Diesel

POWERTECH 8.1 LDiesel Engines

Base Engine

TECHNICAL MANUALPOWERTECH 8.1 L Diesel Engines

Base EngineCTM86 06JUL06 (ENGLISH)

For complete service information also see:POWERTECH 8.1 L DieselEnginesMechanical Fuel Systems . . . . . . CTM243POWERTECH 6.8 L & 8.1 L DieselEnginesLevel 3 Electronic Fuel Systemswith Bosch In-Line Pump . . . . . . . . . . . . . . . CTM134POWERTECH 8.1 L Diesel EnginesLevel 9Electronic Fuel Systems with Denso In-LinePump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM255Electronic Fuel Injection Systems . . . . . . . . CTM68OEM Engine Accessories . . . . . . . . . . . . . . . CTM67Alternators and Starting Motors . . . . . . . . . . CTM77

John Deere Power SystemsLITHO IN U.S.A.

Introduction

DPSG,OUO1004,912 1915JUN991/1

Foreword

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

This manual (CTM86) covers only the base engine. Itis one of five volumes on 8.1 L engines. The followingfour companion manuals cover fuel system repair anddiagnostics:

CTM243Mechanical Fuel Systems CTM134Level 3 Electronic Fuel Systems CTM255Level 9 Electronic Fuel Systems CTM68Electronic Injection Fuel Systems

Other manuals will be added in the future to provideadditional information on electronic fuel systems asneeded.

This manual covers the base engine for all 8.1Lengines, including emission non-certified, Tier Icertified, and Tier II certified (esn 200,000 ).

Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

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

Use this component technical manual in conjunctionwith the machine technical manual. An applicationlisting in the introduction identifiesengine-models/applications. See the machine technicalmanual for information on engine removal andinstallation, and gaining access to engine components.

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

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

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

This manual contains SI Metric units of measurefollowed immediately by the U.S. Customary units ofmeasure. Most hardware on these engines is metricsized.

Some components of this engine may be servicedwithout removing the engine from the machine. Referto the specific machine technical manual forinformation on components that can be servicedwithout removing the engine from the machine and forengine removal and installation procedures.

Read each block of material completely beforeperforming service to check for differences inprocedures that apply to the engine model number youare working on. If only one procedure is given, thatprocedure applies to all the engines in the manual.

Component Technical Manuals are concise serviceguides for specific components. Component technicalmanuals are written as stand-alone manuals coveringmultiple machine applications.

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

CALIFORNIA PROPOSITION 65 WARNING: Dieselengine exhaust and some of its constituents areknown to the State of California to cause cancer,birth defects, and other reproductive harm.

CTM86 (06JUL06) POWERTECH 8.1 L Diesel Engines Base Engine071706

PN=2

Introduction

DPSG,OUO1004,898 1919MAY991/2

John Deere Dealers

The changes listed below make your CTM obsolete.Repair, operation, and diagnostics are now covered infive manuals. Discard CTM86 dated 06JUL99 andreplace with the following new manuals:

CTM86Base Engine CTM243Mechanical Fuel Systems CTM134Level 3 Electronic Fuel Systems CTM255Level 9 Electronic Fuel Systems CTM68Electronic Fuel Injection Systems

Also, copy these pages and route through your ServiceDepartment.

SECTION 01, GROUP 001 (Engine Identification)

Updated engine model designation chart. Updated engine application charts.

SECTION 01, GROUP 002 (Fuels, Lubricants, andCoolants)

Updated engine oil and coolant applicationguidelines.

SECTION 02, GROUP 010 (Engine Rebuild)

Updated engine disassembly sequence. Updated engine assembly sequence. Updated sealant application guidelines.

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

Repair procedures for cylinder head and valves onengines with serial number ( 199,999) are coveredin this group.

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

Repair procedures for cylinder head and valves onengines with serial number (200,000 ) are coveredin this group.

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

Eliminated procedure to check valve lift. Useappropriate procedure from Group 020 or Group021.

Revised specifications for installation of crankshaftgear-driven auxiliary drive.

Revised procedure for installation of thrust washerand timing gear cover.

SECTION 02, GROUP 060 (Lubrication SystemRepair and Adjustment)

Added information for top-load oil filter.

SECTION 02, GROUP 070 (Cooling System Repairand Adjustment)

Added belt routing diagrams. Revised procedure for installation of coolant pump.

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

Revised procedure for turbocharger inspectiontechniques.

Eliminated procedure for adjusting turbochargerwastegate actuator.

Revised specifications for installing turbocharger.

SECTION 02, GROUP 090 (Fuel System Repair andAdjustments)

NOTE: Repair procedures for fuel systems have beenhave been moved to Section 02, Group 090 inthe three following technical manuals:

CTM243Mechanical Fuel Systems CTM134Level 3 Electronic Fuel Systems CTM255Level 9 Electronic Fuel Systems

SECTION 02, GROUP 100 (OEM Starting andCharging Systems)


PN=3

Introduction

DPSG,OUO1004,898 1919MAY992/2

Starting and charging systems are covered in thisnew group.

SECTION 03, GROUP 120 (Base Engine Operation)

Base engine theory of operation is covered in thisnew group.

NOTE: Fuel system theory of operation has beenmoved to Section 03 in the three followingtechnical manuals:


SECTION 04, GROUP 150 (Observable Diagnosticsand Tests)

Base engine observable diagnostics and tests arecovered in this new section/group.

NOTE: Fuel system diagnostics and testing has beenmoved to Section 04 in the three followingtechnical manuals:


SECTION 05 (Tools and Other Materials)

All essential tools, service tools, dealer fabricatedtools, and other materials listed throughout thismanual are consolidated in this section for ease ofreference.

SECTION 06 (Specifications)

All repair, test, and diagnostic specifications listedthroughout this manual are consolidated in thissection for ease of reference.

Updated bolt and cap screw torque values. Updated General OEM specifications. Updated dynamometer specifications. Updated turbocharger boost specifications


PN=4

Introduction

DPSG,OUO1004,913 1915JUN991/1

About this Manual

This component technical manual (CTM) covers the baseengine for POWERTECH 8.1 L (494 cu. in.) diesel enginesproduced in Waterloo, Iowa. This manuals coverageincludes: emissions non-certified, emissions certified TierI, and emissions certified Tier II (esn 200,000 ) engines

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

CTM86 POWERTECH 8.1 L Diesel EnginesBaseEngine

CTM243 POWERTECH 8.1 L Diesel EnginesMechanical Fuel Systems

CTM134 POWERTECH 6.8 L & 8.1 L DieselEnginesLevel 3 Electronic Fuel Systems with BoschIn-Line Pump

CTM255 8.1 L Diesel EnginesLevel 9 ElectronicFuel Systems with Denso In-Line Pump

CTM68 Electronic Fuel Injection Systems

Direction of engine crankshaft rotation in this manual isreferenced as clockwise, as viewed from the rear of theengine. Front of engine is fan drive end.

Read each procedure completely before performing anyservice.

IMPORTANT: For repair, diagnostics, and testingprocedures on the fuel system, refer tothe companion manuals:

CTM243 POWERTECH 8.1 L DieselEnginesMechanical Fuel Systems

CTM134 POWERTECH 6.8 L & 8.1 LDiesel EnginesLevel 3 ElectronicFuel Systems with Bosch In-LinePump

CTM255 8.1 L Diesel EnginesLevel 9 Electronic Fuel Systems withDenso In-Line Pump

CTM68 Electronic Fuel InjectionSystems

POWERTECH is a registered trademark of Deere & Company


PN=5

Introduction

RG,RG34710,4001 1914DEC001/2

Identification Views Serial Number ( 199,999) Non Emissions Certified, and Tier IEmissions Certified Engines

RG

7362

UN

05J

AN98

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

RG

7363

UN

05J

AN98

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

RG

7385

UN

05J

AN98

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

RG

7387

UN

05J

AN98

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


PN=6

Introduction

RG,RG34710,4001 1914DEC002/2

RG

7388

UN

20J

UN00

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

RG

7386

UN

20J

UN00

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

RG

7383

UN

05J

AN98

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

RG

7384

UN

05J

AN98

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


PN=7

Introduction

RG,OUOD007,4002 1901NOV001/1

Identification Views Serial Number (200,000 ) Tier II Emissions Certified Engines

