to Section TOC

Section 02 page 44

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

LEGEND:

A Nozzle Tester
B Fuel Line
C Adapter
D Glass Beaker

Testing Nozzle Opening Pressure

[1] - Connect injection nozzle to D01109AA Nozzle Tester (Y900) (A), using No. Y900-2A Fuel Line (B) and Y900-7 and Y90-15
Straight Adapters (C).

Fuel Injection Nozzle Tester and Attaching Hardware

D01109AA (Y900)

D01109AA (Y900)

Used to test operational performance and opening pressure of nozzles. Shown are D01109AA (Y900) Fuel Injection Nozzle
Tester (A), Y900-2A Fuel Injection Line Assembly (B)

[ Included in D01110AA (Y910A) Adapter Set. ]

, Y900-21 Adapter Nut (C)

[ May be used instead of Y900-7 and Y900-15. ]

, and Y900-7 and Y900-15 Straight Adapters (D).

[ Included in D01110AA (Y910A) Adapter Set. ]

Y900-21 90° Adapter may also be used. Place a glass beaker (D) around nozzle.

[2] - Pump handle several times to flush out nozzle fittings. Tighten fittings.

[3] - Expel air from nozzle by operating pump handle several strokes. Then raise pressure until valve opens.

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Section 02 page 45

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[4] - Recheck by completely releasing pressure, then gradually building pressure until valve opens.

IMPORTANT:

Nozzle tester should be checked periodically for accuracy.

Injection Nozzle Opening Pressure Specifications

LEGEND:

A Spring
B Spring Seat
C Shim

Injection Nozzle Spring and Pressure Adjusting Shims

A new nozzle or a used nozzle with a new spring (A), should open at approximately the following pressures. A used nozzle that
has been rebuilt with a new spring and/or valve should be reset to same pressures as a new nozzle. New nozzle opening
pressures are:

Item Measurement Specification

New Injection Nozzle (All Tip Sizes) Opening Pressure 29 000 kPa (290 bar) (4200 psi) minimum

On nozzles which have been in service, spring and spring seat (B) will have taken a normal set. In this case, opening pressure
is satisfactory if it meets or exceeds used nozzle minimum opening pressure given below, but does not exceed new opening
pressure given above. Used nozzle minimum opening pressures are:

Item Measurement Specification

Used Injection Nozzle (All Tip Sizes) Opening Pressure 26 200 kPa (262 bar) (3800 psi) minimum

IMPORTANT:

ALWAYS use John Deere nozzle adjusting shims which are specially hardened. Other shims will not be
satisfactory.

Shims (C) of different thicknesses are available for changing opening pressure adjustment. Each 0.05 mm (0.002 in.) of shim
thickness changes opening pressure approximately 700 kPa (7 bar) (100 psi).

If nozzle opening pressures are not correct, disassemble injection nozzles (as described in this group) and change shims until
nozzles open at propernew nozzle pressure given above.

The difference in nozzle opening pressures between cylinders in an engine should not exceed 350 kPa (3.5 bar) (50 psi).

<- Go to Section TOC

Section 02 page 46

CTM243-COMPONENT TECHNICAL MANUAL

Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Perform Nozzle Leakage Test

Bosch Injection Nozzle (Nippondenso Similar)

LEGEND:

A Upper Snap Ring (Bosch only)
B Gland Nut O-Ring
C Gland Nut
D Lower Snap Ring
E Nozzle Holder
F Shim
G Nozzle Valve Spring
H Spring Seat
I Intermediate Plate
J Nozzle and Valve
K Nozzle Retaining Nut
L Washer

[1] - Wipe nozzle dry.

[2] - Bring pressure up slowly to 1970 kPa (20 bar) (285 psi) below the opening pressure. Watch for an accumulation of fuel

from spray orifice, indicating a bad seat.

If nozzle drips within 10 seconds, replace nozzle and valve (J).

[3] - Check for leakage around nozzle retaining nut (K) thread connection with nozzle holder (E).

Leakage indicates a bad seat either between nozzle and intermediate plate (I) or between nozzle holder and intermediate
plate.

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Section 02 page 47

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

IMPORTANT:

Nozzle Intermediate Plate

LEGEND:

A Machined Surfaces
B Dowels

Do not lap the machined surfaces (A) of the intermediate plate in an attempt to stop fuel leakage at
these locations. Dowels (spring pins) (B) in plate have to be removed before surfaces can be lapped.
Removing dowels is not recommended as removal is likely to damage them, and replacement dowels are
not available as service parts.

