John Deere Powertech 9.0 L OEM Diesel Engines Base Engine Repair Component Technical Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere Powertech 9.0 L OEM Diesel Engines Base Engine Repair Component Technical Manual – PDF DOWNLOAD
CTM400
For complete service information also see:
9.0 L Diesel Engines — Level 14 Electronic
Fuel System with Denso HPCR …………………….. CTM385
OEM Engine Accessories …………………………….. CTM67
Application List……………………………………………. CTM106819
This repair manual is valid for the engines. This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual. 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.
- 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 & application details, and information about the fuels, lubricants & coolants. Section 02 covers the Repair and Adjustment procedures. Section 03 explains Systems Theory of Operation. Section 04 is the diagnostics section that provides troubleshooting procedures to find problems. Section 05 lists all applicable service equipment and tools, other materials needed to do the job. Section 06 details all specifications, wear tolerances, torque values and contains the wiring diagrams.
- This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric sized.
- Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the component you are working on. Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications.
TABLE OF CONTENTS:
John Deere Powertech 9.0 L OEM Diesel Engines Base Engine Repair Component Technical Manual – PDF DOWNLOAD
Contents 5
General 7
Safety 9
Work In Ventilated Area 9
Recognize Safety Information 9
Work in Clean Area 9
Dispose of Waste Properly 10
Avoid Harmful Asbestos Dust 10
Handle Fuel Safely—Avoid Fires 10
Prepare for Emergencies 11
Handle Starting Fluid Safely 11
Handle Fluids Safely—Avoid Fires 11
Avoid High-Pressure Fluids 12
Use Proper Lifting Equipment 12
Illuminate Work Area Safely 12
Live With Safety 13
Service Machines Safely 13
Handle Chemical Products Safely 13
Protect Against Noise 14
Remove Paint Before Welding or Heating 14
Stay Clear of Rotating Drivelines 15
Service Cooling System Safely 15
Follow Safety Instructions 16
Use Proper Tools 16
Construct Dealer-Made Tools Safely 16
Practice Safe Maintenance 17
Understand Signal Words 17
Replace Safety Signs 18
Prevent Battery Explosions 18
Protect Against High Pressure Spray 18
Avoid Heating Near Pressurized Fluid Lines 19
Wear Protective Clothing 19
Wait Before Opening High-Pressure Fuel System 19
Handle Agricultural Chemicals Safely 20
Handling Batteries Safely 21
Install All Guards 21
Avoid Hot Exhaust 22
Engine Identification 23
Engine Model Designation 23
Engine Serial Number Plate Information 24
OEM Engine Option Code Label 24
Fuels, Lubricants and Coolant 25
Diesel Fuel 25
Biodiesel Fuel 26
Minimizing the Effect of Cold Weather on Diesel Engines 27
Handling and Storing Diesel Fuel 28
Lubricity of Diesel Fuel 28
Testing Diesel Fuel 28
Engine Oil and Filter Service Intervals 28
Diesel Engine Oil 29
Diesel Engine Break-In Oil 30
Oil Filters 30
Grease 31
Alternative and Synthetic Lubricants 31
Lubricant Storage 31
Mixing of Lubricants 32
Heavy Duty Diesel Engine Coolant 32
Supplemental Coolant Additives 33
Operating in Warm Temperature Climates 33
Additional Information About Diesel Engine Coolants and John Dee 34
Diesel Engine Coolant 35
Testing Diesel Engine Coolant 35
Drain Intervals for Diesel Engine Coolant 36
Repair and Adjustments 40
Engine Rebuild 41
Engine Overhaul Guidelines 41
Engine Repair Stand 41
Safety Precautions 42
Install Adapters on Engine Repair Stand 42
Install Engine Lift Straps 43
Engine Lifting Procedure 44
Clean Engine 44