RG

1151

1UN

13D

EC00

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

RG

1151

2UN

31O

CT00

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

RG

1151

3UN

31O

CT00

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

RG

1151

4UN

31O

CT00

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


PN=8

Contents01

SECTION 01GeneralGroup 000SafetyGroup 001Engine IdentificationGroup 002Fuels, Lubricants and Coolant

02SECTION 02Repair and AdjustmentsGroup 010Engine RebuildGroup 020Cylinder Head and Valves Repair and

Adjustment S. N. ( 199,999)Group 021Cylinder Head and Valves Repair and

Adjustment S. N. (200,000 )Group 030Cylinder Block, Liners, Pistons, and

Rods Repair and AdjustmentGroup 040Crankshaft, Main Bearings and

Flywheel Repair and AdjustmentGroup 050Camshaft and Timing Gear Train

03

Repair and AdjustmentGroup 060Lubrication System Repair and

AdjustmentGroup 070Cooling System Repair and AdjustmentGroup 080Air Intake and Exhaust System Repair

and AdjustmentGroup 100OEM Starting and Charging Systems

Repair and Adjustment

SECTION 03Theory of OperationGroup 120Base Engine Operation

04

SECTION 04DiagnosticsGroup 150Observable Diagnostics and Tests

SECTION 05Tools and Other MaterialsGroup 170Repair Tools and Other MaterialsGroup 180Diagnostic Service ToolsGroup 190Dealer Fabricated Service Tools

SECTION 06SpecificationsGroup 200Repair and General OEM

05

SpecificationsGroup 210Diagnostic Specifications

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

06

COPYRIGHT 2005DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious Editions

Copyright 1994,1997,1999, 2001, 2003, 2004

INDX

CTM86 (06JUL06) i POWERTECH 8.1 L Diesel Engines Base Engine071706

PN=1

Contents

01

02

03

04

05

06

INDX

CTM86 (06JUL06) ii POWERTECH 8.1 L Diesel Engines Base Engine071706

PN=2

01

Section 01General

Contents

Page

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

Group 001Engine IdentificationEngine Model Designation. . . . . . . . . . . . . . . .01-001-1Engine Serial Number Plate Information . . . . .01-001-2Engine Option Code Label . . . . . . . . . . . . . . .01-001-3Engine Application Chart (John Deere

Agricultural Equipment) . . . . . . . . . . . . . . . .01-001-3Engine Application Chart (John Deere

Construction Equipment) . . . . . . . . . . . . . . .01-001-6Engine Application Chart (OEM) (Outside

Equipment Manufacturers) . . . . . . . . . . . . . .01-001-6

Group 002Fuels, Lubricants and CoolantDiesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . .01-002-2Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . .01-002-2Testing Diesel Fuel . . . . . . . . . . . . . . . . . . . . .01-002-3Diesel Engine Break-In Oil . . . . . . . . . . . . . . .01-002-3Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . .01-002-4Extended Diesel Engine Oil Service

Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-5Alternative and Synthetic Lubricants . . . . . . . .01-002-5Mixing of Lubricants . . . . . . . . . . . . . . . . . . . .01-002-6Oilscan and Coolscan . . . . . . . . . . . . . . . . . . .01-002-6Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-7Diesel Engine Coolant. . . . . . . . . . . . . . . . . . .01-002-8Diesel Engine Coolants, Supplemental

Additive Information . . . . . . . . . . . . . . . . . .01-002-10Testing Diesel Engine Coolant . . . . . . . . . . .01-002-11Replenishing Supplemental Coolant

Additives (SCAs) Between CoolantChanges . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-12

Operating in Warm Temperature Climates . .01-002-13Flush and Service Cooling System . . . . . . . .01-002-14Disposing of Coolant . . . . . . . . . . . . . . . . . . .01-002-15

CTM86 (06JUL06) 01-1 POWERTECH 8.1 L Diesel Engines Base Engine071706

PN=1

Contents

01


PN=2

Group 000Safety

010001

DX,FLAME 1929SEP981/1

Handle Fluids SafelyAvoid Fires

TS22

7

UN2

3AUG

88

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

Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burnspontaneously.

DX,FIRE3 1916APR921/1

Handle Starting Fluid Safely

TS13

56UN

18M

AR92

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keepstarting fluid away from batteries and cables.

To prevent accidental discharge when storing thepressurized can, keep the cap on the container, and storein a cool, protected location.

Do not incinerate or puncture a starting fluid container.

CTM86 (06JUL06) 01-000-1 POWERTECH 8.1 L Diesel Engines Base Engine071706

PN=13

Safety

01000

2

DPSG,OUO1004,2758 1922DEC051/2

Handling Batteries Safely

TS20

4UN

23A

UG88

TS20

3UN

23A

UG88

Continued on next page


PN=14

Safety

010003

DPSG,OUO1004,2758 1922DEC052/2

CAUTION: Battery gas can explode. Keepsparks and flames away from batteries. Use aflashlight to check battery electrolyte level.

Never check battery charge by placing a metalobject across the posts. Use a voltmeter orhydrometer.

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

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

CAUTION: Sulfuric acid in battery electrolyte ispoisonous. It is strong enough to burn skin, eatholes in clothing, and cause blindness ifsplashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.2. Wearing eye protection and rubber gloves.3. Avoiding breathing fumes when electrolyte is

added.4. Avoiding spilling or dripping electrolyte.5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.2. Apply baking soda or lime to help neutralize

the acid.3. Flush your eyes with water for 1530

minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.2. Drink large amounts of water or milk, but do

not exceed 2 L (2 quarts).3. Get medical attention immediately.

WARNING: Battery posts, terminals, and relatedaccessories contain lead and lead compounds, chemicalsknown to the State of California to cause cancer andreproductive harm. Wash hands after handling.


PN=15

Safety

01000

4

DX,FIRE2 1903MAR931/1

Prepare for Emergencies

TS29

1UN

23A

UG88

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.

DX,FLUID 1903MAR931/1

Avoid High-Pressure Fluids

X981

1UN

23A

UG88

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

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

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


PN=16

Safety

010005

DX,WEAR 1910SEP901/1

Wear Protective Clothing

TS20

6

UN2

3AUG

88

Wear close fitting clothing and safety equipmentappropriate to the job.

Prolonged exposure to loud noise can cause impairmentor loss of hearing.

Wear a suitable hearing protective device such asearmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

Operating equipment safely requires the full attention ofthe operator. Do not wear radio or music headphoneswhile operating machine.

DX,LOOSE 1904JUN901/1

Service Machines Safely

TS22

8UN

23A

UG88

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

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

DX,AIR 1917FEB991/1

Work In Ventilated Area

TS22

0UN

23A

UG88

Engine exhaust fumes can cause sickness or death. If it isnecessary to run an engine in an enclosed area, removethe exhaust fumes from the area with an exhaust pipeextension.

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


PN=17

Safety

01000

6

DX,CLEAN 1904JUN901/1

Work in Clean Area

T664

2EJ

UN

18O

CT88

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.

OUOD006,000009D 1904DEC021/1

Install Fan Guards

TS67

7UN

21S

EP89

Rotating Fan

Rotating cooling system fans can cause serious injury.

Keep fan guards in place at all times during engineoperation. Wear close fitting clothes. Stop the engine andbe sure fan is stopped before making adjustments orconnections, or cleaning near the front of the engine.

OUOD006,000009E 1904DEC021/1

Avoid Hot Parts

TS27

1UN

23A

UG88

Hot Surface

Avoid skin contact with exhaust manifolds, turbochargersand mufflers. Keep flammable materials clear of theturbocharger.

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


PN=18

Safety

010007

DX,PAINT 1924JUL021/1

Remove Paint Before Welding or Heating

TS22

0

UN2

3AUG

88

Avoid potentially toxic fumes and dust.

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

Remove paint before heating:

Remove paint a minimum of 100 mm (4 in.) from areato 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 withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

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

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

Dispose of paint and solvent properly.

