John Deere POWERTECH 2.4L & 3.0L Diesel Engines Technical Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere POWERTECH 2.4L & 3.0L Diesel Engines Technical Manual – PDF DOWNLOAD
Foreword :
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. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
- Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines.
- They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes
TABLE OF CONTENTS:
John Deere POWERTECH 2.4L & 3.0L Diesel Engines Technical Manual – PDF DOWNLOAD
Contents…………………………………………………………………………………. 7
General Information……………………………………………………………………. 9
Safety……………………………………………………………………………. 11
Handle Fluids Safely—Avoid Fires…………………………………………………. 11
Understand Signal Words…………………………………………………………. 11
Handle Chemical Products Safely………………………………………………….. 12
Handle Starting Fluid Safely…………………………………………………….. 12
Prevent Bypass Starting…………………………………………………………. 13
Service Cooling System Safely……………………………………………………. 13
DO NOT USE Starting Fluids………………………………………………………. 13
Prepare for Emergencies…………………………………………………………. 14
Prevent Battery Explosions………………………………………………………. 14
Prevent Acid Burns……………………………………………………………… 15
Handling Batteries Safely……………………………………………………….. 16
Handle Fluids Safely—Avoid Fires…………………………………………………. 17
Avoid High-Pressure Fluids………………………………………………………. 17
Wear Protective Clothing………………………………………………………… 18
Service Machines Safely…………………………………………………………. 18
Work In Ventilated Area…………………………………………………………. 18
Work in Clean Area……………………………………………………………… 19
Remove Paint Before Welding or Heating……………………………………………. 19
Avoid Heating Near Pressurized Fluid Lines………………………………………… 20
Illuminate Work Area Safely……………………………………………………… 20
Use Proper Lifting Equipment…………………………………………………….. 20
Construct Dealer-Made Tools Safely……………………………………………….. 21
Practice Safe Maintenance……………………………………………………….. 21
Use Proper Tools……………………………………………………………….. 22
Dispose of Waste Properly……………………………………………………….. 22
Live With Safety……………………………………………………………….. 23
Engine Identification………………………………………………………………. 25
Engine Model Designation………………………………………………………… 25
PowerTech™ Medallion……………………………………………………………. 25
Engine Serial Number Plate………………………………………………………. 26
Record Engine Serial Number……………………………………………………… 26
OEM Engine Option Code Label…………………………………………………….. 27
Engine Application Chart………………………………………………………… 28
Fuels, Lubricants, and Coolant………………………………………………………. 29
Diesel Fuel……………………………………………………………………. 29
Lubricity of Diesel Fuel………………………………………………………… 30
Diesel Fuel Storage…………………………………………………………….. 31
Bio-Diesel Fuel………………………………………………………………… 32
Handling And Storing Bio-Diesel Fuel……………………………………………… 33
Testing Diesel Fuel…………………………………………………………….. 33
Filling Fuel Tank………………………………………………………………. 34
Minimizing the Effect of Cold Weather on Diesel Engines…………………………….. 35
Diesel Engine Break-In Oil………………………………………………………. 36
Diesel Engine Oil………………………………………………………………. 37
Extended Diesel Engine Oil Service Intervals………………………………………. 38
Mixing of Lubricants……………………………………………………………. 38
Oil Filters……………………………………………………………………. 38
OILSCAN®and COOLSCAN™…………………………………………………………… 39
Alternative and Synthetic Lubricants……………………………………………… 39
Lubricant Storage………………………………………………………………. 40
Grease………………………………………………………………………… 40
Diesel Engine Coolant…………………………………………………………… 41
Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives…. 43
Testing Diesel Engine Coolant……………………………………………………. 44
Supplemental Coolant Additives…………………………………………………… 45
Operating in Warm Temperature Climates……………………………………………. 45
Disposing of Coolant……………………………………………………………. 46
Repair and Adjustments…………………………………………………………………. 47
Engine Rebuild…………………………………………………………………….. 51
Engine Overhaul Guidelines………………………………………………………. 51
Engine Repair Stand…………………………………………………………….. 51