Disconnect Turbocharger Oil Inlet Line 45
Mount Engine on Repair Stand 46
Engine Disassembly Sequence for Overhaul 48
Sealant Application Guidelines 49
Engine Assembly Sequence After Overhaul 50
Engine Break-In Guidelines 50
Perform Engine Break-In 51
Check Crankcase Ventilation System 52
Check Air Intake System 52
Check Exhaust System 52
Check and Service Cooling System 53
Check Electrical System 55
General Tune-Up Recommendations 56
Cylinder Head and Valves Repair and Adjustment 57
Valve — Clearance Adjustment 57
Valve — Lift Check 59
Cylinder Head—Removal 60
Diagnosing Head Gasket Joint Failures 62
Head Gasket Diagnostic Charts 63
Head Gasket Inspection and Repair Sequence 64
Rocker Arm Assembly — Inspection 65
Rocker Arm Shaft — Tear Down 65
Valve — Recess Measurement 66
Preliminary Cylinder Head and Valve Checks 67
Valve — Assembly Removal 68
Valve Springs — Inspection 69
Valve Retainer, Valve Bridges, and Valve Retainer Locks — Inspec 69
Valve — Cleaning and Inspection 69
Valve — Measurement 70
Valve — Grinding 71
Cylinder Head — Cleaning and Inspection 71
Cylinder Head — Flatness Check 72
Cylinder Head — Thickness Measurement 72
Fuel Injector Sleeves — Remove 73
Fuel Injector Sleeves — Install 74
Valve Guide — Cleaning 74
Valve Guide — Measurement 75
Valve Seat — Cleaning and Inspection 75
Valve Seat — Recess Measurement 76
Valve Seat — Grinding 77
Valve Seat Inserts — Removal 77
Valve Seat Inserts — Installation 78
Cylinder Head Nozzle Bore — Cleaning and Inspection 78
Push Rod — Cleaning and Inspection 78
Cylinder Block Top Deck — Cleaning and Inspection 78
Cylinder Liner — Standout Measurement 79
Valve Assembly — Reassemble 80
Cylinder Head — Installation 81
Cylinder Head Cap Screw Torque Procedure 83
Rocker Arm Assembly — Installation 85
Rocker Arm Cover Vent hose — Inspection 85
Final Assembly — Fuel Pump Side of Engine 86
Final Assembly — Exhaust Manifold Side of Engine 87
Perform Engine Break— In 91
Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment 93
Preliminary Liner, Piston, and Rod Checks 93
Remove Pistons and Connecting Rod Assemblies 94
Cylinder Liner — Standout Measurement 97
Remove Cylinder Liners 98
Deglaze Cylinder Liners100
Cylinder Liner — Cleaning100
Piston and Connection Rod Assembly — Tear Down101
Clean Pistons101
Visually Inspect Pistons102
Inspect Piston Pin and Bore102
Visually Inspect Cylinder Liners103
Cylinder Liner Manufacturing Date Code Explanation104
Piston to Liner — Clearance Check104
Inspect Rod and Cap106
Piston Pin and Bushing — Inspection107
Piston Pin Bushing and Pin Bore — Removal109
Measure Liner Flange109
Inspect and Measure Connecting Rod Bearings110
Piston Pin Bushing — Installation111
Complete Disassembly of Cylinder Block (If Required)111
Piston Cooling Orifices — Removal112
Inspect and Clean Cylinder Block112
Measure Cylinder Block114
Piston Cooling Orifices — Installation115
Install Packing on Cylinder Liner and O-Rings in Block116
Install Cylinder Liner in Block117
Install Piston and Connecting Rod118
Torque-Turn Connecting Rod Cap Screws122
Check Engine Rotation for Excessive Tightness122
Complete Final Assembly123
Crankshaft, Main Bearings and Flywheel Repair and Adjustment125
Crankshaft and Main Bearing Failure Analysis125
Crankshaft Rear Oil Seal Assembly General Information125
Crankshaft Rear Oil Seal Assembly Handling Precautions126
Crankshaft Rear Oil Seal & Oil Seal Housing — Installation127
Crankshaft Unitized Rear Oil Seal — Removal129
Crankshaft Unitized Front Oil Seal — Removal (6090AFM75 & 6090HF130
Crankshaft Unitized Front Oil Seal — Installation (6090AFM75 & 6131
Crankshaft Unitized Rear Oil Seal — Installation (6090AFM75 & 60132