DX,TORCH 1910DEC041/1

Avoid Heating Near Pressurized Fluid Lines

TS95

3UN

15M

AY90

Flammable spray can be generated by heating nearpressurized fluid lines, resulting in severe burns toyourself and bystanders. Do not heat by welding,soldering, or using a torch near pressurized fluid lines orother flammable materials. Pressurized lines canaccidentally burst when heat goes beyond the immediateflame area.


PN=19

Safety

01000

8

DX,LIGHT 1904JUN901/1

Illuminate Work Area Safely

TS22

3UN

23A

UG88

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

DX,LIFT 1904JUN901/1

Use Proper Lifting Equipment

TS22

6UN

23A

UG88

Lifting heavy components incorrectly can cause severeinjury or machine damage.

Follow recommended procedure for removal andinstallation of components in the manual.

DPSG,OUO1004,899 1919MAY991/1

Construct Dealer-Made Tools Safely

LX10

1674

9UN

01J

UL97

Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. Whenconstructing tools, use proper, quality materials and goodworkmanship.

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


PN=20

Safety

010009

DX,SERV 1917FEB991/1

Practice Safe Maintenance

TS21

8UN

23A

UG88

Understand service procedure before doing work. Keeparea clean and dry.

Never lubricate, service, or adjust machine while it ismoving. Keep hands, feet , and clothing frompower-driven parts. Disengage all power and operatecontrols to relieve pressure. Lower equipment to theground. Stop the engine. Remove the key. Allow machineto cool.

Securely support any machine elements that must beraised for service work.

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

On self-propelled equipment, disconnect battery groundcable (-) before making adjustments on electrical systemsor welding on machine.

On towed implements, disconnect wiring harnesses fromtractor before servicing electrical system components orwelding on machine.

DX,REPAIR 1917FEB991/1

Use Proper Tools

TS77

9UN

08N

OV8

9

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

Use power tools only to loosen threaded parts andfasteners.

For loosening and tightening hardware, use the correctsize tools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches.

Use only service parts meeting John Deere specifications.


PN=21

Safety

01000

10

DX,DRAIN 1903MAR931/1

Dispose of Waste Properly

TS11

33UN

26N

OV9

0

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

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

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

Air conditioning refrigerants escaping into the air candamage the Earths atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.

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

DX,LIVE 1925SEP921/1

Live With Safety

TS23

119

07O

CT88

Before returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.


PN=22

Group 001Engine Identification

010011

RG,RG34710,1021 1923OCT971/1

Engine Model Designation

RG

7010

UN

26N

OV9

7

Engine Serial Number Plate

AEngine Serial NumberBEngine Model Designation

JOHN DEERE ENGINE MODEL6081

John Deere engine model designation includes number ofcylinders, displacement in liters, aspiration, user code, andapplication code. For example:

6081 HRW01 Engine6 ............................................................................ Number of cylinders8.1 ............................................................................... Liter designationH .................................................................................... Aspiration codeRW ........................................................................................ User code01 ............................................................................... Application CodeAspiration CodeT ............................................................ Turbocharged, no aftercoolingA ...................................... Turbocharged and coolant-to-air aftercooledH ............................................. Turbocharged and air-to-air aftercooledUser CodeCQ ................................................................ S.L.C. Horizontina (Brazil)DW ........................................................................................ DavenportF ............................................ OEM (Original Equipment Manufacturer)FF ........................................ Kernersvill Deere-Hitachi (North Carolina)FM ..................................................................................... OEM MarineH ............................................................................................. HarvesterN ......................................................................................... Des MoinesRW ......................................................................... Waterloo (Tractors)T ................................. Dubuque, and Cameco (Thibodaux, Louisiana)TJ ......................................................... Ontario (Canada) - TimberjackZ ...................................................................... Zweibrucken (Germany)Application Code001, etc. ..... See ENGINE APPLICATION CHART, later in this Group


PN=23

Engine Identification

01001

2

RG,RG34710,1022 1919MAY991/1

Engine Serial Number Plate Information

RG

7010

UN

26N

OV9

7

Engine Serial Number Plate

AEngine Serial NumberBEngine Application Data

IMPORTANT: The engine serial number plate can beeasily destroyed. Remove the plate orrecord the information elsewhere,before hot tank cleaning the block.

Engine Serial Number (A)

Each engine has a 13-digit John Deere engine serialnumber identifying the producing factory, engine modeldesignation, and a 6-digit sequential number. Thefollowing is an example:

RG6081H000000RG ........................................................ Factory code producing engine6081H ........................................................... Engine model designation000000 .......................................................... Sequential serial numberFactory CodeRG .............................................................. Waterloo Engine WorksEngine Model Designation6801H .................................... (See ENGINE MODEL DESIGNATION.)Sequential Number000000 .......................................................... 6-digit sequential number

The engine serial number plate is located either on theright-hand side of engine between the oil filter base andfuel injection pump (viewed from flywheel end) or on theleft-hand side of the engine directly above the startermotor.

Engine Application Data (B)

The second line of information on the engine serialnumber plate identifies the engine/Deere machine or OEMrelationship. SeeENGINE APPLICATION CHART later inthis group.


PN=24


010013

DPSG,OUO1004,900 1919MAY991/1

Engine Option Code Label

RG

1107

4UN

14A

UG00

Option Code Label

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

factory. When in need of parts or service, furnish yourauthorized servicing dealer or engine distributor withthese numbers.

RE38635,000003B 1918JUL051/3

Engine Application Chart (John DeereAgricultural Equipment)

Machine ModelDES MOINESCOTTON PICKERS & SPRAYERS9970 Cotton Picker ............................................................. 6081AN0019976 Cotton Picker .................................................... 6081HN001, 0039986 Cotton Picker ............................................................ 6081HN0034920 Sprayer ...................................................................... 6081HN005HARVESTERCOMBINES9510 Low Power Combine ................................................. 6081HH0019510 High Power Combine ................................................ 6081HH0029550 Low Power Combine ................................................. 6081HH0089550 High Power Combine ................................................ 6081HH0099610 Combine .................................................................... 6081HH0039650 and 9650CTS Combine ............................................ 6081HH0109650 CTS-(Europe) Combine ............................................ 6081HH0119650 STS Combine ............................................................ 6081HH0069750 STS Combine ............................................................ 6081HH005CTS II Combine (Europe-1998 Model Year ...................... 6081HH003CTS II Combine (Europe-1999 Model Year) ..................... 6081HH004CTS II Combine (North America) ....................................... 6081HH003Amadus Peanut Combine .................................................. 6081HH007


PN=25



01001

4

RE38635,000003B 1918JUL052/3

WATERLOOTRACTORS7710 Tractor .............................................. 6081TRW01, 03, 05, 07, 097810 Tractor ....................................... 6081TRW02, 04, 06, 08, 10, 117710/7810 Tractor ................................................ 6081HRW43 (Tier II)7820 Tractor ...................................................................... 6081HRW417920 Tractor ...................................................................... 6081HRW428100 Tractor ...................................................................... 6081HRW068200 Tractor ...................................................................... 6081HRW078300 Tractor ...................................................................... 6081HRW088400 Tractor ................................................................ 6081HRW01, 048100T (Tracks) Tractor ..................................................... 6081HRW108200T (Tracks) Tractor ..................................................... 6081HRW028300T (Tracks) Tractor ..................................................... 6081HRW098400T (Tracks) Tractor ..................................................... 6081HRW038110 Tractor ...................................................................... 6081HRW118210 Tractor ...................................................................... 6081HRW138310 Tractor ...................................................................... 6081HRW158410 Tractor ...................................................................... 6081HRW178110T (Tracks) Tractor ..................................................... 6081HRW128210T (Tracks) Tractor ..................................................... 6081HRW148310T (Tracks) Tractor ..................................................... 6081HRW168410T (Tracks) Tractor ..................................................... 6081HRW188120/8220 Wheel/Tracks (W/T)Tractor ............................. 6081HRW238120/8220 Front Suspended Axle North America ............ 6081HRW318120/8220 Front Suspended Axle Region II .................... 6081HRW328320 W/T Tractor .............................................................. 6081HRW258320 Front Suspended Axle North America ..................... 6081HRW338320 Front Suspended Axle Region II ............................. 6081HRW348420W CIS Tractor (Wheels Only) ................................... 6081HRW268420 W/T Tractor .............................................................. 6081HRW278420 Front Suspended Axle Tractor North America ........ 6081HRW358420 Front Suspended Axle Tractor Region II ................. 6081HRW368520 W/T Tractor .............................................................. 6081HRW288520 Front Suspended Axle Tractor North America ........ 6081HRW378520 Front Suspended Axle Tractor Region II ................. 6081HRW389100 4-Wheel Drive Tractor .............................................. 6081HRW059120 4-WD Wheels Tractor .............................................. 6081HRW30



