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John Deere 4.5L and 6.8L Diesel Engines (Base Engine) Component Technical Manual CTM104 – PDF DOWNLOAD
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John Deere 4.5L and 6.8L Diesel Engines (Base Engine) Component Technical Manual CTM104 – PDF DOWNLOAD
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Description
John Deere 4.5L and 6.8L Diesel Engines (Base Engine) Component Technical Manual CTM104 – PDF DOWNLOAD
FILE DETAILS:
John Deere 4.5L and 6.8L Diesel Engines (Base Engine) Component Technical Manual CTM104 – PDF DOWNLOAD
Language : English
Pages : 946
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 4.5L and 6.8L Diesel Engines (Base Engine) Component Technical Manual CTM104 – PDF DOWNLOAD
- 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 covers the base engine for PowerTech 4.5L and 6.8L engines including PowerTech “Plus”, PowerTech “E”, and PowerTech “M” engine models. It is one of eight volumes on 4.5L and 6.8L engines. The following seven companion manuals cover fuel system and electronics repair, operation, and diagnostics:
• CTM207 — Mechanical Fuel System
• CTM284 — Level 1 Electronic Fuel System
• CTM170 — Level 4 Electronic Fuel System
• CTM220 — Level 11 Electronic Fuel System
• CTM331 — Level 12 Electronic Fuel System
• CTM320 — Level 14 Electronic Fuel System
• CTM502 — Level 16 Electronic Fuel System - Other manuals will be added in the future to provide additional information on electronic fuel systems as needed.
Information in this manual is organized in sections and sub divided into groups. - Section 01 covers the safety measures to follow while repairing the engine; engine identification features, engine emission and application details, and information about the fuels, lubricants, and coolants.
- Section 02a covers the repair and adjustment procedures for 4.5L engines.
- Section 02b covers the repair and adjustment procedures for 6.8L engines.
- Section 03 explains the theory of operation of each system.
- Section 04 is the diagnostics section that provides troubleshooting procedures to find problems.
- Section 05 covers other materials needed to do the job.
- Section 06 summarizes all specifications, wear tolerances, and torque values.
TABLE OF CONTENTS:
John Deere 4.5L and 6.8L Diesel Engines (Base Engine) Component Technical Manual CTM104 – PDF DOWNLOAD
Contents................................................................................................................................... 15 General Information.................................................................................................................... 17 Safety............................................................................................................................. 19 Understand Signal Words........................................................................................................ 19 Recognize Safety Information................................................................................................... 19 Replace Safety Signs........................................................................................................... 19 Follow Safety Instructions..................................................................................................... 20 Park Machine Safely............................................................................................................ 20 Support Machine Properly....................................................................................................... 20 Use Proper Lifting Equipment................................................................................................... 21 Prevent Machine Runaway........................................................................................................ 21 Construct Dealer-Made Tools Safely............................................................................................. 21 Illuminate Work Area Safely.................................................................................................... 22 Work in Clean Area............................................................................................................. 22 Use Proper Tools............................................................................................................... 22 Install All Guards............................................................................................................. 23 Service Machines Safely........................................................................................................ 23 Practice Safe Maintenance...................................................................................................... 24 Handle Fuel Safely—Avoid Fires................................................................................................. 24 Prepare for Emergencies........................................................................................................ 25 Handle Starting Fluid Safely................................................................................................... 25 In Case of Fire................................................................................................................ 25 Handle Fluids Safely—Avoid Fires............................................................................................... 26 Avoid Static Electricity Risk When Refueling................................................................................... 26 Protect Against Noise.......................................................................................................... 26 Protect Against High Pressure Spray............................................................................................ 27 Stay Clear of Rotating Drivelines.............................................................................................. 27 Avoid High-Pressure Fluids..................................................................................................... 27 Remove Paint Before Welding or Heating......................................................................................... 28 Avoid Heating Near Pressurized Fluid Lines..................................................................................... 28 Decommissioning — Proper Recycling and Disposal of Fluids and Components....................................................... 29 Wear Protective Clothing....................................................................................................... 29 Handling Batteries Safely...................................................................................................... 30 Prevent Acid Burns............................................................................................................. 31 Wait Before Opening High-Pressure Fuel System.................................................................................. 31 Prevent Battery Explosions..................................................................................................... 32 Avoid Hot Exhaust.............................................................................................................. 32 Work In Ventilated Area........................................................................................................ 32 Service Cooling System Safely.................................................................................................. 33 Service Cooling System Safely.................................................................................................. 33 Precautions for Welding........................................................................................................ 34 Live With Safety............................................................................................................... 34 Engine Identification.............................................................................................................. 35 Engine Serial Number Plate Information......................................................................................... 35 OEM Engine Option Code Label................................................................................................... 37 Information Relative to Emissions Regulations.................................................................................. 38 Emissions Control System Certification Label................................................................................... 39 Fuels, Lubricants, and Coolant..................................................................................................... 41 Storing Fuel................................................................................................................... 41 Diesel Fuel.................................................................................................................... 41 Lubricity of Diesel Fuel....................................................................................................... 42 Handling and Storing Diesel Fuel............................................................................................... 42 Supplemental Diesel Fuel Additives............................................................................................. 42 BioDiesel Fuel................................................................................................................. 43 Testing Diesel Fuel............................................................................................................ 44 Minimizing the Effect of Cold Weather on Diesel Engines........................................................................ 45 Diesel Engine Coolant (engine with wet sleeve cylinder liners)................................................................. 46 Diesel Engine Coolant (engine without wet sleeve cylinder liners).............................................................. 47 Operating in Warm Temperature Climates......................................................................................... 47 Water Quality for Mixing with Coolant Concentrate.............................................................................. 48 Testing Coolant Freeze Point................................................................................................... 49 Engine Oil and Filter Service Intervals — Tier 3 and Stage IIIA — OEM Applications............................................. 50 Diesel Engine Oil — Tier 3 and Stage III....................................................................................... 51 Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III.... 52 Oil Filters.................................................................................................................... 52 Fuel Filters................................................................................................................... 52 Alternative and Synthetic Lubricants........................................................................................... 53 Lubricant Storage.............................................................................................................. 53 Mixing of Lubricants........................................................................................................... 53 Repair and Adjustments (4 Cylinder Engine)............................................................................................. 61 Engine Rebuild (4045).............................................................................................................. 63 Check Air Intake System (4045)................................................................................................. 63 Check and Service Cooling System (4045)........................................................................................ 63 Check Crankcase Vent System (4045)............................................................................................. 64 Check Electrical System (4045)................................................................................................. 65 Check Exhaust System (4045).................................................................................................... 65 Clean Engine (4045)............................................................................................................ 66 Engine Break-In Guidelines (4045).............................................................................................. 67 Engine Overhaul Guidelines (4045).............................................................................................. 68 General Tune-Up Recommendations (4045)......................................................................................... 68 Engine Repair Stand (4045)..................................................................................................... 69 Install JT07268 Engine Mounting Adapter to D05223ST Repair Stand (4045)........................................................ 69 Install JDG11853 Engine Mounting Adapter to D05223ST Repair Stand (4045)....................................................... 70 Lift Straps — Installation (4045).............................................................................................. 70 Lift Straps — Removal (4045)................................................................................................... 72 Lifting Procedure (4045)....................................................................................................... 73 Mount Engine to Repair Stand Using JT07268 (4045).............................................................................. 74 Mount Engine to Repair Stand Using JDG11853 (4045)............................................................................. 75 Safety Precautions (4045)...................................................................................................... 76 Sealant Application Guidelines (4045).......................................................................................... 76 Cylinder Head and Valve Repair and Adjustment (4045) (Two-Valve Head Engines)...................................................... 77 Cylinder Block Top Deck — Cleaning and Inspection (4045) (Two-Valve Head)...................................................... 77 Cylinder Head — Cleaning and Inspection (4045) (Two-Valve Head)................................................................ 78 Cylinder Head — Flatness Check (4045) (Two-Valve Head)......................................................................... 79 Cylinder Head — Installation (4045) (Two-Valve Head)........................................................................... 79 Cylinder Head — Removal (4045) (Two-Valve Head)................................................................................ 82 Cylinder Head — Thickness Measurement (4045) (Two-Valve Head).................................................................. 83 Cylinder Head Gasket — Inspection (4045) (Two-Valve Head)...................................................................... 84 Fuel Injector Heat Shield — Installation (4045) (Two-Valve Head)............................................................... 85 Fuel Injector Heat Shield — Removal (4045) (Two-Valve Head).................................................................... 