Inspect Vibration Damper133
Check Crankshaft End Play134
Remove Crankshaft Vibration Damper135
Remove Crankshaft Front Oil Seal and Wear Sleeve136
Remove Timing Gear Cover—Engine Removed138
Inspect and Measure Flywheel138
Check Flywheel Housing Face Runout138
Check Flywheel Face Flatness139
Check Pilot Bearing Bore Concentricity139
Remove Flywheel140
Remove SAE 1 Flywheel Housing140
Remove SAE 2 and 3 Flywheel Housing140
Replace Flywheel Ring Gear141
Remove Rear Oil Seal Housing—Engine Removed142
Remove Main Bearing Caps143
Check Main Bearing Oil Clearance145
Remove Connecting Rod Caps and Remove Crankshaft146
Crankshaft — Inspection147
Measure Assembled ID of Bearings and OD of Crankshaft Journa148
Main Bearing Cap Line Bore Specifications149
Thrust Bearing New Part Specifications151
Replace (Crankshaft) Oil Pump Drive Gear152
Replace Crankshaft Gear153
Inspect Thrust Bearings153
Install Main Bearings and Crankshaft154
Check Crankshaft Rear Oil Seal Housing Runout156
Install Thrust Washer and Timing Gear Cover157
Install Unitized Front Crankshaft Oil Seal159
Install Vibration Damper161
Install SAE 2 and 3 Flywheel Housing162
Install Flywheel163
Install SAE 1 Flywheel Housing163
Complete Final Assembly163
Camshaft and Timing Gear Train Repair and Adjustment165
Check Camshaft End Play and Measure Gear Backlash165
Remove Vibration Damper and Timing Gear Cover166
Remove, Inspect, and Install Crankshaft Gear-Driven Auxiliary Dr167
Remove Camshaft170
Remove Camshaft Gears171
Measure Thrust Washer Thickness171
Inspect and Measure Camshaft Followers172
Visually Inspect Camshaft172
Measure Camshaft Journal OD and Bushing ID172
Measure Camshaft Lobe Lift173
Camshaft Gears — Installation173
Service Camshaft Bushings Using JDG602 Adapter Set174
Service Camshaft Bushings Using JDG606 Adapter Set176
Camshaft Roller Followers — Install178
Install Camshaft179
Install Thrust Washer and Timing Gear Cover180
Complete Final Assembly181
Lubrication System Repair and Adjustment183
Diagnosing Lubrication System Malfunctions183
Top-Load Oil Filter Assembly183
Top Load Oil Filter – Theory of Operation184
Install Oil Filter Assembly185
Changing Top-Load Oil Filter185
Engine Oil Cooler Assembly186
Remove, Inspect, and Install Engine Oil Cooler187
Remove Engine from Tractors for Access to Engine Oil Pump188
Remove Oil Pan188
Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash188
Remove Engine Oil Pump189
Inspect and Clean Oil Pump189
Check Drive Shaft End Play190
Check Drive Shaft Side Movement190
Check Pumping Gear Backlash191
Inspect Oil Pump Drive Gear191
Install Engine Oil Pump192
Install Oil Bypass & Oil Pump Tubes & Oil Pump Adapter193
Remove, Inspect, and Install Oil Pump Pickup Tube193
Install Engine Oil Pan194
Tighten Cap Screws on Front Frame/Oil Sump – Tractors195
Cooling System Repair and Adjustment197
Inspect Fan Hub & Replace Bearings in Heavy-Duty, Adjustable Fan197
Replace Bearings in Coolant Manifold-Mounted, Fixed Fan Drive As200
Fan Drive Assembly201
Checking Belt Tensioner Spring Tension and Belt Wear204
Inspect and Install Fan Assembly205
Visually Inspect Coolant Pump206
Remove Coolant Pump Assembly207
Install Coolant Pump Assembly211
Replace Bypass Tube & O-Rings in Thermostat Housing212
Remove and Test Thermostats213
Remove Thermostat Housing213
Install Thermostats214
Install Thermostat Housing214
Remove and Install Coolant Temperature Sensor214
Servicing of Engine Coolant Heater215
Bleed Air from Coolant System215
Complete Final Assembly216
Air Intake and Exhaust System Repair and Adjustment217
Extending Turbocharger Life217
Remove Turbocharger219
Remove Turbocharger Oil Drain Line220
Remove Turbocharger Oil Supply Line221