PN=26


010015

RE38635,000003B 1918JUL053/3

ZWEIBRUCKENCOMBINES/FORAGE HARVESTERS2256 Combine ............................................................. 6081HZ003, 0072258 Combine ............................................................... 6081HZ002, 052264 Combine ..................................................................... 6081HZ0022266 Combine ..................................................................... 6081HZ0012268 Combine ..................................................................... 6081HZ0069640/9640HM ...................................................................... 6081HZ0099640/9640HM & 9850/9850HM Combine ................................................................................................................ 6081HZ017 (replaces HZ009)9680/9680HM Combine ...................................................... 6081HZ0119780/9780HM Combine ...................................................... 6081HZ0129680/9680HM & 9780/9780HM Combine ................................................................................................ 6081HZ019 (replaces HZ011 & HZ012)9660/9660HM Combine ...................................................... 6081HZ0109660/9660HM Combine ......................... 6081HZ018 (replaces HZ010)6650 Self-Propelled Forage Harvester ............................... 6081HZ0047200 Self-Propelled Forage Harvester . 6081HZ013 (European Model)7200 Self-Propelled Forage Harvester ......................................................................................................... 6081HZ016 (North American Model)S.L.C. HORIZONTINA (BRAZIL)COMBINES1185A Combine ................................................................. 6081ACQ01


PN=27


01001

6

RG41183,0000024 1925JAN011/1

Engine Application Chart (John DeereConstruction Equipment)

Machine ModelDAVENPORT644G Loader ..................................................................... 6081HDW04644H Loader ..................................................................... 6081HDW05644H-MH Loader ................................................... 6081HDW06 (Tier I)644H-MH Loader .................................................. 6081HDW08 (Tier II)724J Loader ......................................................... 6081HDW09 (Tier II)740G/748G/748G II/748G III Skidder ............................... 6081TDW01770C (Late)/770CH/772CH Motor Grader ........................ 6081HDW01770C Motor Grader (Early) ............................................... 6081HDW03870C/872CH Motor Grader ............................................. 6081HDW013DUBUQUE762B Series II Scraper ........................................................ 6081AT001850C Series II Crawler Dozer (822868 ) ........................ 6081AT002850J Crawler Dozer ................................................. 6081HT006 Tier IIBELL EQUIPMENT - SOUTH AFRICA250D/300D Articulated Truck .............................................. 6081HT003L2006/L2306 Bell Loaders .................................................. 6081HT007DEERE-HITACHI (CANADA)2054 Logger (based on JD200 Excavator) ......................... 6081HT0532554 Logger (based in JD230 Excavator ........................... 6081HT054DEERE-HITACHI (JAPAN)330/370 Logger (based on JD330 Excavator) .................... 6081HT002WOODSTOCK, ON. (TIMBERJACK) & THIBODAUX, LA. (CAMECO)660D Skidder ...................................................................... 6081ATJ02530B/535 Log Loader ................................................... 6081ATJ01, 03608B Feller Buncher .............................................. 6081HTJ07 (Tier II)608S Feller Buncher .............................................. 6081HTJ08 (Tier II)1710 Forwarder ................................................................... 6081HTJ021270 Harvester .................................................................... 6081HTJ032500 Cane Harvester .......................................................... 6081HT801

RG41183,000003A 1928FEB011/1

Engine Application Chart (OEM) (OutsideEquipment Manufacturers)

Application Engine ModelOEM Engine (Tier I Emissions Certified) ........................ 6081TF001OEM Engine (Tier I Emissions Certified) ............................ 6081AF001OEM Engine (Tier I Emissions Certified) ............................ 6081HF001Marine Engine .................................................................... 6081AFM01OEM Engine (Tier II Emissions Certified) ........................... 6081HF070


PN=28

Group 002Fuels, Lubricants and Coolant

010021

RG41165,0000071 1913MAR011/1

Diesel Fuel

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

In general, diesel fuels are blended to satisfy the lowtemperature requirements of the geographical area inwhich they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 arerecommended.

In all cases, the fuel shall meet the followingproperties:

Cetane number of 40 minimum. Cetane numbergreater than 50 is preferred, especially fortemperatures below -20 C (-4 F) or elevations above1500 m (5000 ft).

Cold Filter Plugging Point (CFPP) below theexpected low temperature OR Cloud Point at least5 C (9 F) below the expected low temperature.

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

Sulfur content:

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

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

DO NOT use diesel fuel with sulfur content greaterthan 1.0%.

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


PN=29

Fuels, Lubricants and Coolant

01002

2

RG41183,0000046 1918DEC011/1

Bio-Diesel Fuel

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

Bio-diesel fuels may be used ONLY if the bio-dieselfuel properties meet the latest edition of ASTM PS121,DIN 51606 or equivalent specification.

It has been found that bio-diesel fuels may improvelubricity in concentrations up to a 5% blend inpetroleum diesel fuel.

When using a blend of bio-diesel fuel, the engine oillevel must be checked daily when the air temperatureis -10 C (14 F) or lower. If the oil becomes diluted withfuel, shorten oil change intervals accordingly.

IMPORTANT: Raw pressed vegetable oils are NOTacceptable for use for fuel in anyconcentration in John Deereengines.

These oils do not burn completely,and will cause engine failure byleaving deposits on injectors and inthe combustion chamber.

A major environmental benefit of bio-diesel fuel is itsability to biodegrade. This makes proper storage andhandling of bio-diesel fuel especially important. Areasof concern include:

Quality of new fuel Water content of the fuel Problems due to aging of the fuel

Potential problems resulting from deficiencies in theabove areas when using bio-diesel fuel inconcentrations above 5% may lead to the followingsymptoms:

Power loss and deterioration of performance Fuel leakage Corrosion of fuel injection equipment Coked and/or blocked injector nozzles, resulting in

engine misfire Filter plugging Lacquering and/or seizure of internal components Sludge and sediments Reduced service life of engine components

DX,FUEL5 1927OCT051/1

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States,Canada, and the European Union have adequatelubricity to ensure proper operation and durability offuel injection system components. However, dieselfuels manufactured in some areas of the world maylack the necessary lubricity.

IMPORTANT: Make sure the diesel fuel used inyour machine demonstrates goodlubricity characteristics.

Fuel lubricity should pass a minimum load level of3100 grams as measured by ASTM D6078 or amaximum scar diameter of 0.45 mm as measured byASTM D6079 or ISO 12156-1.

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


PN=30


010023

DX,FUEL6 1914NOV051/1

Testing Diesel Fuel

DIESELSCAN is a John Deere fuel analysis programthat can be used to monitor the quality of your fuel. TheDIESELSCAN analysis verifies fuel type, cleanliness,water content, suitability for cold weather operation, andwhether the fuel meets specifications.

Check with your John Deere dealer for availability ofDIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

DX,ENOIL4 1919DEC051/1

Diesel Engine Break-In Oil

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

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

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

If John Deere ENGINE BREAK-IN OIL is not available,use a diesel engine oil meeting one of the followingduring 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

After the break-in period, use John Deere PLUS-50 or other diesel engine oil as recommended in thismanual.

IMPORTANT: Do not use PLUS-50 oil or engineoils meeting any of the followingduring the first 100 hours ofoperation of a new or rebuilt engine:

API CI-4 PLUS API CFAPI CI-4 ACEA E7API CH-4 ACEA E6API CG-4 ACEA E5API CF-4 ACEA E4API CF-2 ACEA E3

These oils will not allow the engineto break-in properly.

PLUS-50 is a trademark of Deere & Company.


PN=31


01002

4

DX,ENOIL 1923NOV051/1

Diesel Engine Oil

TS16

81UN

18D

EC03

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

John Deere PLUS-50 oil is preferred

Oils meeting one of the following specifications are alsorecommended:

ACEA Oil Sequence E7 ACEA Oil Sequence E6 ACEA Oil Sequence E5 ACEA Oil Sequence E4

Extended service intervals may apply when John DeerePLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4engine oils are used. Consult your John Deere dealer formore information.