85 Fuel Injector Sleeves — Installation (4045) (Two-Valve Head)................................................................... 86 Fuel Injector Sleeves — Removal (4045) (Two-Valve Head)........................................................................ 87 Fuel Supply Pump Push Rod — Installation (4045) (Two-Valve Head)............................................................... 89 Fuel Supply Pump Push Rod — Measurement (4045) (Two-Valve Head)................................................................ 90 Fuel Supply Pump Push Rod — Removal (4045) (Two-Valve Head).................................................................... 91 Push Rod — Cleaning and Inspection (4045) (Two-Valve Head)..................................................................... 91 Push Rod — Installation (4045) (Two-Valve Head)................................................................................ 92 Push Rod — Removal (4045) (Two-Valve Head)..................................................................................... 94 Rocker Arm Cover Baffle — Installation (4045) (Two-Valve Head)................................................................. 94 Rocker Arm Cover Baffle — Removal (4045) (Two-Valve Head)...................................................................... 95 Rocker Arm Cover — Installation (4045) (Two-Valve Head)........................................................................ 96 Rocker Arm Cover — Removal (4045) (Two-Valve Head)............................................................................. 98 Rocker Arm Shaft Assembly — Tear Down (4045) (Two-Valve Head).................................................................. 99 Rocker Arm Shaft Assembly — Inspection (4045) (Two-Valve Head).................................................................100 Rocker Arm Shaft Assembly — Assemble (4045) (Two-Valve Head)...................................................................101 Rocker Arm Shaft Assembly — Installation (4045) (Two-Valve Head)...............................................................102 Rocker Arm Shaft Assembly — Removal (4045) (Two-Valve Head)....................................................................103 Valve — Cleaning and Visual Inspection (4045) (Two-Valve Head).................................................................104 Valve — Clearance Adjustment (4045) (Two-Valve Head)...........................................................................105 Valve — Grinding (4045) (Two-Valve Head).......................................................................................107 Valve — Measurement (4045) (Two-Valve Head)....................................................................................108 Valve — Recess Measurement (4045) (Two-Valve Head).............................................................................109 Valve Assembly — Installation (4045) (Two-Valve Head)..........................................................................109 Valve Assembly — Removal (4045) (Two-Valve Head)...............................................................................111 Valve Guide — Cleaning (4045) (Two-Valve Head).................................................................................111 Valve Guide — Measurement (4045) (Two-Valve Head)..............................................................................112 Valve Guide — Knurling (4045) (Two-Valve Head).................................................................................112 Valve Keeper, Rocker Arm Insert, and Valve Rotator — Inspection (4045) (Two-Valve Head)........................................113 Valve Seat — Cleaning and Inspection (4045) (Two-Valve Head)...................................................................113 Valve Seat — Grinding and Measurement (4045) (Two-Valve Head)..................................................................114 Valve Seat Inserts — Installation (4045) (Two-Valve Head)......................................................................115 Valve Seat Inserts — Removal (4045) (Two-Valve Head)...........................................................................116 Valve Spring — Inspection and Measurement (4045) (Two-Valve Head)..............................................................118 Cylinder Head and Valve Repair and Adjustment (4045) (Four-Valve Head Engines).....................................................119 Cylinder Block Top Deck — Cleaning and Inspection (4045) (Four-Valve Head).....................................................119 Cylinder Head — Cleaning and Inspection (4045) (Four-Valve Head)...............................................................119 Cylinder Head — Flatness Check (4045) (Four-Valve Head)........................................................................120 Cylinder Head — Installation (4045) (Four-Valve Head)..........................................................................120 Cylinder Head — Removal (4045) (Four-Valve Head)...............................................................................124 Cylinder Head — Thickness Measurement (4045) (Four-Valve Head).................................................................125 Cylinder Head Gasket — Inspection (4045) (Four-Valve Head).....................................................................126 Fuel Leak-Off Line Heat Shield — Installation (4045) (Four-Valve Head).........................................................127 Fuel Leak-Off Line Heat Shield — Removal (4045) (Four-Valve Head)..............................................................127 Fuel Injector Sleeves — Installation (4045) (Four-Valve Head)..................................................................128 Fuel Injector Sleeves — Removal (4045) (Four-Valve Head).......................................................................129 Fuel Supply Pump Push Rod — Installation (4045) (Four-Valve Head)..............................................................131 Fuel Supply Pump Push Rod — Measurement (4045) (Four-Valve Head)...............................................................131 Fuel Supply Pump Push Rod — Removal (4045) (Four-Valve Head)...................................................................132 Push Rod — Cleaning and Inspection (4045) (Four-Valve Head)....................................................................133 Push Rod — Installation (4045) (Four-Valve Head)...............................................................................133 Push Rod — Removal (4045) (Four-Valve Head)....................................................................................135 Glow Plug — Installation (4045) (Four-Valve Head)..............................................................................136 Glow Plug — Removal (4045) (Four-Valve Head)...................................................................................136 Glow Plug Bore — Cleaning and Inspection (4045) (Four-Valve Head)..............................................................136 Rocker Arm Cover Baffle — Installation (4045) (Four-Valve Head)................................................................137 Rocker Arm Cover Baffle — Removal (4045) (Four-Valve Head).....................................................................137 Rocker Arm Cover — Installation (4045) (Four-Valve Head).......................................................................138 Rocker Arm Cover — Removal (4045) (Four-Valve Head)............................................................................139 Rocker Arm Shaft Assembly — Tear Down (4045) (Four-Valve Head).................................................................140 Rocker Arm Shaft Assembly — Inspection (4045) (Four-Valve Head)................................................................141 Rocker Arm Shaft Assembly — Assemble (4045) (Four-Valve Head)..................................................................142 Rocker Arm Shaft Assembly — Installation (4045) (Four-Valve Head)..............................................................144 Rocker Arm Shaft Assembly — Removal (4045) (Four-Valve Head)...................................................................146 Rocker Arm Shaft Carrier Assembly — Installation (External Fuel Leak-Off System) (4045) (Four-Valve Head)......................148 Rocker Arm Shaft Carrier Assembly — Installation (Internal Fuel Leak-Off System) (4045) (Four-Valve Head)......................150 Rocker Arm Shaft Carrier Assembly — Removal (4045) (Four-Valve Head)...........................................................153 Rocker Arm Shaft Carrier — Inspection (4045) (Four-Valve Head).................................................................155 Valve — Cleaning and Visual Inspection (4045) (Four-Valve Head)................................................................155 Valve — Clearance Adjustment (4045) (Four-Valve Head)..........................................................................156 Valve — Grinding (4045) (Four-Valve Head)......................................................................................158 Valve — Measurement (4045) (Four-Valve Head)...................................................................................159 Valve — Recess Measurement (4045) (Four-Valve Head)............................................................................160 Valve Assembly — Installation (4045) (Four-Valve Head).........................................................................161 Valve Assembly — Removal (4045) (Four-Valve Head)..............................................................................163 Valve Guide — Cleaning (4045) (Four-Valve Head)................................................................................163 Valve Guide — Measurement (4045) (Four-Valve Head).............................................................................164 Valve Guide — Knurling (4045) (Four-Valve Head)................................................................................164 Valve Keeper, Valve Bridges, and Valve Rotator — Inspection (4045) (Four-Valve Head)...........................................165 Valve Seat — Cleaning and Inspection (4045) (Four-Valve Head)..................................................................165 Valve Seat — Grinding and Measurement (4045) (Four-Valve Head).................................................................166 Valve Seat Inserts — Installation (4045) (Four-Valve Head).....................................................................167 Valve Seat Inserts — Removal (4045) (Four-Valve Head)..........................................................................168 Valve Spring — Inspection and Measurement (4045) (Four-Valve Head).............................................................170 Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment (4045).............................................................171 Connecting Rod — Center-to-Center Bore Measurement (4045)......................................................................171 Connecting Rod — General Information (4045)....................................................................................171 Connecting Rod and Cap — Inspection (4045).....................................................................................172 Connecting Rod Bearing — Inspection and Measurement (4045).....................................................................173 Connecting Rod Bearing — Inspection and Measurement (Rod and Crankshaft in Engine) (4045)......................................174 Connecting Rod Cap Screw — Torque Procedure (4045).............................................................................175 Connecting Rod Pin Bore — Cleaning and Inspection (4045).......................................................................175 Connecting Rod Piston Pin Bushing — Installation (4045)........................................................................176 Connecting Rod Piston Pin Bushing — Removal (4045).............................................................................177 Cylinder Block — Inspection and Plug Installation (4045).......................................................................178 Cylinder Block Components — Measurement (4045).................................................................................184 Cylinder Block O-Ring — Installation (4045)....................................................................................185 Cylinder Liner — Cleaning (4045)...............................................................................................185 Cylinder Liner — Installation (4045)...........................................................................................186 Cylinder Liner — Removal (4045)................................................................................................188 Cylinder Liner — Standout Measurement (4045)...................................................................................190 Cylinder Liner — Visual Inspection (4045)......................................................................................191 Cylinder Liner Flange — Measurement (4045).....................................................................................192 Cylinder Liner O-Ring Bore — Cleaning (4045)...................................................................................193 Cylinder Liner Packing — Installation (4045)...................................................................................194 Piston — Cleaning (4045).......................................................................................................194 Piston — Visual Inspection (4045)..............................................................................................195 Piston and Connecting Rod Assembly — Assemble (4045)...........................................................................196 Piston and Connecting Rod Assembly — Installation (4045).......................................................................197 Piston and Connecting Rod Assembly — Removal (4045)............................................................................199 Piston and Connecting Rod Assembly — Tear Down (4045)..........................................................................200 Piston — Height Measurement (4045).............................................................................................200 Piston — Protrusion Measurement (4045).........................................................................................201 Piston Pin Bore — Measurement (4045)...........................................................................................201 Piston Pin — Inspection (4045).................................................................................................202 Piston Rings — Installation (4045).............................................................................................204 Piston Skirt — Measurement (4045)..............................................................................................206 Piston Spray Jet — Cleaning and Inspection (4045)..............................................................................206 Piston Spray Jet — Installation (4045).........................................................................................207 Piston Spray Jet — Removal (4045)..............................................................................................208 