Engine Stand Safety Precautions………………………………………………….. 52
Install Adapters on Engine Repair Stand…………………………………………… 53
Engine Lifting Procedure………………………………………………………… 53
Clean Engine…………………………………………………………………… 54
Disconnect Turbocharger Oil Inlet Line……………………………………………. 54
Mount Engine on Repair Stand…………………………………………………….. 55
Engine Disassembly Sequence……………………………………………………… 56
Engine Assembly Sequence………………………………………………………… 57
Engine Break-In Guidelines………………………………………………………. 58
Perform Engine Break-In…………………………………………………………. 59
Cylinder Head and Valves……………………………………………………………. 61
Cylinder Head – Exploded View……………………………………………………. 61
Remove Rocker Arm Cover…………………………………………………………. 62
Remove Cylinder Head……………………………………………………………. 63
Disassemble and Inspect Rocker Arm Assembly……………………………………….. 67
Inspect, Remove, and Install Glow Plugs and Wire Harness……………………………. 67
Measure Valve Recess in Cylinder Head…………………………………………….. 69
Preliminary Cylinder Head and Valve Checks………………………………………… 70
Remove Valve Assembly…………………………………………………………… 71
Inspect and Measure Valve Springs………………………………………………… 71
Clean Valves…………………………………………………………………… 72
Inspect and Measure Valves………………………………………………………. 72
Grind Valves…………………………………………………………………… 74
Head Gasket Inspection and Repair Sequence………………………………………… 75
Inspect and Clean Cylinder Head………………………………………………….. 76
Check Cylinder Head Flatness…………………………………………………….. 77
Knurl Valve Guides……………………………………………………………… 77
Clean and Inspect Valve Seats……………………………………………………. 78
Grind Valve Seats………………………………………………………………. 79
Install Valves…………………………………………………………………. 80
Inspect Cylinder Head Cap Screws…………………………………………………. 81
Inspect and Clean Exhaust Manifold……………………………………………….. 81
Install Cylinder Head (4-Cylinder)……………………………………………….. 82
Install Cylinder Head (5-Cylinder)……………………………………………….. 83
Install Rocker Arm Assembly……………………………………………………… 84
Cylinder Block, Pistons, and Rods……………………………………………………. 93
Connecting Rods—General Information………………………………………………. 93
Preliminary Cylinder Block, Pistons, and Rod Checks………………………………… 94
Remove Pistons and Connecting Rod Assembly………………………………………… 95
Disassemble Piston and Rod Assembly………………………………………………. 97
Clean Pistons………………………………………………………………….. 98
Visually Inspect Pistons………………………………………………………… 99
Check Piston Ring Groove Wear…………………………………………………….100
Measure Piston Pin Bore………………………………………………………….100
Measure Piston Skirt…………………………………………………………….101
Measure Piston Height……………………………………………………………101
Determine Piston-to-Cylinder Bore Clearance………………………………………..101
Deglaze Cylinder Bores…………………………………………………………..103
Rebore Cylinder Bores……………………………………………………………104
Inspect and Measure Connecting Rod Bearings (Rods Removed from Engine)………………..105
Inspect and Measure Connecting Rod Bearings (Rod and Crankshaft in Engine)…………….106
Inspect Rod and Cap……………………………………………………………..107
Inspect Piston Pins and Bushings………………………………………………….108
Measure Rod Center-to-Center Bores………………………………………………..109
Inspect and Clean Cylinder Block………………………………………………….110
Measure Cylinder Block Main Bearing Bore…………………………………………..111
Measure Camshaft Follower Machined Bore……………………………………………112
Measure Camshaft Bushing Bores in Block……………………………………………112
Inspect and Measure Cylinder Bore…………………………………………………114
Measure Cylinder Block Top Deck Flatness…………………………………………..115
Remove, Inspect, and Install Piston Cooling Orifices………………………………..115
Assemble Piston and Connecting Rod………………………………………………..116
Install Piston Rings…………………………………………………………….117
Install Piston and Connecting Rod Assembly…………………………………………119
Torque-Turn Connecting Rod Cap Screws……………………………………………..121
Check Engine Rotation for Excessive Tightness………………………………………122
Measure Piston Protrusion – Locate TDC…………………………………………….123
Complete Final Assembly………………………………………………………….124