If leakage is observed, tighten nozzle retaining nut to a maximum of 79 N˙m (58 lb-ft). Replace injection nozzle if leakage
continues.

Perform Chatter and Spray Pattern Test

[1] - Injection nozzle should chatter very softly, and only when hand lever movement is very rapid (four to six downward

movements per second). Failure to chatter may be caused by a binding or bent nozzle valve.

[2] - Until chattering range is reached, the test oil emerges as non-atomized streams. When lever movement is accelerated,
sprays should be very broad and finely atomized.

A partially clogged or eroded orifice will usually cause spray to deviate from the correct angle. Spray will also be steady rather
than finely atomized.

[3] - Disassemble nozzle for cleaning or reconditioning if it fails to chatter or spray properly.

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Section 02 page 48

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Disassemble Fuel Injection Nozzle

LEGEND:

A Leak-off Connector
B Nozzle Holder
C O-Ring and Upper Snap Ring
D Gland Nut

Disassembly of Injection Nozzle

General Nozzle Repair Notes:

→NOTE:

Disassembly of nozzles is not recommended unless servicing is indicated by nozzle operation and testing.

Since dirt and water are the worst contaminants in fuel injection systems, working area, tools, and cleaning materials must be
kept spotlessly clean. Whenever possible, work in an isolated, dust-free area.

Cover workbench with clean paper before disassembly of injection nozzles.

As parts are disassembled, place them in a pan of clean diesel fuel and leave there until needed. Do not permit parts to strike
each other.

Use a separate pan of clean diesel fuel for washing parts before assembly.

→NOTE:

Bosch KDEL and Nippondenso KDAL injection nozzles are metric design. Use only metric tools to service
nozzles.

[1] - Use an 11 mm box or open-ended wrench and unscrew leak-off connector (A) (if not removed previously) out of nozzle

holder (B).

[2] - Clamp flats of nozzle holder in a soft-jawed vise. Remove upper snap ring (C) from nozzle holder.

[3] - Slip gland nut (D) off nozzle holder.

→NOTE:

Bosch nozzles have a snap ring and O-ring at top of gland nut that must be removed before gland nut can
be removed.

[4] -

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Section 02 page 49

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Bosch Injection Nozzle (Nippondenso Similar)

LEGEND:

A Upper Snap Ring (Bosch only)
B Gland Nut O-Ring
C Gland Nut
D Lower Snap Ring
E Nozzle Holder
F Shim
G Nozzle Valve Spring
H Spring Seat
I Intermediate Plate
J Nozzle and Valve
K Nozzle Retaining Nut
L Washer

Remove lower snap ring (D).

[5] - Clamp the two flats of the nozzle holder (fuel inlet end) in a soft-jawed vise and remove nozzle retaining nut (K), using a
12-point 19 mm wrench.

[6] - Remove nozzle and valve assembly (J).

[7] - Pull off intermediate plate (I).

[8] - Remove spring seat (H), spring (G), and shims (F).

[9] - Remove gland nut O-ring (B).

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Section 02 page 50

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[10] -

CAUTION:

Use nozzle cleaning fluids in accordance with manufacturer′s instructions.

Withdraw nozzle valve from nozzle. If valve is stuck, it may be necessary to soak nozzle assembly in Bendix cleaner, acetone,
or other commercial cleaners sold especially for freeing stuck valves.

Do not permit lapped surfaces of valve and nozzle to come in contact with any hard substance. DO NOT touch valve unless
your hands are wet with fuel.

Clean and Inspect Fuel Injection Nozzle Assembly

LEGEND:

A Nozzle Valve
B Fuel Injection Nozzle Assembly

Inspecting Nozzle Parts

IMPORTANT:

Never use a steel brush to clean nozzles. Steel brush may damage injection nozzles.

[1] - Remove anti-corrosive coating from new or reconditioned nozzles by washing them thoroughly with diesel fuel.

[2] - Remove carbon from used nozzles and clean by washing them in diesel fuel. If parts are coated with hardened carbon or

lacquer, it may be necessary to use a brass wire brush.