Piston to Cylinder Liner — Clearance Check (4045)..............................................................................209 Crankshaft, Main Bearings, and Flywheel Repair and Adjustment (4045)...............................................................211 Crankshaft — End Play Check (4045).............................................................................................211 Crankshaft — Grinding Specifications (4045)....................................................................................211 Crankshaft — Inspection (4045).................................................................................................212 Crankshaft — Installation (4045)...............................................................................................213 Crankshaft — Removal (4045)....................................................................................................216 Crankshaft Gear — Installation (4045)..........................................................................................217 Crankshaft Gear — Removal (4045)...............................................................................................218 Crankshaft Grinding — Guidelines (4045)........................................................................................219 Crankshaft Journal and Main Bearing — Measurement (4045).......................................................................220 Crankshaft Main Bearing Cap — Removal (4045)...................................................................................221 Crankshaft Main Bearing Cap — Line Bore Specification (4045)...................................................................222 Crankshaft Main Bearing Cap — Oil Clearance Check (4045).......................................................................223 Crankshaft Pulley — Removal (4045).............................................................................................223 Crankshaft Pulley — Installation (4045)........................................................................................224 Crankshaft Pulley — Removal (Add-On Pulley Capable) (4045).....................................................................225 Crankshaft Pulley — Installation (Add-On Pulley Capable) (4045)................................................................228 Crankshaft Rear Oil Seal — Installation (4045).................................................................................230 Crankshaft Rear Oil Seal — Removal (4045)......................................................................................232 Crankshaft Front Oil Seal — Installation (4045)................................................................................234 Crankshaft Front Oil Seal — Removal (4045).....................................................................................240 Crankshaft Thrust Bearing — Inspection (4045)..................................................................................245 Crankshaft Timing Wheel — Installation (4045)..................................................................................246 Crankshaft Timing Wheel — Removal (4045).......................................................................................247 Flywheel — Inspection (4045)...................................................................................................247 Flywheel — Installation (4045).................................................................................................248 Flywheel — Removal (4045)......................................................................................................249 Flywheel Face — Flatness Check (4045)..........................................................................................249 Flywheel Housing — Installation (4045).........................................................................................250 Flywheel Housing — Removal (4045)..............................................................................................251 Flywheel Pilot Bearing Bore — Concentricity Check (4045).......................................................................252 Flywheel Ring Gear — Installation (4045).......................................................................................252 Flywheel Ring Gear — Removal (4045)............................................................................................253 Flywheel Sleeve — Installation (4045)..........................................................................................253 Flywheel Sleeve — Removal (4045)...............................................................................................254 Camshaft, Balancing Shaft and Timing Gear Train Repair and Adjustment (4045).......................................................255 Balancer Shaft — Installation (4045)...........................................................................................255 Balancer Shaft — Measure End Play (4045).......................................................................................256 Balancer Shaft — Removal (4045)................................................................................................257 Balancer Shaft — Visual Inspection and Measurement (4045)......................................................................258 Balancer Shaft and Lower Idler Gear — Timing (4045)............................................................................259 Balancer Shaft Bushing — Installation (4045)...................................................................................261 Balancer Shaft Bushing — Removal (4045)........................................................................................262 Balancer Shaft Gear — Check and Replace Components (4045)......................................................................262 Balancer Shaft Thrust Plate — Measure Clearance and Thickness (4045)...........................................................263 Balancer Shaft Weight — Installation (4045)....................................................................................264 Balancer Shaft Weight — Removal (4045).........................................................................................265 Camshaft — Installation (4045).................................................................................................265 Camshaft — Measure End Play (4045).............................................................................................266 Camshaft — Removal (4045)......................................................................................................266 Camshaft — Visual Inspection (4045)............................................................................................267 Camshaft and Upper Idler Gear — Timing (4045)..................................................................................268 Camshaft Bushing — Installation (4045).........................................................................................271 Camshaft Bushing Journal #1 — Measurement (4045)...............................................................................271 Camshaft Bushing — Removal (4045)..............................................................................................272 Camshaft Follower — Inspection and Measurement (4045)..........................................................................273 Camshaft Follower — Installation (4045)........................................................................................273 Camshaft Follower — Removal (4045).............................................................................................274 Camshaft Gear — Inspection (4045)..............................................................................................274 Camshaft Gear-Driven Auxiliary Drive — Installation (4045).....................................................................275 Camshaft Gear-Driven Auxiliary Drive — Removal (4045)..........................................................................277 Camshaft Journal — Measurement (4045)..........................................................................................278 Camshaft Lobe — Lift Measurement (4045)........................................................................................279 Camshaft Thrust Plate — Measure Clearance and Thickness (4045).................................................................279 Camshaft and Fuel Injection Pump — Timing (4045)...............................................................................280 Front Plate — Installation (4045)..............................................................................................285 Front Plate — Removal (4045)...................................................................................................287 Idler Gears — Measure End Play (4045)..........................................................................................288 Idler Gear Bushing — Removal (4045)............................................................................................289 Idler Gear Bushing — Installation (4045).......................................................................................290 Idler Shaft Spring Pin — Installation (4045)...................................................................................290 Lower Idler Gear — Check and Replace Components (4045).........................................................................291 Lower Idler Gear — Installation (4045).........................................................................................291 Lower Idler Gear — Removal (4045)..............................................................................................291 Lower Idler Shaft — Installation (4045)........................................................................................292 Lower Idler Shaft — Removal (4045).............................................................................................292 Timing Gear Cover — Installation (4045)........................................................................................293 Timing Gear Cover — Removal (4045).............................................................................................296 Timing Gears — Check Backlash (4045)...........................................................................................297 Upper Idler Gear — Check and Replace Components (4045).........................................................................298 Upper Idler Gear — Installation (4045).........................................................................................299 Upper Idler Gear — Removal (4045)..............................................................................................300 Lubrication System Repair and Adjustment (4045)....................................................................................303 Closed Crankcase Ventilation System — Inspection (4045)........................................................................303 Closed Crankcase Ventilation System — Installation (4045)......................................................................304 Closed Crankcase Ventilation System — Removal (4045)...........................................................................305 Dipstick Tube and Dipstick — Installation (4045)...............................................................................306 Dipstick Tube and Dipstick — Removal (4045)....................................................................................307 Oil Cooler Assembly — Installation (4045)......................................................................................308 Oil Cooler Assembly — Removal and Inspection (4045)............................................................................309 Oil Cooler Coolant Adapter — Removal (4045)....................................................................................310 Oil Cooler Coolant Adapter — Installation (4045)...............................................................................311 Oil Fill Adapter — Installation (4045).........................................................................................312 Oil Fill Adapter — Removal (4045)..............................................................................................314 Oil Fill Adapter Cover Plate — Installation (4045).............................................................................315 Oil Fill Adapter Cover Plate — Removal (4045)..................................................................................315 Oil Filter Bypass Valve — Installation (4045)..................................................................................315 Oil Filter Bypass Valve — Removal (4045).......................................................................................316 Oil Filter Header — Installation (4045)........................................................................................316 Oil Filter Header — Removal (4045).............................................................................................321 Oil Pan — Installation (4045)..................................................................................................325 Oil Pan — Removal (4045).......................................................................................................328 Oil Pump and Tube — Installation (4045)........................................................................................330 Oil Pump and Tube — Removal (4045).............................................................................................331 Oil Pick-Up Tube — Installation (4045).........................................................................................332 Oil Pick-Up Tube — Removal (4045)..............................................................................................334 Oil Pressure Regulating Valve — Installation (Old Version) (4045)..............................................................334 Oil Pressure Regulating Valve — Removal (Old Version) (4045)...................................................................335 Oil Pressure Regulating Valve — Installation (New Version) (4045)..............................................................336 Oil Pressure Regulating Valve — Removal (New Version) (4045)...................................................................336 Open Crankcase Ventilation System — Inspection (4045)..........................................................................337 Cooling System Repair and Adjustment (4045)........................................................................................339 Belt — Wear Check (4045).......................................................................................................339 Belt Tensioner — Adjustment (4045).............................................................................................340 Belt Tensioner — Installation (4045)...........................................................................................342 Belt Tensioner — Removal (4045)................................................................................................344 Belt Tensioner — Spring Tension Check (4045)...................................................................................345 Cold Start Advance