Crankshaft, Main Bearings and Flywheel………………………………………………..125
Crankshaft and Main Bearing Failure Analysis……………………………………….125
Inspect Vibration Damper (If Equipped)…………………………………………….126
Remove Crankshaft Pulley/Damper…………………………………………………..128
Inspect Pulley and Wear Sleeve……………………………………………………128
Replace Front Crankshaft Oil Seal (Without Removing Timing Gear Cover)………………..129
Install Crankshaft Pulley/Damper………………………………………………….131
Check Crankshaft End Play………………………………………………………..132
Inspect Flywheel………………………………………………………………..132
Check Flywheel Face Flatness……………………………………………………..133
Check Pilot Bearing Bore Concentricity…………………………………………….133
Remove Flywheel…………………………………………………………………134
Replace Flywheel Ring Gear……………………………………………………….134
Remove Flywheel Housing………………………………………………………….135
Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions………………………..135
Remove Crankshaft Rear Oil Seal and Housing………………………………………..136
Clean and Inspect Crankshaft Flange……………………………………………….137
Install Crankshaft Rear Oil Seal Housing…………………………………………..138
Install Crankshaft Rear Oil Seal………………………………………………….139
Remove Crankshaft Main Bearings…………………………………………………..141
Check Main Bearing Oil Clearance………………………………………………….142
Remove Crankshaft……………………………………………………………….143
Inspect Crankshaft………………………………………………………………144
Measure Crankshaft Journals and Main Bearing ID…………………………………….145
Crankshaft Grinding Guidelines……………………………………………………146
Crankshaft Grinding Specifications………………………………………………..147
Measure Main Thrust Journal Width and Thrust Washers ……………………………….148
Measure Assembled ID of Main Bearing Caps………………………………………….149
Install Main Bearings, Thrust Washers and Crankshaft………………………………..150
Install Flywheel Housing…………………………………………………………152
Install Flywheel………………………………………………………………..153
Camshaft, Balancer Shafts and Timing Gear Train………………………………………..155
Remove Timing Gear Cover…………………………………………………………155
Remove Balancer Shafts (If Equipped)………………………………………………156
Inspect and Measure Balancer Shaft Bushings and Journals…………………………….157
Inspect Balancer Shaft Gears and Thrust Plates……………………………………..157
Remove, Inspect and Install Balancer Idler Gears and Shafts (If Equipped)……………..158
Measure Idler Gear Bushing and Shaft………………………………………………159
Remove Balancer Bushings…………………………………………………………159
Install Balancer Bushings………………………………………………………..160
Install Balancer Shafts (If Equipped)…………………………………………….161
Remove Governor Assembly and Camshaft Drive Gear……………………………………162
Remove Camshaft…………………………………………………………………162
Inspect Camshaft………………………………………………………………..163
Inspect and Measure Camshaft Bushing ID and Journal OD………………………………164
Remove and Install Camshaft Bushings ……………………………………………..165
Measure Camshaft Lobe Height……………………………………………………..167
Inspect Camshaft Followers……………………………………………………….168
Install Camshaft………………………………………………………………..169
Time Camshaft ………………………………………………………………….170
Install Governor Assembly………………………………………………………..172
Clean and Inspect Timing Gear Cover……………………………………………….172
Install Timing Gear Cover………………………………………………………..173
Lubrication System………………………………………………………………….175
General Lubrication System Information…………………………………………….175
Remove and Install Cold Start Advance Valve………………………………………..176
Remove Oil Cooler……………………………………………………………….176
Install Oil Cooler………………………………………………………………177
Remove and Install Oil Pan……………………………………………………….179
Remove and Install Oil Pressure Regulating Valve……………………………………181
Remove, Inspect, and Install Oil Pick-up Tube Assembly………………………………182
Remove and Inspect Oil Pump………………………………………………………183
Install Oil Pump………………………………………………………………..183
Remove and Install Oil Dipstick Tube with Oil Pan Installed………………………….184
Cooling System……………………………………………………………………..185
Remove and Install Thermostat…………………………………………………….185