[3] - After removing carbon or lacquer from nozzle exterior, inspect lapped surface for nicks or scratches. Replace if not in
good condition.

[4] - Inspect piston part of nozzle valve (A) to see that it is not scratched or scored. If any of these conditions are present,
replace nozzle assembly.

[5] - Inspect nozzle valve seat, nozzle, and intermediate plate. Contact area of parts (B) must not be scored or pitted. Use
inspection magnifier in JDF13 (JDE105) Nozzle Cleaning Kit to aid inspection.

Nozzle Cleaning Kit

JDF13 (JDE105)

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

JDF13 (JDE105)

Used to clean injection nozzles.

→NOTE:

A bad nozzle valve seat will cause fuel to drip from nozzle. This condition will usually be noted when
making the “Leakage Test”.

Perform Nozzle Slide Test

LEGEND:

A Nozzle Valve
B Nozzle
C Free-Fall Distance
D Lapped Surface

Performing Nozzle Slide Test

→NOTE:

DO NOT touch lapped surface (D) unless hands are wet with diesel fuel.

[1] - Dip nozzle valve (A) in clean diesel fuel.

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[2] - Insert valve in nozzle (B).

[3] - Hold nozzle vertical and pull valve out about one-third of its engaged length.

[4] - Release valve. Valve should slide down (C) to its seat by its own weight. Always replace a nozzle assembly if the valve

does not fall freely to its seat.

Clean Spray Orifices

LEGEND:

A Pin Vise
B Nozzle
C Orifice
D Cleaning Wire

Cleaning Nozzle Spray Orifices

[1] - Begin with cleaning wire (D) 0.07—0.10 mm (0.003—0.004 in.) from JDE105 Nozzle Cleaning Kit.

Nozzle Cleaning Kit

JDF13 (JDE105)

JDF13 (JDE105)

Used to clean injection nozzles.

→NOTE:

Stoning wire to provide a flat surface on one side will help in reaming carbon from clogged hole.

[2] - Clamp cleaning wire in pin vise (A). Wire should not protrude from vise more than 0.8 mm (1/32 in.).

[3] - Insert wire into orifice (C) and rotate.

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[4] - For final cleaning, use cleaning wire 0.03 mm (0.01 in.) smaller than orifice size. Follow previous steps until orifices are
clean of any carbon deposits.

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Inspect Nozzle Holder

LEGEND:

A Lapped Surface
B Nozzle Holder
C M19 x 0.75
D M6 x 1.0
E M14 x 1.5

Nozzle Holder

Inspecting Nozzle Holder

[1] - Inspect lapped surface (A) on bottom end of nozzle holder (B) for nicks or scratches. Replace holder if not in good
condition.

[2] - Inspect threads M19 x 0.75 (C), M6 x 1.0 (D), and M14 x 1.5 (E) on nozzle holder for general condition. Threads that are
nicked slightly may be “dressed-up”. Replace holder if threads cannot be restored to a serviceable condition.

[3] - Check fuel passages in nozzle holder to make sure they are open. Clean with compressed air.

[4] - Remove carbon deposits on both inner and outer surfaces of nozzle retaining nut.

[5] - Inspect retaining nut for cracks caused by overtightening or a damaged lower seating surface. A seat may be restored by

rubbing surface with emery cloth. Any nozzle nut which cannot be reconditioned, must be replaced.

[6] -

LEGEND:

A Intermediate Plate
B Dowel Pins

Inspecting Nozzle Intermediate Plate

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Inspecting Nozzle Spring Seat

Examine lapped surfaces on intermediate plate (A) for nicks, scratches, or worn areas which would permit fuel to leak past.

[7] -

IMPORTANT:

Do not lap the machined surfaces of the intermediate plate. Dowel pins (B) in plate have to be removed
before surfaces can be lapped. Removing dowels is not recommended as removal is likely to damage
them, and replacement dowels are not available as service parts.

Replace intermediate plate if lapped surfaces are worn or damaged.

[8] - Inspect spring seat for splitting, cracking, or excessive wear.

Replace seat if any of these conditions are evident.

[9] -

Inspecting Nozzle Spring and Shims

LEGEND:

A Nozzle Holder Fuel Passage

Cleaning Nozzle Filter

Examine spring and shims for pitting or excessive wear.

Replace as necessary.

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

[10] -

→NOTE:

The edge-type filter is pressed into nozzle holder and is not removable for service.