Switch — Servicing (4045)...................................................................................345 Coolant Heater — Servicing (4045)..............................................................................................346 Coolant Pump Assembly — Assemble (4045)........................................................................................347 Coolant Pump Assembly — Disassembly (4045).....................................................................................349 Coolant Pump Assembly — Installation (4045)....................................................................................350 Coolant Pump Assembly — Removal (4045).........................................................................................352 Coolant Pump Inlet Adapter — Installation (4045)...............................................................................353 Coolant Pump Inlet Adapter — Removal (4045)....................................................................................353 Coolant Pump Pulley — Installation (4045)......................................................................................354 Coolant Pump Pulley — Removal (4045)...........................................................................................354 Coolant Pump — Visual Inspection (4045)........................................................................................355 Cooling System — Air Bleeding (4045)...........................................................................................355 Fan Drive Assembly — Installation (4045).......................................................................................355 Fan Drive Assembly — Removal and Inspection (4045).............................................................................359 Fan Drive Idler Pulley — Installation (4045)...................................................................................361 Fan Drive Idler Pulley — Removal (4045)........................................................................................363 Fan Drive Pulley — Installation (4045).........................................................................................364 Fan Drive Pulley — Removal (4045)..............................................................................................364 Fan (Fixed Speed Fan) — Inspection and Installation (4045).....................................................................365 Fan (Fixed Speed Fan) — Removal (4045).........................................................................................365 Thermostat and Cover — Installation (4045).....................................................................................366 Thermostat and Cover — Removal (4045)..........................................................................................376 Air Intake and Exhaust System Repair and Adjustment (4045).........................................................................387 Air Heater — Servicing (4045)..................................................................................................387 Air Inlet and Mixing Sleeve — Installation (4045)..............................................................................388 Air Inlet and Mixing Sleeve — Removal (4045)...................................................................................390 EGR Cooler Assembly — Installation (4045)......................................................................................391 EGR Cooler Assembly — Removal (4045)...........................................................................................392 EGR Cooler Coolant Inlet Tube — Installation (4045)............................................................................393 EGR Cooler Coolant Inlet Tube — Removal (4045).................................................................................395 EGR Cooler Gas Outlet Tube — Installation (4045)...............................................................................397 EGR Cooler Gas Outlet Tube — Removal (4045)....................................................................................398 Exhaust Manifold — Installation (4045).........................................................................................399 Exhaust Manifold — Removal (4045)..............................................................................................400 Extending Turbocharger Life (4045).............................................................................................402 Intake Manifold — Installation (4045)..........................................................................................403 Intake Manifold — Removal (4045)...............................................................................................405 Turbocharger — Break-In (4045).................................................................................................406 Turbocharger — Recommendations for Use (4045)..................................................................................406 Turbocharger — Inspection (4045)...............................................................................................407 Turbocharger — Failure Analysis (4045).........................................................................................412 Turbocharger — Installation (4045).............................................................................................414 Turbocharger — Removal (4045)..................................................................................................416 Turbocharger Oil Drain Line — Installation (4045)..............................................................................418 Turbocharger Oil Drain Line — Removal (4045)...................................................................................421 Turbocharger Oil Supply Line — Installation (4045).............................................................................423 Turbocharger Oil Supply Line — Removal (4045)..................................................................................426 VGT Actuator Coolant Return Line — Installation (4045).........................................................................428 VGT Actuator Coolant Return Line — Removal (4045)..............................................................................430 VGT Actuator Coolant Supply Line — Installation (4045).........................................................................431 VGT Actuator Coolant Supply Line — Removal (4045)..............................................................................433 Electronic Fuel System Repair and Adjustment (4045)................................................................................435 Fuel System (4045).............................................................................................................435 OEM Starting and Charging Systems Repair and Adjustment (4045).....................................................................437 Alternator — Installation (4045)...............................................................................................437 Alternator — Removal (4045)....................................................................................................438 Starter Motor — Installation (4045)............................................................................................439 Starter Motor — Removal (4045).................................................................................................441 Repair and Adjustments (6 Cylinder Engine).............................................................................................448 Engine Rebuild (6068)..............................................................................................................449 Check Air Intake System (6068).................................................................................................449 Check and Service Cooling System (6068)........................................................................................449 Check Crankcase Vent System (6068).............................................................................................450 Check Electrical System (6068).................................................................................................451 Check Exhaust System (6068)....................................................................................................451 Clean Engine (6068)............................................................................................................452 Engine Break-In Guidelines (6068)..............................................................................................453 Engine Overhaul Guidelines (6068)..............................................................................................454 General Tune-Up Recommendations (6068).........................................................................................454 Engine Repair Stand (6068).....................................................................................................455 Install JT07268 Engine Mounting Adapter to D05223ST Repair Stand (6068)........................................................455 Install JDG11853 Engine Mounting Adapter to D05223ST Repair Stand (6068).......................................................456 Lift Straps — Installation (6068)..............................................................................................456 Lift Straps — Removal (6068)...................................................................................................458 Lifting Procedure (6068).......................................................................................................459 Mount Engine to Repair Stand Using JT07268 (6068)..............................................................................460 Mount Engine to Repair Stand Using JDG11853 (6068).............................................................................461 Safety Precautions (6068)......................................................................................................462 Sealant Application Guidelines (6068)..........................................................................................462 Cylinder Head and Valve Repair and Adjustment (6068) (Two-Valve Head Engines)......................................................463 Cylinder Block Top Deck — Cleaning and Inspection (6068) (Two-Valve Head)......................................................463 Cylinder Head — Cleaning and Inspection (6068) (Two-Valve Head)................................................................464 Cylinder Head — Flatness Check (6068) (Two-Valve Head).........................................................................465 Cylinder Head — Installation (6068) (Two-Valve Head)...........................................................................465 Cylinder Head — Removal (6068) (Two-Valve Head)................................................................................468 Cylinder Head — Thickness Measurement (6068) (Two-Valve Head)..................................................................469 Cylinder Head Gasket — Inspection (6068) (Two-Valve Head)......................................................................470 Fuel Injector Heat Shield — Installation (6068) (Two-Valve Head)...............................................................470 Fuel Injector Heat Shield — Removal (6068) (Two-Valve Head)....................................................................471 Fuel Injector Sleeves — Installation (6068) (Two-Valve Head)...................................................................471 Fuel Injector Sleeves — Removal (6068) (Two-Valve Head)........................................................................472 Fuel Supply Pump Push Rod — Installation (6068) (Two-Valve Head)...............................................................475 Fuel Supply Pump Push Rod — Measurement (6068) (Two-Valve Head)................................................................475 Fuel Supply Pump Push Rod — Removal (6068) (Two-Valve Head)....................................................................476 Push Rod — Cleaning and Inspection (6068) (Two-Valve Head).....................................................................477 Push Rod — Installation (6068) (Two-Valve Head)................................................................................477 Push Rod — Removal (6068) (Two-Valve Head).....................................................................................478 Rocker Arm Cover Baffle — Installation (6068) (Two-Valve Head).................................................................478 Rocker Arm Cover Baffle — Removal (6068) (Two-Valve Head)......................................................................479 Rocker Arm Cover — Installation (6068) (Two-Valve Head)........................................................................480 Rocker Arm Cover — Removal (6068) (Two-Valve Head).............................................................................482 Rocker Arm Shaft Assembly — Tear Down (6068) (Two-Valve Head)..................................................................483 Rocker Arm Shaft Assembly — Inspection (6068) (Two-Valve Head).................................................................484 Rocker Arm Shaft Assembly — Assemble (6068) (Two-Valve Head)...................................................................485 Rocker Arm Shaft Assembly — Installation (6068) (Two-Valve Head)...............................................................486 Rocker Arm Shaft Assembly — Removal (6068) (Two-Valve Head)....................................................................487 Valve — Cleaning and Visual Inspection (6068) (Two-Valve Head).................................................................488 Valve — Clearance Adjustment (6068) (Two-Valve Head)...........................................................................489 Valve — Grinding (6068) (Two-Valve Head).......................................................................................491 Valve — Measurement (6068) (Two-Valve Head)....................................................................................492 Valve — Recess Measurement (6068) (Two-Valve Head).............................................................................493 Valve Assembly — Installation (6068) (Two-Valve Head)..........................................................................494 Valve Assembly — Removal (6068) (Two-Valve Head)...............................................................................495 Valve Guide — Cleaning (6068) (Two-Valve Head).................................................................................496 Valve Guide — Measurement (6068) (Two-Valve Head)..............................................................................496 Valve Guide — Knurling (6068) (Two-Valve Head).................................................................................497 Valve Keeper, Rocker Arm Insert, and Valve Rotator — Inspection (6068) (Two-Valve Head)........................................497 Valve Seat — Cleaning and Inspection (6068) (Two-Valve Head)...................................................................497 Valve Seat — Grinding and Measurement (6068) (Two-Valve