Replacing Fan and Alternator Belt…………………………………………………187
Remove and Install Automatic (Spring) Belt Tensioner………………………………..188
Checking Belt Tensioner Spring Tension and Belt Wear (Automatic Tensioner)…………….188
Remove Coolant Pump……………………………………………………………..191
Inspect and Clean Coolant Pump Parts………………………………………………192
Install Coolant Pump…………………………………………………………….193
Cooling System Deaeration………………………………………………………..194
Inspect and Install Fan Assembly………………………………………………….195
Remove Fan Bearing Serial Number (— 0010609)……………………………………….196
Install Fan Bearing Serial Number (— 0010609)………………………………………197
Remove and Install Fan Bearing Serial Number (0010609 —)…………………………….198
Air Intake and Exhaust System………………………………………………………..199
Extending Turbocharger Life………………………………………………………199
Remove Turbocharger……………………………………………………………..201
Turbocharger Failure Analysis…………………………………………………….202
Turbocharger Inspection………………………………………………………….204
Repair Turbocharger……………………………………………………………..210
Prelube Turbocharger…………………………………………………………….210
Install Turbocharger…………………………………………………………….211
Remove, Inspect, and Install Exhaust Manifold………………………………………213
Remove, Inspect, and Install Intake Manifold……………………………………….214
Fuel System………………………………………………………………………..217
Remove and Install Fuel Supply Pump……………………………………………….217
Remove and Install Injection Nozzles………………………………………………217
Remove and Inspect Injection Pump Units……………………………………………219
Remove, Inspect and Install Fuel Control Rack………………………………………220
Measure Fuel Control Rack Travel………………………………………………….222
Install and Synchronize Injection Pumps……………………………………………223
Remeasure Fuel Control Rack Travel………………………………………………..230
Install Electronic Governor Coupler……………………………………………….231
Install Electronic Governor………………………………………………………231
Adjust Electronic Governor Actuator Arm……………………………………………232
Install Speed Sensor…………………………………………………………….234
Remove and Install Fuel Rail Check Valve…………………………………………..236
Change Main Governor Spring………………………………………………………236
Change Low Idle Bumper Spring…………………………………………………….239
Remove and Install Governor Lever Assembly…………………………………………241
Remove and Install Throttle Control Assembly……………………………………….244
Remove and Install Full Load Stop Screw……………………………………………246
Remove and Install Idle Bias Adjustment Screw………………………………………247
Remove and Install Fuel Shut-Off Solenoid………………………………………….248
Remove and Install Aneroid……………………………………………………….249
Starting and Charging Systems………………………………………………………..251
Remove and Install Starter……………………………………………………….251
Remove and Install Alternator…………………………………………………….251
Theory of Operation…………………………………………………………………….253
Base Engine Operation……………………………………………………………….255
General Engine Operation…………………………………………………………255
Lubrication System Operation……………………………………………………..258
Coolant System Operation…………………………………………………………260
Air Intake and Exhaust System Operation……………………………………………262
Air Cleaner Operation……………………………………………………………264
Turbocharger Operation…………………………………………………………..265
Turbocharger Lubrication…………………………………………………………266
Fuel/Governor System Operation……………………………………………………….267
Fuel System Operation……………………………………………………………267
Fuel Supply Pump………………………………………………………………..268
Fuel Filter/Water Separator Operation……………………………………………..269
Governor Operation………………………………………………………………270
Electronic Governor……………………………………………………………..270
Integrated Fuel System (IFS) Operation…………………………………………….271
Light Load and Speed Advance Operation…………………………………………….273
Cold Start Advance Operation……………………………………………………..274
Glow Plug Cold Start Aid Operation………………………………………………..275
Diagnostics……………………………………………………………………………277
Base Engine Observable Diagnostics and Tests…………………………………………..279
About This Group of the Manual……………………………………………………279
Guideline for Acceptable Oil Consumption…………………………………………..280