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

John Deere TORQ-GARD SUPREME API Service Category CI-4 PLUS API Service Category CI-4 API Service Category CH-4 API Service Category CG-4 API Service Category CF-4 ACEA Oil Sequence E3 ACEA Oil Sequence E2

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

Multi-viscosity diesel engine oils are preferred.

Diesel fuel quality and fuel sulfur content must complywith all existing emissions regulations for the area inwhich the engine operates. If diesel fuel with sulfurcontent greater than 0.50% (5000 ppm) is used, reducethe service interval by 50%. DO NOT use diesel fuel withsulfur content greater than 1.00% (10 000 ppm).

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


PN=32


010025

DX,ENOIL6 1919DEC051/1

Extended Diesel Engine Oil Service Intervals

When John Deere PLUS-50 , ACEA E7, ACEA E6,ACEA E5, or ACEA E4 oils are used with specifiedJohn Deere filter, the service interval for engine oil andfilter changes may be increased by 50% but not toexceed a maximum of 500 hours.

If John Deere PLUS-50, ACEA E7, ACEA E6, ACEAE5, or ACEA E4 oils are used with other than thespecified John Deere filter, change the engine oil andfilter at the normal service interval.

If John Deere TORQ-GARD SUPREME , API CI-4PLUS, API CI-4, API CH-4, or ACEA E3 oils are used,change the engine oil and filter at the normal serviceinterval.

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

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

DX,ALTER 1915JUN001/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may requirelubricant recommendations different from those printed inthis manual.

Some John Deere brand coolants and lubricants may notbe available in your location.

Consult your John Deere dealer to obtain information andrecommendations.

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

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

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


PN=33


01002

6

DX,LUBMIX 1918MAR961/1

Mixing of Lubricants

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

Mixing different oils can interfere with the properfunctioning of these additives and degrade lubricantperformance.

Consult your John Deere dealer to obtain specificinformation and recommendations.

DPSG,OUOD002,1824 1902AUG001/1

OILSCAN and CoolScan

T682

8AB

UN

15J

UN89

T682

9AB

UN

18O

CT88

OILSCAN and CoolScan are John Deere samplingprograms to help you monitor machine performance andidentify potential problems before they cause seriousdamage.

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

Check with your John Deere dealer for the availability ofOILSCAN and CoolScan kits.

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


PN=34


010027

DX,GREA1 1907NOV031/1

Grease

TS16

73UN

31O

CT03

Use grease based on NLGI consistency numbers and theexpected 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 arenot compatible with others. Consultyour grease supplier before mixingdifferent types of grease

GREASE-GARD is a trademark of Deere & Company


PN=35


01002

8

DX,COOL3 1927OCT051/2

Diesel Engine Coolant

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

John Deere COOL-GARD Prediluted Coolant ispreferred for service.

John Deere COOL-GARD Prediluted Coolant isavailable in a concentration of either 50% ethyleneglycol or 55% propylene glycol.

Additional recommended coolants

The following engine coolant is also recommended:

John Deere COOL-GARD Coolant Concentrate in a40% to 60% mixture of concentrate with qualitywater.

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

Other fully formulated coolants

Other fully formulated low silicate ethylene orpropylene glycol base coolants for heavy-duty enginesmay be used if they meet one of the followingspecifications:

ASTM D6210 prediluted (50%) coolant ASTM D6210 coolant concentrate in a 40% to 60%

mixture of concentrate with quality water

Coolants meeting ASTM D6210 do not require use ofsupplemental coolant additives, except for periodicreplenishment of additives during the drain interval.

Coolants requiring supplemental coolant additives

Other low silicate ethylene glycol base coolants forheavy-duty engines may also be used if they meet oneof the following specifications:

ASTM D4985 ethylene glycol base prediluted (50%)coolant

ASTM D4985 ethylene glycol base coolantconcentrate in a 40% to 60% mixture of concentratewith quality water

Coolants meeting ASTM D4985 require an initialcharge of supplemental coolant additives, formulatedfor protection of heavy duty diesel engines againstcorrosion and cylinder liner erosion and pitting. Theyalso require periodic replenishment of additives duringthe drain interval.

Other coolants

It is possible that neither John Deere COOL-GARD norcoolants meeting one of the coolant standards listedabove is available in the geographical area whereservice is performed. If these coolants are unavailable,use a coolant concentrate or prediluted coolant with aquality additive package that provides cylinder linercavitation protection and protects the cooling systemmetals (cast iron, aluminum alloys, and copper alloyssuch as brass) from corrosion.

The additive package must be part of one of thefollowing coolant mixtures:

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

ethylene glycol or propylene glycol base coolantconcentrate in a 40% to 60% mixture of concentratewith quality water

Water quality

COOL-GARD is a trademark of Deere & Company


PN=36



010029

DX,COOL3 1927OCT052/2

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycoland propylene glycol base engine coolant concentrate.

IMPORTANT: Do not use cooling system sealingadditives or antifreeze that containssealing additives.

IMPORTANT: Do not mix ethylene glycol andpropylene glycol base coolants.


PN=37


01002

10

DPSG,OUOD002,1835 1903AUG001/2

Diesel Engine Coolants, Supplemental Additive Information

Engine coolants are a combination of three chemicalcomponents: ethylene glycol (antifreeze), inhibitingcoolant additives, and quality water.

Coolant Specifications

Some products, including John Deere COOL-GARDPrediluted Coolant, are fully formulated coolants thatcontain all three components in their correctconcentrations. Do not add an initial charge ofsupplemental coolant additives to these fullyformulated products.

Some coolant concentrates, including John DeereCOOL-GARD Coolant Concentrate, contain bothethylene glycol antifreeze and inhibiting coolantadditives. Mix these products and quality water, but donot add an initial charge of supplemental coolantadditives.

Coolants meeting ASTM D5345 (prediluted coolant) orASTM D4985 (coolant concentrate) require an initialcharge of supplemental coolant additives.

Replenish Coolant Additives

The concentration of coolant additives is graduallydepleted during engine operation. Periodicreplenishment of inhibitors is required, even whenJohn Deere COOL-GARD is used. Follow therecommendations in this manual for the use ofsupplemental coolant additives.

Why Use Supplemental Coolant Additives?

Operating without proper coolant additives will result inincreased corrosion, cylinder liner erosion and pitting,and other damage to the engine and cooling system. Asimple mixture of ethylene glycol and water will notgive adequate protection.

Use of supplemental coolant additives reducescorrosion, erosion, and pitting. These chemicalsreduce the number of vapor bubbles in the coolant andhelp form a protective film on cylinder liner surfaces.

This film acts as a barrier against the harmful effectsof collapsing vapor bubbles.

Avoid Automotive-Type Coolants

Never use automotive-type coolants (such as thosemeeting ASTM D3306 or ASTM D4656). Thesecoolants do not contain the correct additives to protectheavy-duty diesel engines. They often contain a highconcentration of silicates and may damage the engineor cooling system.

Non-Aqueous Propylene Glycol

Non-aqueous propylene glycol should not be used withJohn Deere diesel engines. This coolant works bestwith coolant temperatures above the acceptableengine operating range. This could decrease enginelife due to lower engine oil viscosity. In addition,electronically controlled engines could experiencepremature power de-rate due to high coolanttemperature.

Water Quality

Water quality is important to the performance of thecooling system. Distilled, deionized, or demineralizedwater is recommended for mixing with ethylene glycolbase engine coolant concentrate. All water used in thecooling system should meet the following minimumspecifications for quality:

Chlorides 40 mg/L or lessSulfates 100 mg/L or lessTotal Dissolved Solids 340 mg/L or lessTotal Hardness 170 mg/L or lesspH Level 5.5 to 9.0

Freeze Protection

The relative concentrations of ethylene glycol andwater in the engine coolant determine its freezeprotection limit. Refer to the chart on the followingpage.


PN=38



0100211

DPSG,OUOD002,1835 1903AUG002/2

Ethylene Glycol Freeze Protection Limit40% -24 C (-12 F)50% -37 C (-34 F)60% -52 C (-62 F)

DO NOT use a coolant-water mixture greater than60% ethylene glycol.