Head)..................................................................498 Valve Seat Inserts — Installation (6068) (Two-Valve Head)......................................................................499 Valve Seat Inserts — Removal (6068) (Two-Valve Head)...........................................................................500 Valve Spring — Inspection and Measurement (6068) (Two-Valve Head)..............................................................502 Cylinder Head and Valve Repair and Adjustment (6068) (Four-Valve Head Engines).....................................................503 Cylinder Block Top Deck — Cleaning and Inspection (6068) (Four-Valve Head).....................................................503 Cylinder Head — Cleaning and Inspection (6068) (Four-Valve Head)...............................................................503 Cylinder Head — Flatness Check (6068) (Four-Valve Head)........................................................................504 Cylinder Head — Installation (6068) (Four-Valve Head)..........................................................................504 Cylinder Head — Removal (6068) (Four-Valve Head)...............................................................................507 Cylinder Head — Thickness Measurement (6068) (Four-Valve Head).................................................................508 Cylinder Head Gasket — Inspection (6068) (Four-Valve Head).....................................................................509 Fuel Leak-Off Line Heat Shield — Installation (6068) (Four-Valve Head).........................................................510 Fuel Leak-Off Line Heat Shield — Removal (6068) (Four-Valve Head)..............................................................510 Fuel Injector Sleeves — Installation (6068) (Four-Valve Head)..................................................................511 Fuel Injector Sleeves — Removal (6068) (Four-Valve Head).......................................................................512 Fuel Supply Pump Push Rod — Installation (6068) (Four-Valve Head)..............................................................514 Fuel Supply Pump Push Rod — Measurement (6068) (Four-Valve Head)...............................................................514 Fuel Supply Pump Push Rod — Removal (6068) (Four-Valve Head)...................................................................515 Push Rod — Cleaning and Inspection (6068) (Four-Valve Head)....................................................................516 Push Rod — Installation (6068) (Four-Valve Head)...............................................................................516 Push Rod — Removal (6068) (Four-Valve Head)....................................................................................518 Glow Plug — Installation (6068) (Four-Valve Head)..............................................................................518 Glow Plug — Removal (6068) (Four-Valve Head)...................................................................................519 Glow Plug Bore — Cleaning and Inspection (6068) (Four-Valve Head)..............................................................519 Rocker Arm Cover Baffle — Installation (6068) (Four-Valve Head)................................................................519 Rocker Arm Cover Baffle — Removal (6068) (Four-Valve Head).....................................................................520 Rocker Arm Cover — Installation (6068) (Four-Valve Head).......................................................................520 Rocker Arm Cover — Removal (6068) (Four-Valve Head)............................................................................522 Rocker Arm Shaft and Components — Tear Down (6068) (Four-Valve Head)...........................................................523 Rocker Arm Shaft Assembly — Inspection (6068) (Four-Valve Head)................................................................524 Rocker Arm Shaft Assembly — Assemble (6068) (Four-Valve Head)..................................................................525 Rocker Arm Shaft Assembly — Installation (6068) (Four-Valve Head)..............................................................527 Rocker Arm Shaft Assembly — Removal (6068) (Four-Valve Head)...................................................................529 Rocker Arm Shaft Carrier — Installation (External Fuel Leak-Off System) (6068) (Four-Valve Head)...............................531 Rocker Arm Shaft Carrier Assembly — Installation (Internal Fuel Leak-Off System) (6068) (Four-Valve Head)......................533 Rocker Arm Shaft Carrier — Removal (6068) (Four-Valve Head)....................................................................536 Rocker Arm Shaft Carrier — Inspection (6068) (Four-Valve Head).................................................................537 Valve — Cleaning and Visual Inspection (6068) (Four-Valve Head)................................................................538 Valve — Clearance Adjustment (6068) (Four-Valve Head)..........................................................................539 Valve — Grinding (6068) (Four-Valve Head)......................................................................................541 Valve — Measurement (6068) (Four-Valve Head)...................................................................................542 Valve — Recess Measurement (6068) (Four-Valve Head)............................................................................543 Valve Assembly — Installation (6068) (Four-Valve Head).........................................................................544 Valve Assembly — Removal (6068) (Four-Valve Head)..............................................................................546 Valve Guide — Cleaning (6068) (Four-Valve Head)................................................................................546 Valve Guide — Measurement (6068) (Four-Valve Head).............................................................................547 Valve Guide — Knurling (6068) (Four-Valve Head)................................................................................547 Valve Keeper, Valve Bridges, and Valve Rotator — Inspection (6068) (Four-Valve Head)...........................................548 Valve Seat — Cleaning and Inspection (6068) (Four-Valve Head)..................................................................548 Valve Seat — Grinding and Measurement (6068) (Four-Valve Head).................................................................549 Valve Seat Inserts — Installation (6068) (Four-Valve Head).....................................................................550 Valve Seat Inserts — Removal (6068) (Four-Valve Head)..........................................................................551 Valve Spring — Inspection and Measurement (6068) (Four-Valve Head).............................................................553 Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment (6068).............................................................555 Connecting Rod — Center-to-Center Bore Measurement (6068)......................................................................555 Connecting Rod — General Information (6068)....................................................................................555 Connecting Rod and Cap — Inspection (6068).....................................................................................556 Connecting Rod Bearing — Inspection and Measurement (6068).....................................................................557 Connecting Rod Bearing — Inspection and Measurement (Rod and Crankshaft in Engine) (6068)......................................558 Connecting Rod Cap Screw — Torque Procedure (6068).............................................................................559 Connecting Rod Pin Bore — Cleaning and Inspection (6068).......................................................................560 Connecting Rod Piston Pin Bushing — Installation (6068)........................................................................561 Connecting Rod Piston Pin Bushing — Removal (6068).............................................................................562 Cylinder Block — Inspection and Plug Installation (6068).......................................................................563 Cylinder Block Components — Measurement (6068).................................................................................568 Cylinder Block O-Ring — Installation (6068)....................................................................................569 Cylinder Liner — Cleaning (6068)...............................................................................................569 Cylinder Liner — Installation (6068)...........................................................................................570 Cylinder Liner — Removal (6068)................................................................................................572 Cylinder Liner — Standout Measurement (6068)...................................................................................574 Cylinder Liner — Visual Inspection (6068)......................................................................................575 Cylinder Liner Flange — Measurement (6068).....................................................................................576 Cylinder Liner O-Ring Bore — Cleaning (6068)...................................................................................577 Cylinder Liner Packing — Installation (6068)...................................................................................578 Piston — Cleaning (6068).......................................................................................................578 Piston — Visual Inspection (6068)..............................................................................................579 Piston and Connecting Rod Assembly — Assemble (6068)...........................................................................580 Piston and Connecting Rod Assembly — Installation (6068).......................................................................581 Piston and Connecting Rod Assembly — Removal (6068)............................................................................583 Piston and Connecting Rod Assembly — Tear Down (6068)..........................................................................584 Piston — Height Measurement (6068).............................................................................................584 Piston — Protrusion Measurement (6068).........................................................................................585 Piston Pin Bore — Measurement (6068)...........................................................................................585 Piston Pin — Inspection (6068).................................................................................................586 Piston Rings — Installation (6068).............................................................................................588 Piston Skirt — Measurement (6068)..............................................................................................590 Piston Spray Jet — Cleaning and Inspection (6068)..............................................................................590 Piston Spray Jet — Installation (6068).........................................................................................591 Piston Spray Jet — Removal (6068)..............................................................................................592 Piston to Cylinder Liner — Clearance Check (6068)..............................................................................593 Crankshaft, Main Bearings, and Flywheel Repair and Adjustment (6068)...............................................................595 Crankshaft — End Play Check (6068).............................................................................................595 Crankshaft — Grinding Specifications (6068)....................................................................................595 Crankshaft — Installation (6068)...............................................................................................596 Crankshaft — Inspection (6068).................................................................................................599 Crankshaft — Removal (6068)....................................................................................................599 Crankshaft Gear — Installation (6068)..........................................................................................601 Crankshaft Gear — Removal (6068)...............................................................................................602 Crankshaft Grinding — Guidelines (6068)........................................................................................602 Crankshaft Journal and Main Bearing — Measurement (6068).......................................................................602 Crankshaft Main Bearing Cap — Removal (6068)...................................................................................604 Crankshaft Main Bearing Cap — Line Bore Specification (6068)...................................................................605 Crankshaft Main Bearing — Oil Clearance Check (6068)...........................................................................606 Crankshaft Vibration Damper — Installation (6068)..............................................................................606 Crankshaft Vibration Damper — Removal (6068)...................................................................................609 Crankshaft Vibration Damper — Inspection (6068)................................................................................611 Crankshaft Vibration Damper Add-On Pulley — Installation (6068)................................................................613 Crankshaft Vibration Damper Add-On Pulley — Removal (6068).....................................................................613 Crankshaft Rear Oil Seal — Installation (6068).................................................................................614 Crankshaft Rear Oil Seal — Removal (6068)......................................................................................615 Crankshaft Front Oil Seal — Installation (6068)................................................................................618 Crankshaft Front Oil Seal — Removal (6068).....................................................................................625 Crankshaft Thrust Bearing — Inspection (6068)..................................................................................630 Crankshaft Timing Wheel — Installation (6068)..................................................................................631 Crankshaft Timing Wheel — Removal (6068).......................................................................................632 Flywheel — Installation (6068).................................................................................................632 Flywheel — Inspection (6068)...................................................................................................633 Flywheel — Removal (6068)......................................................................................................633 