L1 – Excessive Oil Consumption……………………………………………………281
L1 – Excessive Oil Consumption……………………………………………………281
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L2 – Engine Oil Pressure Low……………………………………………………..284
L3 – Engine Oil Pressure High…………………………………………………….286
C1 – Engine Coolant Temperature Above Normal……………………………………….287
C2 – Engine Coolant Temperature Below Normal……………………………………….288
C3 – Coolant in Oil or Oil in Coolant……………………………………………..288
A2 – Glow Plug Check…………………………………………………………….289
A2 – Glow Plug Check…………………………………………………………….289
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Test Engine Compression Pressure………………………………………………….291
Test Engine Cranking Speed……………………………………………………….293
Dynamometer Test………………………………………………………………..294
Engine Oil Consumption…………………………………………………………..295
Check Engine Oil Pressure………………………………………………………..296
Check for Excessive Engine Crankcase Pressure (Blow-By)……………………………..297
Check for Turbocharger Oil Seal Leak………………………………………………298
Inspect Thermostat and Test Opening Temperature…………………………………….299
Pressure Test Cooling System and Radiator Cap………………………………………300
Check for Head Gasket Failures……………………………………………………301
Check and Service Cooling System………………………………………………….304
Check Air Intake System………………………………………………………….306
Measure Intake Manifold Pressure (Turbocharger Boost)……………………………….307
Check for Intake and Exhaust Restrictions………………………………………….309
Test for Intake Air Leaks………………………………………………………..310
Check for Exhaust Air Leaks (Turbocharged Engines)………………………………….311
Test Turbocharger Wastegate………………………………………………………311
Glow Plug Operation……………………………………………………………..312
Test Fuel Shutoff Solenoid……………………………………………………….312
Cylinder Misfire Test……………………………………………………………313
Fuel System Observable Diagnostics and Tests…………………………………………..315
About This Group of the Manual……………………………………………………315
E1 – Engine Cranks/Won’t Start……………………………………………………316
E1 – Engine Cranks/Won’t Start Diagnostic Procedure…………………………………316
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E2 – Engine Misfires/Runs Irregularly……………………………………………..318
E2 – Engine Misfires/Runs Irregularly Diagnostic Procedure…………………………..318
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E3 – Engine Does Not Develop Full Power……………………………………………320
E3 – Engine Does Not Develop Full Power Diagnostic Procedure…………………………320
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E4 – Engine Emits Excessive White Exhaust Smoke…………………………………….324
E4 – Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure………………….324
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E5 – Engine Emits Excessive Black Or Gray Exhaust Smoke……………………………..326
E5 – Engine Emits Excessive Black Or Gray Exhaust Smoke Diagnostic Procedure…………..326
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E6 – Engine Will Not Crank……………………………………………………….328
E7 – Engine Idles Poorly…………………………………………………………329
E8 – Abnormal Engine Noise……………………………………………………….330
F1 – Fuel Supply System Check…………………………………………………….332
F1 – Fuel Supply System Check Diagnostic Procedure………………………………….332
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F2 – Excessive Fuel Consumption…………………………………………………..335
F3 – Fuel in Oil………………………………………………………………..335
Check Fuel Supply Quality………………………………………………………..336
Test for Fuel Drain Back…………………………………………………………337
Test Air in Fuel………………………………………………………………..338
Bleed the Fuel System……………………………………………………………339
Check for Restricted Fuel Return Line……………………………………………..340
Measure Fuel Transfer Pump Pressure……………………………………………….341
Bench Test Fuel Transfer Pump…………………………………………………….342
Check Cold Start Advance Operation………………………………………………..344
Check Fuel Shut-Off Solenoid Operation…………………………………………….345
Check and Adjust Fast Idle Speed………………………………………………….346
Check and Adjust Slow Idle Speed………………………………………………….347