DPSG,OUOD002,1825 1902AUG001/1

Testing Diesel Engine Coolant

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

Test the coolant solution at intervals of 12 months or lessand whenever excessive coolant is lost through leaks oroverheating.

Coolant Test Strips

Coolant test strips are available from your John Deeredealer. These test strips provide a simple, effectivemethod to check the freeze point and additive levels ofyour engine coolant.

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

CoolScan

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


PN=39


01002

12

RG,01,DT7035 1914NOV001/2

Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes

RG

6261

UN

08D

EC97

RG

6262

UN

05D

EC97

IMPORTANT: Do not add supplemental coolantadditives when the cooling system isdrained and refilled with John DeereANTIFREEZE/SUMMER COOLANT orJohn Deere COOL-GARD .

NOTE: If a system is to be filled with coolant that doesnot contain SCAs, the coolant must beprecharged. Determine the total systemcapacity and premix with 3% John DeereCoolant Conditioner.

Through time and use, the concentration of coolantadditives is gradually depleted during engine operation.Periodic replenishment of inhibitors is required, evenwhen John Deere ANTIFREEZE/SUMMER COOLANTis used. The cooling system must be recharged withadditional supplemental coolant additives available inthe form of liquid coolant conditioner.

Maintaining the correct coolant conditionerconcentration (SCAs) and freeze point is essential inyour cooling system to protect against rust, liner pittingand corrosion, and freeze-ups due to incorrect coolantdilution.

John Deere LIQUID COOLANT CONDITIONER isrecommended as a supplemental coolant additivein John Deere engines.

DO NOT mix one brand of SCA with a differentbrand.

Test the coolant solution at 600 hours or 12 months ofoperation using either John Deere coolant test strips ora COOLSCAN analysis. If a COOLSCAN analysis isnot available, recharge system per instructions printedon label of John Deere Liquid Coolant Conditioner.

COOL-GARD is a registered trademark of Deere & CompanyCOOLSCAN is a registered trademark of Deere & Company. Continued on next page


PN=40


0100213

RG,01,DT7035 1914NOV002/2

IMPORTANT: ALWAYS maintain coolant at correctlevel and concentration. DO NOToperate engine without coolant foreven a few minutes.

If frequent coolant makeup isrequired, the glycol concentrationshould be checked with JT07298Coolant/Battery Tester to ensure thatthe desired freeze point ismaintained. Follow manufacturersinstructions provided withCoolant/Battery Tester.

Add the manufacturers recommended concentration ofsupplemental coolant additive. DO NOT add more thanthe recommended amount.

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

If other coolants are used, consult the coolant supplierand follow the manufacturers recommendation for useof supplemental coolant additives.

See DIESEL ENGINE COOLANTS, SUPPLEMENTALADDITIVE INFORMATION earlier in this group forproper mixing of coolant ingredients before adding tothe cooling system.

DX,COOL6 1918MAR961/1

Operating in Warm Temperature Climates

John Deere engines are designed to operate using glycolbase engine coolants.

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

IMPORTANT: Water may be used as coolant inemergency situations only.

Foaming, hot surface aluminum andiron corrosion, scaling, and cavitationwill occur when water is used as thecoolant, even when coolantconditioners are added.

Drain cooling system and refill withrecommended glycol base enginecoolant as soon as possible.


PN=41


01002

14

RG,01,DT7033 1929OCT971/2

Flush and Service Cooling System

TS28

1UN

23A

UG88

CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns. Shut off engine. Only remove filler capwhen cool enough to touch with bare hands.Slowly loosen cap to first stop to relievepressure before removing cap completely.

IMPORTANT: Air must be expelled from coolingsystem when system is refilled. SeeCHECKING COOLING SYSTEM inoperators manual.

The ethylene glycol base (antifreeze) can becomedepleted of SCAs allowing various acids to form that willdamage engine components. In addition, heavy metals,such as lead, copper and zinc, accumulate in the ethyleneglycol base. The heavy metals come from corrosion thatoccurs to some degree with in a cooling system. When acoolant is saturated to the point where it can no longerhold heavy metals and other dissolved solids, they settleout and act as abrasives on engine parts.

NOTE: Refer to your operators manual for a specificservice interval. See LUBRICATION ANDMAINTENANCE SERVICE INTERVAL CHART inoperators manual.

Flush cooling system as described in your operatorsmanual. See FLUSHING COOLING SYSTEM inoperators manual. Clean cooling system with clean waterand TY15979 John Deere Heavy-Duty Cooling SystemCleaner or an equivalent cleaner such as FLEETGUARD RESTORE or RESTORE PLUS . Follow the instructionsprovided with the cleaner. Refill cooling system with theappropriate coolant solution. See DIESEL ENGINECOOLANT, earlier in this group.

FLEETGUARD is a registered trademark of the Cummins EngineCompany.RESTORE is a trademark of FLEETGUARD.RESTORE PLUS is a trademark of FLEETGUARD.


PN=42



0100215

RG,01,DT7033 1929OCT972/2

IMPORTANT: NEVER overfill the system. Apressurized system needs space forheat expansion without overflowing atthe top of the radiator. Coolant levelshould be at bottom of radiator fillerneck.

Air must be expelled from coolingsystem when system is refilled. Loosenplug in side of thermostat housing toallow air to escape when filling system.Retighten plug when all the air hasbeen expelled.

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

Contact your engine servicing dealer, if there are furtherquestions.

RG,01,DT7032 1929OCT971/1

Disposing of Coolant

TS11

33UN

26N

OV9

0

Improperly disposing of engine coolant can threaten theenvironment and ecology.

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

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

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


PN=43


01002

16


PN=44

Section 02Repair and AdjustmentsContents 02

Page Page

Group 010Engine Rebuild Inspect Valve Spring Caps, Wear Caps, andEngine Overhaul Guidelines . . . . . . . . . . . . . .02-010-1 Retainer Locks Serial NumberEngine Repair Stand . . . . . . . . . . . . . . . . . . . .02-010-1 ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-17Safety Precautions . . . . . . . . . . . . . . . . . . . . .02-010-2 Clean Valves Serial Number ( 199,999). . .02-020-17Install Adapters on Engine Repair Stand. . . . .02-010-2 Inspect and Measure Valves Serial NumberEngine Lifting Procedure . . . . . . . . . . . . . . . . .02-010-3 ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-18Clean Engine . . . . . . . . . . . . . . . . . . . . . . . . .02-010-4 Grind (Reface) Valves Serial NumberDisconnect Turbocharger Oil Inlet Line . . . . . .02-010-5 ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-19Mount Engine on Repair Stand . . . . . . . . . . . .02-010-6 Inspect and Clean Cylinder Head SerialEngine Disassembly Sequence for Number ( 199,999) . . . . . . . . . . . . . . . . .02-020-19

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . .02-010-8 Check Cylinder Head Combustion FaceSealant Application Guidelines . . . . . . . . . . . .02-010-9 Flatness Serial Number ( 199,999). . . . .02-020-206081 Engine Assembly Sequence After Measure Cylinder Head Thickness SerialOverhaul . . . . . . . . . . . . . . . . . . . . . . . . . .02-010-11 Number ( 199,999) . . . . . . . . . . . . . . . . .02-020-21Engine Break-In Guidelines. . . . . . . . . . . . . .02-010-13 Clean Valve Guides Serial NumberPerform Engine Break-In . . . . . . . . . . . . . . . .02-010-14 ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-22Check Crankcase Ventilation System . . . . . .02-010-16 Measure Valve Guides Serial NumberCheck Air Intake System. . . . . . . . . . . . . . . .02-010-16 ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-22Check Exhaust System . . . . . . . . . . . . . . . . .02-010-17 Knurl Valve Guides Serial NumberCheck and Service Cooling System . . . . . . .02-010-17 ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-23Check Electrical System . . . . . . . . . . . . . . . .02-010-19 Clean and Inspect Valve Seats SerialGeneral Tune-Up Recommendations . . . . . .02-010-21