Clean filter by applying compressed air to nozzle holder fuel passage (A) at nozzle end.

Inspect Gland Nut

LEGEND:

A Gland Nut Threads

Inspecting Nozzle Gland Nut

[1] - Inspect nozzle holder gland nut for general condition; be sure that it is not cracked or split.

[2] - Inspect M28 x 1.5 threads (A) for general condition. Threads which are slightly nicked or damaged may be “dressed up”.

Replace gland nut if unable to restore to a serviceable condition.

[3] -

LEGEND:

A Connector Body (Metal Lines)
B Leak-Off Threads
C O-Ring (Metal Lines)
D O-Ring (Nylon Lines)
E Connector Body (Nylon Lines)

Leak-Off Connector (Metal Lines)

Leak-Off Connector (Nylon Lines)

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Check passage in leak-off connector to see that is open.

[4] - Blow through connector passage with compressed air.

[5] - Inspect the M6 x 1 threads (B) for general condition. Replace connector if threads are damaged and cannot be restored to

a serviceable condition.

[6] -

→NOTE:

Engines with metal leak-off lines have O-rings (C) between leak-off connector and nozzle. Engines with
nylon leak-off lines have O-rings in groove of connector body on line nut end.

Replace O-rings (C) or (D).

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Assemble Fuel Injection Nozzle

LEGEND:

A Number “7”
B “0.23”

Markings on Nozzle Tip

IMPORTANT:

Be sure to install correct nozzle assembly on nozzle holder. Do not intermix different size nozzle
assemblies.

To help determine correct nozzle assembly for each application, note markings on lower part of nozzle.

The illustration shows a nozzle marked 7 x 0.23. The number “7” (A) indicates the number of orifices and “0.23” (B) indicates
the size of each orifice in millimeters.

IMPORTANT:

Immerse parts in clean fuel before assembly. DO NOT dry parts with towels or compressed air. Dust
particles might collect and stay on pressure faces of nozzle valve and nozzle holder.

[1] -

LEGEND:

A Shims
B Spring
C Spring Seat
D Nozzle Holder
E Intermediate Plate

Assembling Nozzle Holder Parts

Place shims (A), spring (B), and spring seat (C) in nozzle holder (D) while still wet with diesel fuel.

→NOTE:

Make sure intermediate plate (E) is free of any foreign material before reassembling.

[2] -

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

LEGEND:

A Intermediate Plate
B Nozzle Holder
C Dowel Pins
D Nozzle and Valve

Assembling Nozzle Valve Parts

Position intermediate plate (A) on nozzle holder (B). Dowel pins (C) in plate will permit installation only one way.

[3] - Insert nozzle valve into nozzle (D) while holding parts below diesel fuel level in pan.

[4] -

Bosch Injection Nozzle (Nippondenso Similar)

LEGEND:

A Upper Snap Ring (Bosch only)
B Gland Nut O-Ring
C Gland Nut
D Lower Snap Ring
E Nozzle Holder
F Shim
G Nozzle Valve Spring
H Spring Seat
I Intermediate Plate
J Nozzle and Valve
K Nozzle Retaining Nut

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

L Washer

Install nozzle assembly on nozzle holder (E) and secure with nozzle retaining nut (K).

[5] - Clamp nozzle holder in a soft-jawed vise. Tighten nozzle retaining nut to specifications.

Item Measurement Specification

Fuel Injection Nozzle Retaining Nut Torque 60—80 N˙m (44—59 lb-ft)

[6] - Install lower snap ring (D) on nozzle holder.

[7] - Coat bore of gland nut (C) liberally with PT569 NEVER-SEEZ ™ compound to prevent gland nut from seizing on holder

body.

Number Name Use

• PT569 (us) NEVER-SEEZ ™ Compound Injection nozzle gland nut threads and barrel.

[8] - Install upper snap ring (A) on nozzle holder (Bosch only) and position O-ring (B) against gland nut.

[9] - Install leak-off connector on nozzle holder (E) using a new O-ring.

→NOTE:

Leak-off connector and O-ring should be installed on nozzle holder even though they will have to be
removed to install injection nozzle in cylinder head. This will prevent misplacement of connector and
washer before installation on engine.

Engines with metal leak-off lines have O-rings between the connector and nozzle. Engines with nylon
leak-off lines have O-rings in groove of connector body on line nut end.