Governor Adjustment……………………………………………………………..348
Disable Fuel Control Rack Magnet………………………………………………….349
Fuel Control Rack Magnet Adjustment……………………………………………….350
Check Engine Power………………………………………………………………351
Adjust Engine Power……………………………………………………………..352
Test Cylinder Misfire……………………………………………………………353
Electronic Controller Diagnostics and Tests……………………………………………355
About this Group of the Manual……………………………………………………355
Electrical Concepts……………………………………………………………..355
Using a Digital Multimeter……………………………………………………….356
Electrical Circuit Malfunctions…………………………………………………..356
Troubleshooting Circuit Malfunctions………………………………………………359
Engine Control Unit (ECU) Wiring …………………………………………………363
Connecting Parameter Setup Tool (PST)……………………………………………..365
Parameter Reference……………………………………………………………..366
Viewing and Modifying ECU Parameters………………………………………………367
Reprogramming the ECU……………………………………………………………368
Electronic Governor Calibration…………………………………………………..369
LED Status Indicators……………………………………………………………370
Electronically Controlled Governor System Diagnostics……………………………….371
Tools and Other Materials……………………………………………………………….373
Repair Tools and Other Materials……………………………………………………..375
Engine Rebuild Essential Tools……………………………………………………375
Engine Rebuild Service Equipment and Tools…………………………………………375
Group 020 — Cylinder Head and Valves Essential Tools………………………………..376
Group 020 — Cylinder Head and Valves Service Equipment and Tools……………………..378
Group 020 — Cylinder Head and Valves Other Materials………………………………..378
Group 030 — Cylinder Block, Liners, Pistons, and Rods Essential Tools…………………378
Group 040 — Crankshaft, Main Bearings and Flywheel Essential Tools……………………380
Group 040 — Crankshaft, Main Bearings and Flywheel Service Equipment and Tools…………383
Group 040 — Crankshaft, Main Bearings and Flywheel Other Materials……………………384
Group 050 — Camshaft and Timing Gear Train Essential Tools…………………………..385
Group 060 — Lubrication System Essential Tools……………………………………..386
Group 070 — Cooling System Essential Tools…………………………………………388
Group 090 — Fuel Injection System Essential Tools…………………………………..388
Diagnostic Service Tools…………………………………………………………….393
Base Engine Diagnostic Tools……………………………………………………..393
Fuel System Observable Diagnostic Tools……………………………………………395
Dealer Fabricated Service Tools………………………………………………………397
How to Make Tools……………………………………………………………….397
DFRG7 — Notched Screwdriver Spring Tool……………………………………………397
Specifications…………………………………………………………………………399
Repair and General OEM Specifications…………………………………………………402
General OEM Engine Specifications—2.4 L Engines…………………………………….402
General OEM Engine Specifications—3.0 L Engines…………………………………….403
Engine Power Rating and Speed Specifications……………………………………….404
Engine Crankcase Oil Fill Quantities………………………………………………404
Unified Inch Bolt and Screw Torque Values………………………………………….405
Metric Bolt and Screw Torque Values……………………………………………….406
Engine Rebuild Specifications…………………………………………………….407
Cylinder Head and Valves Specifications……………………………………………408
Cylinder Block, Liners, Pistons, and Rods Specifications…………………………….410
Crankshaft, Main Bearings, and Flywheel Specifications………………………………412
Camshaft, Balancer Shafts and Timing Gear Train Specifications……………………….414
Lubrication System Specifications…………………………………………………415
Cooling System Specifications…………………………………………………….415
Air Intake and Exhaust System Specifications……………………………………….416
Starting and Charging Systems Specifications……………………………………….416
Fuel System…………………………………………………………………….417
Diagnostic Specifications……………………………………………………………419
Intake Manifold Pressure (Turbocharger Boost) Specifications…………………………419
Electronic Governor Specifications………………………………………………..420
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