Flywheel Face — Flatness Check (6068)..........................................................................................633 Flywheel Housing — Installation (6068).........................................................................................634 Flywheel Housing — Removal (6068)..............................................................................................636 Flywheel Pilot Bearing Bore — Concentricity Check (6068).......................................................................636 Flywheel Ring Gear — Installation (6068).......................................................................................637 Flywheel Ring Gear — Removal (6068)............................................................................................637 Flywheel Sleeve — Installation (6068)..........................................................................................638 Flywheel Sleeve — Removal (6068)...............................................................................................638 Camshaft and Timing Gear Train Repair and Adjustment (6068)........................................................................639 Camshaft — Installation (6068).................................................................................................639 Camshaft — Measure End Play (6068).............................................................................................639 Camshaft — Removal (6068)......................................................................................................640 Camshaft — Visual Inspection (6068)............................................................................................641 Camshaft and Upper Idler Gear — Timing (6068)..................................................................................642 Camshaft Bushing — Installation (6068).........................................................................................645 Camshaft Bushing Journal #1 — Measurement (6068)...............................................................................645 Camshaft Bushing — Removal (6068)..............................................................................................646 Camshaft Follower — Inspection and Measurement (6068)..........................................................................647 Camshaft Follower — Installation (6068)........................................................................................647 Camshaft Follower — Removal (6068).............................................................................................648 Camshaft Gear — Inspection (6068)..............................................................................................648 Camshaft Gear-Driven Auxiliary Drive — Removal (6068)..........................................................................649 Camshaft Gear-Driven Auxiliary Drive — Installation (6068).....................................................................651 Camshaft Journal — Measurement (6068)..........................................................................................652 Camshaft Lobe — Lift Measurement (6068)........................................................................................653 Camshaft Thrust Plate — Measure Clearance and Thickness (6068).................................................................653 Camshaft and Fuel Pump — Timing (6068).........................................................................................654 Front Plate — Installation (6068)..............................................................................................659 Front Plate — Removal (6068)...................................................................................................661 Idler Gears — Measure End Play (6068)..........................................................................................662 Idler Gear Bushing — Removal (6068)............................................................................................663 Idler Gear Bushing — Installation (6068).......................................................................................664 Idler Shaft Spring Pin — Installation (6068)...................................................................................664 Lower Idler Gear — Check and Replace Components (6068).........................................................................665 Lower Idler Gear — Installation (6068).........................................................................................665 Lower Idler Gear — Removal (6068)..............................................................................................666 Timing Gear Cover — Installation (6068)........................................................................................667 Timing Gear Cover — Removal (6068).............................................................................................670 Timing Gears — Check Backlash (6068)...........................................................................................671 Upper Idler Gear — Check and Replace Components (6068).........................................................................672 Upper Idler Gear — Removal (6068)..............................................................................................673 Upper Idler Gear — Installation (6068).........................................................................................674 Lubrication System Repair and Adjustment (6068)....................................................................................677 Crankcase Vent Hose — Installation (6068)......................................................................................677 Crankcase Vent Hose — Removal (6068)...........................................................................................677 Dipstick Tube and Dipstick — Installation (6068)...............................................................................678 Dipstick Tube and Dipstick — Removal (6068)....................................................................................679 Oil Cooler Assembly — Installation (6068)......................................................................................680 Oil Cooler Assembly — Removal and Inspection (6068)............................................................................681 Oil Fill Adapter — Removal (6068)..............................................................................................682 Oil Fill Adapter — Installation (6068).........................................................................................683 Oil Filter Bypass Valve — Installation (6068)..................................................................................683 Oil Filter Bypass Valve — Removal (6068).......................................................................................684 Oil Filter Header — Installation (6068)........................................................................................684 Oil Filter Header — Removal (6068).............................................................................................689 Oil Pan — Installation (6068)..................................................................................................693 Oil Pan — Removal (6068).......................................................................................................697 Oil Pump and Tube — Installation (6068)........................................................................................699 Oil Pump and Tube — Removal (6068).............................................................................................700 Oil Pick-up Tube — Installation (6068).........................................................................................701 Oil Pick-Up Tube — Removal (6068)..............................................................................................703 Oil Pressure Regulating Valve — Installation (Old Version) (6068)..............................................................703 Oil Pressure Regulating Valve — Removal (Old Version) (6068)...................................................................704 Oil Pressure Regulating Valve — Installation (New Version) (6068)..............................................................705 Oil Pressure Regulating Valve — Removal (New Version) (6068)...................................................................705 Open Crankcase Ventilation Hose — Inspection (6068)............................................................................706 Cooling System Repair and Adjustment (6068)........................................................................................707 Belt — Wear Check (6068).......................................................................................................707 Belt Tensioner — Adjustment (6068).............................................................................................708 Belt Tensioner — Installation (6068)...........................................................................................710 Belt Tensioner — Removal (6068)................................................................................................712 Belt Tensioner — Spring Tension Check (6068)...................................................................................713 Cold Start Advance Switch — Servicing (6068)...................................................................................713 Coolant Heater — Servicing (6068)..............................................................................................714 Coolant Pump Assembly — Assemble (6068)........................................................................................715 Coolant Pump Assembly — Disassemble (6068).....................................................................................717 Coolant Pump Assembly — Installation (6068)....................................................................................718 Coolant Pump Assembly — Removal (6068).........................................................................................720 Coolant Pump Inlet Adapter — Installation (6068)...............................................................................721 Coolant Pump Inlet Adapter — Removal (6068)....................................................................................721 Coolant Pump Pulley — Installation (6068)......................................................................................722 Coolant Pump Pulley — Removal (6068)...........................................................................................722 Coolant Pump — Visual Inspection (6068)........................................................................................723 Cooling System — Air Bleeding (6068)...........................................................................................723 Fan Drive Assembly — Installation (6068).......................................................................................723 Fan Drive Assembly — Removal and Inspection (6068).............................................................................727 Fan Drive Pulley — Installation (6068).........................................................................................730 Fan Drive Pulley — Removal (6068)..............................................................................................732 Fan (Fixed Speed Fan) — Inspection and Installation (6068).....................................................................734 Fan (Fixed Speed Fan) — Removal (6068).........................................................................................734 Thermostat and Cover — Installation (6068).....................................................................................735 Thermostat and Cover — Removal (6068)..........................................................................................745 Air Intake and Exhaust System Repair and Adjustment (6068).........................................................................757 Air Heater — Servicing (6068)..................................................................................................757 Air Inlet and Mixing Sleeve — Installation (6068)..............................................................................758 Air Inlet and Mixing Sleeve — Removal (6068)...................................................................................760 EGR Cooler Assembly — Installation (6068)......................................................................................761 EGR Cooler Assembly — Removal (6068)...........................................................................................763 EGR Cooler Coolant Inlet Tube — Installation (6068)............................................................................764 EGR Cooler Coolant Inlet Tube — Removal (6068).................................................................................766 EGR Cooler Gas Outlet Tube — Installation (6068)...............................................................................768 EGR Cooler Gas Outlet Tube — Removal (6068)....................................................................................769 Exhaust Manifold — Installation (6068).........................................................................................770 Exhaust Manifold — Removal (6068)..............................................................................................773 Extending Turbocharger Life (6068).............................................................................................776 Intake Manifold — Installation (6068)..........................................................................................778 Intake Manifold — Removal (6068)...............................................................................................779 Turbocharger — Break-In (6068).................................................................................................779 Turbocharger — Recommendations for Use (6068)..................................................................................779 Turbocharger — Inspection (6068)...............................................................................................780 Turbocharger — Failure Analysis (6068).........................................................................................785 Turbocharger — Installation (6068).............................................................................................787 Turbocharger — Removal (6068)..................................................................................................789 Turbocharger Oil Drain Line — Installation (6068)..............................................................................791 Turbocharger Oil Drain Line — Removal (6068)...................................................................................794 Turbocharger Oil Supply Line — Installation (6068).............................................................................796 Turbocharger Oil Supply Line — Removal (6068)..................................................................................799 VGT Actuator Coolant Return Line — Installation (6068).........................................................................801 VGT Actuator Coolant Return