Number ( 199,999) . . . . . . . . . . . . . . . . .02-020-23Measure Valve Sears Serial NumberGroup 020Cylinder Head and Valves Repair and ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-24Adjustment S. N. ( 199,999) Grind Valve Seats Serial NumberCheck and Adjust Valve Clearance Serial ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-25Number ( 199,999) . . . . . . . . . . . . . . . . . .02-020-1 Remove Valve Seat Inserts Serial NumberCheck Valve Lift Serial Number ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-26( 199,999) . . . . . . . . . . . . . . . . . . . . . . . .02-020-5 Install Valve Seat Inserts Serial NumberRemove Cylinder Head Serial Number ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-27( 199,999) . . . . . . . . . . . . . . . . . . . . . . . .02-020-6Inspect and Clean Cylinder Head NozzleHead Gasket Inspection and Repair

Bore Serial Number ( 199,999). . . . . . . .02-020-27Sequence Serial Number ( 199,999) . . . .02-020-9Clean and Inspect Push Rods Serial NumberDisassemble and Inspect Rocker Arm Shaft ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-29Assembly Serial NumberInspect and Clean Ventilator Outlet Hose( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-11

Serial Number ( 199,999) . . . . . . . . . . . .02-020-29Assemble Rocker Arm Shaft AssemblyClean and Inspect Top Deck of CylinderSerial Number ( 199,999) . . . . . . . . . . . .02-020-12

Block Serial Number ( 199,999) . . . . . . .02-020-30Measure Valve Recess Serial NumberMeasure Cylinder Liner Standout (Height( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-13

Above Block) Serial NumberPreliminary Cylinder Head and Valve( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-31Checks Serial Number ( 199,999) . . . . .02-020-14

Assemble Valve Assembly Serial NumberRemove Valve Assembly Serial Number( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-15 ( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-32

Inspect and Measure Valve Springs SerialNumber ( 199,999) . . . . . . . . . . . . . . . . .02-020-16 Continued on next page


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Install Cylinder Head and Cap Screws Inspect and Measure Valves - Serial NumberSerial Number ( 199,999) . . . . . . . . . . . .02-020-33 (200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-21

Torque-to-Yield Flanged-Head Cap Screws Grind (Reface) Valves - Serial NumberGrade 180 Marked SPECIAL Serial (200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-22Number ( 199,999) . . . . . . . . . . . . . . . . .02-020-35 Inspect and Clean Cylinder Head - Serial

Install Rocker Arm Assembly Serial Number Number (200,000 ) . . . . . . . . . . . . . . . . .02-021-23

02

( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-36 Check Cylinder Head Combustion FaceInspect and Clean Ventilator Outlet Hose Flatness - Serial Number (200,000 ). . . .02-021-24

Serial Number ( 199,999) . . . . . . . . . . . .02-020-37 Measure Cylinder Head Thickness - SerialComplete Final Assembly of Injection Pump Number (200,000 ) . . . . . . . . . . . . . . . . .02-021-25

Side of Engine Serial Number Clean Valve Guides - Serial Number( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-38 (200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-26

Complete Final Assembly on Exhaust Measure Valve Guides - Serial NumberManifold Side of Engine Serial Number (200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-26( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-39 Knurl Valve Guides - Serial Number

Perform Engine Break-In Serial Number (200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-27( 199,999) . . . . . . . . . . . . . . . . . . . . . . .02-020-40 Clean and Inspect Valve Seats - Serial

Number (200,000 ) . . . . . . . . . . . . . . . . .02-021-27Measure Valve Seats - Serial NumberGroup 021Cylinder Head and Valves Repair and

(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-28Adjustment S. N. (200,000 )Grind Valve Seats - Serial NumberCheck Valve Clearance Serial Number

(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-29(200,000 ) . . . . . . . . . . . . . . . . . . . . . . . .02-021-1Remove Valve Seat Inserts and MeasureAdjust Valve Clearance Serial Number

Bores in Cylinder Head - Serial Number (200,000(200,000 ) . . . . . . . . . . . . . . . . . . . . . . . .02-021-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-021-30Check Valve Lift Serial Number

Install Valve Seat Inserts - Serial Number(200,000 ) . . . . . . . . . . . . . . . . . . . . . . . .02-021-8(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-31Remove Cylinder Head Serial Number

Inspect and Clean Cylinder Head Nozzle(200,000 ) . . . . . . . . . . . . . . . . . . . . . . . .02-021-9Bore - Serial Number (200,000 ) . . . . . .02-021-31Diagnosing Head Gasket Joint Failures -

Clean and Inspect Push Rods - SerialSerial Number (200,000 ) . . . . . . . . . . . .02-021-11Number (200,000 ) . . . . . . . . . . . . . . . . .02-021-32Head Gasket Diagnostic Charts - Serial

Clean and Inspect Top Deck of CylinderNumber (200,000 ) . . . . . . . . . . . . . . . . .02-021-13Block - Serial Number (200,000 ) . . . . . .02-021-32Head Gasket Inspection and Repair

Measure Cylinder Liner Standout (HeightSequence - Serial Number (200,000Above Block) Serial Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-021-14(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-33Inspect Rocker Arm Assembly - Serial

Assemble Valve Assembly - Serial NumberNumber (200,000 ) . . . . . . . . . . . . . . . . .02-021-16(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-34Disassemble and Assemble Rocker Arm

Install Cylinder Head and Cap Screws -Assembly - Serial Number (200,000 ). . .02-021-17Serial Number (200,000 ) . . . . . . . . . . . .02-021-36Measure Valve Recess - Serial Number

Torque-to-Yield Flanged-Head Cap Screws(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-17Grade 180 Marked SPECIAL - SerialPreliminary Cylinder Head and ValveNumber (200,000 ) . . . . . . . . . . . . . . . . .02-021-38Checks - Serial Number (200,000 ) . . . .02-021-18

Install Rocker Arm Assembly - Serial NumberRemove Valve Assembly - Serial Number(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-40(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-19

Inspect and Measure Valve Springs - Inspect and Clean Ventilator Outlet Hose -Serial Number (200,000 ) . . . . . . . . . . . .02-021-20 Serial Number (200,000 ) . . . . . . . . . . . .02-021-41

Inspect Valve Spring Caps, Wear Caps, and Complete Final Assembly of Fuel Pump SideRetainer Locks Serial Number of Engine Serial Number(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-20 (200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-41

Clean Valves - Serial Number (200,000Continued on next page) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-021-21


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Complete Final Assembly on Exhaust Check Engine Rotation for ExcessiveTightness. . . . . . . . . . . . . . . . . . . . . . . . . .02-030-44Manifold Side of Engine - Serial Number (200,000

Complete Final Assembly . . . . . . . . . . . . . . .02-030-45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-021-42 02Perform Engine Break-In - Serial Number

Group 040Crankshaft, Main Bearings and(200,000 ) . . . . . . . . . . . . . . . . . . . . . . .02-021-43Flywheel Repair and Adjustment

Crankshaft and Main Bearing FailureGroup 030Cylinder Block, Liners, Pistons, and Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-1Rods Repair and Adjustment Crankshaft Rear Oil Seal and Wear SleevePreliminary Liner, Piston, and Rod Checks . . .02-030-1 General Information . . . . . . . . . . . . . . . . . . .02-040-2Connecting RodsGeneral Information . . . . .02-030-2 Remove Crankshaft Rear Oil Seal and WearRemove Pistons and Connecting Rod Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-3

Assemblies . . . . . . . . . . . . . . . . . . . . . . . . .02-030-3 Crankshaft Rear Oil Seal and Wear SleeveMeasure Cylinder Liner Standout (Height Handling Precautions. . . . . . . . . . . . . . . . . .02-040-5

Above Block) . . . . . . . . . . . . . . . . . . . . . . . .02-030-7 Install Crankshaft Rear Oil Seal and WearRemove Cylinder Liners . . . . . . . . . . . . . . . . .02-030-8 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-6Deglaze Cylinder Liners . . . . . . . . . . . . . . . . .02-030-9 Inspect Vibration Damper . . . . . . . . . . . . . . . .02-040-8Clean Cylinder Liners . . . . . . . . . . . . . . . . . .02-030-10 Check Crankshaft End Play . . . . . . . . . . . . . .02-040-9Disassemble Piston and Rod Assembly . . . .02-030-11 Remove Crankshaft Vibration Damper . . . . .02-040-10Clean Pistons . . . . . . . . . . . . . . . . . . . . . . . .02-030-12 Remove Crankshaft Front Oil Seal and WearVisually Inspect Pistons. . . . . . . . . . . . . . . . .02-030-13 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-11Check Piston Ring Groove Wear. . . . . . . . . .02-030-14 Remove and Install Timing GearInspect Piston Pin and Bore . . . . . . . . . . . . .02-030-15 CoverEngine Installed in Vehicle (8000 Series