Test and Adjust Injection Nozzle Opening Pressure

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

CAUTION:

Avoid High-Pressure Fluids

`Nozzle tip should always be directed away from operator. Fuel from spray orifices can penetrate
clothing and skin causing serious personal injury. Enclosing nozzle in a glass beaker is recommended.

Before applying pressure to nozzle tester, be sure all connections are tight and fittings are not damaged.
Fluid escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather
than hands, to search for suspected leaks.

If injured by escaping fluid, 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 may call
the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

[1] - Refer to PERFORM OPENING PRESSURE TEST , earlier in this group to test nozzle opening pressure. Adjust opening

pressure as needed.

[2] - Refer to PERFORM NOZZLE LEAKAGE TEST , earlier in this group to test for leakage. Repair as needed.

[3] - Refer to PERFORM CHATTER AND SPRAY PATTERN TEST , earlier in this group to test nozzle overall operation. Repair as

needed.

Inspect and Clean Cylinder Head Nozzle Bore

Cleaning Nozzle Bores in Cylinder Head

[1] - Inspect condition of threads for gland nut. Threads are metric (M28 x 1.5).

[2] - Inspect condition of nozzle seating in cylinder head.

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Cylinder head threads and nozzle seating surface must be free of debris and carbon deposits.

[3] -

IMPORTANT:

If injection nozzle gland nut threads are not clean, a false torque wrench reading may be obtained when
injection nozzle is installed. This may prevent injection nozzle from seating properly in cylinder head.

Clean threads which have light foreign deposits using an electric drill and D17030BR Thread Cleaning Brush.

Nozzle Thread Cleaning Brush

D17030BR

D17030BR

Used to clean nozzle threads in cylinder head.

Work brush up and down several times to clean threads.

[4] -

Using Tap to Clean Threads in Nozzle Bores

Clean threads with heavy foreign deposits or clean up damaged threads by using JDF5 Tap (M28 X 1.5 mm).

Tap

JDF5

JDF5

Used to restore nozzle threads in cylinder head.

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Be sure to start tap straight to avoid possible cross-threading. A light coat of grease on tap will help collect foreign deposits on
tap and prevent them from falling into nozzle bore.

[5] - After cleaning threads, insert a 13 mm (1/2 in.) tapered hardwood dowel to plug nozzle tip bore.

[6] - Blow out debris from nozzle cavity with compressed air; then remove wood dowel.

Inspect and Clean Nozzle Seating Surface

Cleaning Nozzle Seats in Head

[1] - Inspect nozzle seating surface for carbon deposits.

[2] - If seat is not clean, use the JDG609 Nozzle Seat Reamer to remove carbon.

Nozzle Seat Reamer

JDG609

JDG609

Used to clean carbon from nozzle seats in cylinder head.

Stop using tool when seat comes clean.

[3] - Insert a 13 mm (1/2 in.) tapered hardwood dowel to plug the nozzle tip bore.

[4] - Blow out debris from nozzle cavity with compressed air; then remove wood dowel.

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Section 02 - REPAIR AND ADJUSTMENT Group 090: Mechanical Fuel System Repair and Adjustments

Install Fuel Injection Nozzles

LEGEND:

A Special Steel Washer

Preparing Nozzle for Installation

[1] - Apply PT569 NEVER-SEEZ ™ Compound to gland nut threads and nozzle barrel (arrows).

Number Name Use

• PT569 (us) NEVER-SEEZ ™ Compound Injection nozzle gland nut threads and barrel.

Be sure that NEVER-SEEZ ™ compound was also applied to inside bore of gland nut during assembly.

→NOTE:

Applying NEVER-SEEZ ™ Compound at these locations will help prevent possible seizure of gland nut to
holder body.

[2] -

IMPORTANT:

Do not intermix injection nozzles of different suppliers or different tip sizes within a single engine.

Install a new special steel washer (A) on tip end of assembled injection nozzle.

[3] -

LEGEND:

A Leak-Off Connector Threads

Installing Injection Nozzles in Cylinder Head

Insert injection nozzle into cylinder head. Turn gland nut by hand to make sure it is threaded straight in cylinder head.

[4] - Use outer socket of JDE92 Nozzle Socket and turn gland nut down to remove most of the looseness.

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