Line — Removal (6068)..............................................................................803 VGT Actuator Coolant Supply Line — Installation (6068).........................................................................804 VGT Actuator Coolant Supply Line — Removal (6068)..............................................................................805 Electronic Fuel System Repair and Adjustment (6068)................................................................................807 Fuel System (6068).............................................................................................................807 OEM Starting and Charging Systems Repair and Adjustment (6068).....................................................................809 Alternator — Installation (6068)...............................................................................................809 Alternator — Removal (6068)....................................................................................................810 Starter Motor — Installation (6068)............................................................................................811 Starter Motor — Removal (6068).................................................................................................812 Base Engine Theory of Operation........................................................................................................813 Base Engine Operation..............................................................................................................815 General Engine Operation.......................................................................................................815 Head Gasket Joint Construction and Operation...................................................................................817 Cooling System.....................................................................................................................819 Cooling System Operation.......................................................................................................819 Lubrication System.................................................................................................................822 Lubrication System Operation...................................................................................................822 Electronic Fuel System.............................................................................................................827 Electronic Fuel System Operation...............................................................................................827 Air Intake and Exhaust System......................................................................................................829 Air Intake and Exhaust System Operation........................................................................................829 Diagnostics............................................................................................................................831 Observable Diagnostics and Tests...................................................................................................833 About This Section of the Manual...............................................................................................833 4.5L/6.8L — L1 — Excessive Oil Consumption.....................................................................................833 4.5L/6.8L - L1 - Excessive Oil Consumption.................................................................................833 4.5L/6.8L — L2 — Engine Oil Pressure Low.......................................................................................835 4.5L/6.8L — L3 — Engine Oil Pressure High......................................................................................836 4.5L/6.8L — L4 — Soot or Sludge in Oil.........................................................................................837 4.5L/6.8L — C1 — Engine Coolant Temperature Above Normal.......................................................................839 4.5L/6.8L — C2 — Engine Coolant Temperature Below Normal.......................................................................839 4.5L/6.8L — C3 — Coolant in Oil or Oil in Coolant..............................................................................840 4.5L/6.8L — C4 — Coolant Leaking from Weep Hole................................................................................841 Test Engine Compression Pressure...............................................................................................842 Test Engine Cranking Speed.....................................................................................................847 Engine Oil Consumption.........................................................................................................848 Check Engine Oil Pressure......................................................................................................848 Check for Excessive Engine Crankcase Pressure (Blow-By) (Base Pressure)........................................................849 Crankcase Pressure (Blow-By) Diagnostic Procedure..........................................................................849 Check for Turbocharger Oil Seal Leak...........................................................................................856 Inspect Thermostat and Test Opening Temperature................................................................................857 Cooling System Pressure Test...................................................................................................858 Pressure Test EGR Cooler for Air Leaks.........................................................................................860 Check for Head Gasket Failures.................................................................................................861 Check and Service Cooling System...............................................................................................862 Check Air Intake System........................................................................................................864 Measure Intake Manifold Pressure (Turbocharger Boost for Tier 3/Stage IIIA Engines)............................................864 Measure Intake Manifold Pressure (Turbocharger Boost/Power Check)..............................................................865 Check for Intake and Exhaust Restrictions......................................................................................866 Test for Intake Air Leaks......................................................................................................867 Check for Exhaust Air Leaks (Turbocharged Engines).............................................................................868 Turbocharger Wastegate Check...................................................................................................868 Excessive Engine Vibration.....................................................................................................868 Excessive Engine Vibration.................................................................................................868 Tools and Other Materials..............................................................................................................872 Special Tools......................................................................................................................873 75240..........................................................................................................................873 D01045AA.......................................................................................................................873 D01061AA.......................................................................................................................873 D01062AA.......................................................................................................................873 D01168AA.......................................................................................................................874 D01200AA.......................................................................................................................874 D01218AA.......................................................................................................................874 D01300AA.......................................................................................................................875 D05012ST-A.....................................................................................................................875 D05022ST.......................................................................................................................875 D05104ST.......................................................................................................................876 D05223ST.......................................................................................................................876 D05226ST.......................................................................................................................876 D15001NU.......................................................................................................................877 D17015BR.......................................................................................................................877 D17024BR.......................................................................................................................877 D17525CI.......................................................................................................................878 D17526CI.......................................................................................................................878 D17527CI.......................................................................................................................878 DFRG9..........................................................................................................................879 DFRG11.........................................................................................................................880 DFRG14.........................................................................................................................881 DFRG15.........................................................................................................................881 DFYZ49.........................................................................................................................882 FKM10002.......................................................................................................................882 JD244..........................................................................................................................883 JD248A.........................................................................................................................883 JD249..........................................................................................................................883 JD252..........................................................................................................................883 JD254A.........................................................................................................................884 JD286..........................................................................................................................884 JDE81-4........................................................................................................................884 JDE83..........................................................................................................................884 JDE85..........................................................................................................................885 JDE88..........................................................................................................................885 JDE138.........................................................................................................................885 JDE41296.......................................................................................................................885 JDG22..........................................................................................................................886 JDG23..........................................................................................................................886 JDG451.........................................................................................................................886 JDG536.........................................................................................................................886 JDG537.........................................................................................................................887 JDG576.........................................................................................................................887 JDG675.........................................................................................................................887 JDG676.........................................................................................................................887 JDG678.........................................................................................................................888 JDG680.........................................................................................................................888 JDG698A........................................................................................................................888 JDG738-2.......................................................................................................................888 JDG739B........................................................................................................................889 JDG739-1.......................................................................................................................889 JDG739-3.......................................................................................................................889 JDG739-4.......................................................................................................................889 JDG739-5B......................................................................................................................889 JDG739-7.......................................................................................................................890 JDG739-8.......................................................................................................................890 JDG782A........................................................................................................................890 JDG791A........................................................................................................................891 JDG820.........................................................................................................................891 JDG839.........................................................................................................................891 JDG886.........................................................................................................................891 