Tractors) . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-13Visually Inspect Cylinder Liners. . . . . . . . . . .02-030-16Remove Timing Gear CoverEngineCylinder Liner Manufacturing Date Code

Removed . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-14Explanation . . . . . . . . . . . . . . . . . . . . . . . .02-030-18Inspect and Measure Flywheel . . . . . . . . . . .02-040-15Determine Piston-to-Liner Clearance. . . . . . .02-030-19Check Flywheel Housing Face Runout . . . . .02-040-15Inspect Rod and Cap . . . . . . . . . . . . . . . . . .02-030-21Check Flywheel Face Flatness . . . . . . . . . . .02-040-16Inspect Piston Pins and Bushings . . . . . . . . .02-030-23Check Pilot Bearing Bore Concentricity . . . . .02-040-16Remove Piston Pin Bushing, Clean andRemove Flywheel . . . . . . . . . . . . . . . . . . . . .02-040-17Inspect Pin Bore . . . . . . . . . . . . . . . . . . . .02-030-25Remove SAE 1 Flywheel Housing. . . . . . . . .02-040-17Measure Liner Flange . . . . . . . . . . . . . . . . . .02-030-26Remove SAE 2 and 3 Flywheel Housing. . . .02-040-18Inspect and Measure Connecting RodReplace Flywheel Ring Gear. . . . . . . . . . . . .02-040-18Bearings . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-27Remove and Install Rear Oil SealInstall Piston Pin Bushing in Connecting

HousingEngine Installed in Vehicle (8000 SeriesRod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-29Tractors) . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-19Complete Disassembly of Cylinder Block (If Remove Rear Oil Seal HousingEngineRequired). . . . . . . . . . . . . . . . . . . . . . . . . .02-030-30 Removed . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-20Remove and Clean Piston Cooling Remove Main Bearing Caps . . . . . . . . . . . . .02-040-21Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-30 Check Main Bearing Oil Clearance . . . . . . . .02-040-23Inspect and Clean Cylinder Block . . . . . . . . .02-030-31 Remove Connecting Rod Caps and Remove

Measure Cylinder Block . . . . . . . . . . . . . . . .02-030-33 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . .02-040-24Install Piston Cooling Orifices and Gallery Inspect Crankshaft . . . . . . . . . . . . . . . . . . . .02-040-25

Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-34 Measure Assembled I.D. of Bearings andRecheck Cylinder Liner Standout . . . . . . . . .02-030-34 O.D. of Crankshaft Journals. . . . . . . . . . . .02-040-26Install Liner ShimsIf Required . . . . . . . . . .02-030-35 Main Bearing Cap Line BoreInstall Packing on Cylinder Liner and O-Rings Specifications. . . . . . . . . . . . . . . . . . . . . . .02-040-28

in Block . . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-36 Thrust Bearing New Part Specifications . . . .02-040-29Install Cylinder Liner in Block . . . . . . . . . . . .02-030-37 Crankshaft Grinding Guidelines. . . . . . . . . . .02-040-30Install Piston and Connecting Rod. . . . . . . . .02-030-38 Crankshaft Grinding Specifications . . . . . . . .02-040-32Torque-Turn Connecting Rod Cap

Continued on next pageScrews. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-43


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Replace (Crankshaft) Oil Pump Drive Oil Filter Base and Oil PressureGear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-33 Regulating Valve Housing Assembly . . . . . .02-060-2

Replace Crankshaft Gear . . . . . . . . . . . . . . .02-040-34 Top-Load Oil Filter Assembly . . . . . . . . . . . . .02-060-3Inspect Thrust Bearings . . . . . . . . . . . . . . . .02-040-35 Remote Oil Filter Assembly . . . . . . . . . . . . . . .02-060-5Remove and Clean Piston Cooling Changing Top-Load Oil Filter . . . . . . . . . . . . .02-060-6

Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-35 Remove and Install Oil Filter Base and Oil

02

Install Main Bearings and Crankshaft . . . . . .02-040-36 Pressure Regulating Valve Housing. . . . . . .02-060-7Install Crankshaft Rear Oil Seal Housing. . . .02-040-39 Engine Oil Cooler Assembly . . . . . . . . . . . . . .02-060-9Check Crankshaft Rear Oil Seal Housing Remove, Inspect, and Install Engine Oil

Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-41 Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-060-10Crankshaft Rear Oil Seal and Wear Sleeve Remove, Inspect, and Install Oil Pressure

Handling Precautions. . . . . . . . . . . . . . . . .02-040-42 Regulating Valve, Oil Filter BypassInstall Crankshaft Rear Oil Seal and Wear Valve, and Oil Cooler Bypass Valve . . . . .02-060-12Sleeve Assembly . . . . . . . . . . . . . . . . . . . .02-040-43 Remove Engine from 8000 Tractors forInstall Timing Gear Cover . . . . . . . . . . . . . . .02-040-45 Access to Engine Oil Pump . . . . . . . . . . . .02-060-13Install Front Wear Sleeve . . . . . . . . . . . . . . .02-040-46 Remove Oil Pan . . . . . . . . . . . . . . . . . . . . . .02-060-13Install Crankshaft Front Oil Seal . . . . . . . . . .02-040-47 Check Crankshaft Gear-to-Oil Pump DriveInstall Vibration Damper . . . . . . . . . . . . . . . .02-040-48 Gear Backlash . . . . . . . . . . . . . . . . . . . . . .02-060-14Install SAE 2 and 3 Flywheel Housing. . . . . .02-040-49

Remove Engine Oil Pump . . . . . . . . . . . . . . .02-060-14Install Flywheel & Flex Plates - OptionInspect and Clean Oil Pump . . . . . . . . . . . . .02-060-15Code 1502. . . . . . . . . . . . . . . . . . . . . . . . .02-040-51Check Drive Shaft End Play . . . . . . . . . . . . .02-060-16Install Flywheel . . . . . . . . . . . . . . . . . . . . . . .02-040-53Check Drive Shaft Side Movement . . . . . . . .02-060-16Install SAE 1 Flywheel Housing. . . . . . . . . . .02-040-54Check Pumping Gear Backlash. . . . . . . . . . .02-060-17Complete Final Assembly . . . . . . . . . . . . . . .02-040-54Inspect Oil Pump Drive Gear. . . . . . . . . . . . .02-060-17

Group 050Camshaft and Timing Gear Train Adjust Oil Pump Set Screw . . . . . . . . . . . . . .02-060-18Repair and Adjustment Install Engine Oil Pump. . . . . . . . . . . . . . . . .02-060-18

Check Camshaft End Play and Measure Gear Remove and Install Oil Pump Outlet TubeBacklash . . . . . . . . . . . . . . . . . . . . . . . . . . .02-050-1 and Oil Cooler Crossover Tube

Remove Vibration Damper and Timing Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . .02-060-20Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . .02-050-2 Remove, Inspect, and Install Oil PumpRemove, Inspect, and Install Crankshaft Pickup Tube . . . . . . . . . . . . . . . . . . . . . . .02-060-21Gear-Driven Auxiliary DriveIf Equipped . .02-050-3 Install Engine Oil Pan . . . . . . . . . . . . . . . . . .02-060-22Remove Camshaft. . . . . . . . . . . . . . . . . . . . . .02-050-8 Tighten Cap Screws on Front Frame/OilRemove Camshaft Gears . . . . . . . . . . . . . . .02-050-10 Sump (8000 Series Tractors) . . . . . . . . . . .02-060-24Measure Thrust Washer Thickness . . . . . . . .02-050-11Inspect and Measure Camshaft Followers. . .02-050-11

Group 070Cooling System Repair andVisually Inspect Camshaft . . . . . . . . . . . . . . .02-050-12Me

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