JDG953.........................................................................................................................892 JDG953-1.......................................................................................................................892 JDG953-2.......................................................................................................................892 JDG954B........................................................................................................................893 JDG954-1B......................................................................................................................893 JDG954-2.......................................................................................................................893 JDG954-3.......................................................................................................................894 JDG954-4.......................................................................................................................894 JDG954-5.......................................................................................................................894 JDG954-6.......................................................................................................................895 JDG954-7.......................................................................................................................895 JDG954-8.......................................................................................................................895 JDG956.........................................................................................................................895 JDG963.........................................................................................................................896 JDG965.........................................................................................................................896 JDG966.........................................................................................................................896 JDG992-1.......................................................................................................................896 JDG992-2.......................................................................................................................897 JDG1069........................................................................................................................897 JDG1145........................................................................................................................897 JDG1146........................................................................................................................897 JDG1341........................................................................................................................898 JDG1517........................................................................................................................898 JDG1517-1......................................................................................................................898 JDG1517-2......................................................................................................................899 JDG1520........................................................................................................................899 JDG1559........................................................................................................................899 JDG1571........................................................................................................................900 JDG1649A.......................................................................................................................900 JDG1651........................................................................................................................900 JDG1653........................................................................................................................900 JDG1653-1......................................................................................................................901 JDG1653-2......................................................................................................................901 JDG1923A.......................................................................................................................901 JDG2047A.......................................................................................................................901 JDG2047AP1.....................................................................................................................902 JDG2074A.......................................................................................................................902 JDG10539A......................................................................................................................902 JDG10576.......................................................................................................................902 JDG10631.......................................................................................................................903 JDG10824.......................................................................................................................903 JDG11064.......................................................................................................................903 JDG11065A......................................................................................................................903 JDG11205.......................................................................................................................904 JDG11413.......................................................................................................................904 JDG11853.......................................................................................................................904 JDG11864.......................................................................................................................904 JT01674A.......................................................................................................................905 JT05470........................................................................................................................905 JT05697A.......................................................................................................................905 JT07268........................................................................................................................906 JT07336........................................................................................................................906 JT30040B.......................................................................................................................906 JT30041A.......................................................................................................................907 JT30042........................................................................................................................907 KCD10001.......................................................................................................................907 KJD10123.......................................................................................................................907 KJD10140.......................................................................................................................908 KJD10213.......................................................................................................................908 KJD10233.......................................................................................................................908 Lubricants, Sealants, and Other Materials..........................................................................................909 Other Materials................................................................................................................909 Specifications.........................................................................................................................911 Repair and General OEM Specifications..............................................................................................913 Unified Inch Bolt and Screw Torque Values......................................................................................913 Metric Bolt and Screw Torque Values............................................................................................914 Cylinder Head and Valves Specifications (Two-Valve Head).......................................................................915 Cylinder Head and Valves Specifications (Four-Valve Head)......................................................................917 Cylinder Block, Liners, Pistons, and Rods Specifications.......................................................................920 Crankshaft, Main Bearings, and Flywheel Specifications.........................................................................923 Camshaft, Balancer Shafts, and Timing Gear Train Specifications................................................................925 Lubrication System Specifications..............................................................................................928 Cooling System Specifications..................................................................................................930 Air Intake and Exhaust System Specifications...................................................................................931 Starting and Charging System Specifications....................................................................................932 Page Number................................................................................................................................ 15 Section 01............................................................................................................................. 17 Group 000.......................................................................................................................... 19 Group 001.......................................................................................................................... 35 Group 002.......................................................................................................................... 41 Section 02A............................................................................................................................ 61 Group 010.......................................................................................................................... 63 Group 020.......................................................................................................................... 77 Group 021..........................................................................................................................119 Group 030..........................................................................................................................171 Group 040..........................................................................................................................211 Group 050..........................................................................................................................255 Group 060..........................................................................................................................303 Group 070..........................................................................................................................339 Group 080..........................................................................................................................387 Group 090..........................................................................................................................435 Group 100..........................................................................................................................437 Section 02B............................................................................................................................448 Group 010..........................................................................................................................449 Group 020..........................................................................................................................463 Group 021..........................................................................................................................503 Group 030..........................................................................................................................555 Group 040..........................................................................................................................595 Group 050..........................................................................................................................639 Group 060..........................................................................................................................677 Group 070..........................................................................................................................707 Group 080..........................................................................................................................757 Group 090..........................................................................................................................807 Group 100..........................................................................................................................809 Section 03.............................................................................................................................813 Group 120..........................................................................................................................815 Group 123..........................................................................................................................819 Group 126..........................................................................................................................822 Group 130..........................................................................................................................827 Group 135..........................................................................................................................829 Section 04.............................................................................................................................831 Group 150..........................................................................................................................833 Section 05.............................................................................................................................872 Group 170..........................................................................................................................873 Group 180..........................................................................................................................909 Section 06.............................................................................................................................911 Group 200..........................................................................................................................913
S.S 17/02/2025