Turbocharger Failure Analysis222
Turbocharger Inspection224
Repair Turbocharger228
Prelube Turbocharger228
Install Turbocharger229
Install Turbocharger Oil Supply Line Brackets230
Install Turbocharger Oil Supply Line231
Install Turbocharger Oil Drain Line232
Install Heat Shield & Turbocharger Oil Supply Line Bracket233
Remove and Install Turbocharger Actuator234
Install Actuator Coolant Line Fittings235
Install Turbocharger Actuator Coolant Return Line235
Install Turbocharger Actuator Coolant Supply Line236
Install Actuator Coolant Supply Line – Tractors237
Remove and Install Actuator Linkage238
Remove and Install Turbocharger Actuator Linkage – Ball Type241
Remove Exhaust Gas Recirculator (EGR) Assembly242
Remove & Install EGR Valve243
Remove and Install EGR Coolant Manifold244
Remove and Install EGR Cooler Supply Line244
Remove and Install EGR Cooler Return Line245
Remove, Inspect, and Install Exhaust Manifold246
Remove, Inspect, and Install Intake Manifold248
Install EGR251
Remove and Install Air Inlet/Heater252
PowerTech E Air Intake and Exhaust System Repair and Adjustment253
Turbocharger — Extending Life253
Turbocharger — Remove Oil Drain Line254
Turbocharger — Install Oil Drain Line256
Turbocharger — Remove258
Turbocharger — Install259
Exhaust Manifold — Remove260
Exhaust Manifold — Install261
Air Intake Assembly — Remove263
Air Intake Assembly — Install264
OEM Starting and Charging Systems Repair and Adjustment267
Remove and Install Alternator (OEM Engines)267
Remove and Install Starter Motor (OEM Engines)268
Theory of Operation269
Base Engine Operation271
Engine Sectional View Serial Number271
General Engine Operation272
Lubrication System Operation274
Cooling System Operation276
Exhaust Gas Recirculator (EGR) and Variable Geometry Turbocharge278
Head Gasket Joint Construction and Operation280
Air Intake and Exhaust System Operation281
Turbocharger Operation281
How the Turbocharger is Lubricated282
PowerTech E Base Engine Operation283
Engine Sectional View Serial Number283
General Engine Operation284
Lubrication System Operation285
Cooling System Operation288
Air Intake and Exhaust System Operation289
Turbocharger Operation289
How the Turbocharger is Lubricated290
Head Gasket Joint Construction and Operation291
Diagnostics293
Observable Diagnostics and Tests295
About This Group of the Manual295
Excessive Oil Consumption296
9 L – L1 – Excessive Oil Consumption296
Engine Oil Consumption298
90L – L2 – Engine Oil Pressure Low299
90L – L2 – Engine Oil Pressure Low301
90L – L3 – Engine Oil Pressure High302
90 L – C1 – Engine Coolant Temperature Above Normal303
90L – C2 – Engine Coolant Temperature Below Normal304
90L – C3 – Coolant In Oil or Oil In Coolant304
Test Engine Compression Pressure with Mechanical Gauge305
Check Engine Cranking Speed306
Check Engine Oil Pressure307
Check for Excessive Engine Crankcase Pressure (Blow-by)307
Check for Turbocharger Oil Seal Leak308
Inspect Thermostat and Test Opening Temperature308
Pressure Test Cooling System and Radiator Cap309
Pressure Test EGR Cooler for Air Leaks309
Charge Air System Diagnostic309
Check for Head Gasket Failures312
Measure Intake Manifold Pressure (Turbo Boost)313
Check for Intake and Exhaust Restrictions314
Check for Exhaust Air Leaks315
Tools and Other Materials317
Repair Tools and Other Materials319
Group 021 — Cylinder Head and Valves – Essential Tools319
Group 021 — Cylinder Head and Valves – Service Equipment and Too321
Group 021 — Cylinder Head and Valves – Other Materials322
Group 030 — Cylinder Block, Liners, Pistons, and Rods Essential 322
Group 030 — Cylinder Block, Liners, Pistons, and Rods Other Mate326
Group 040 — Crankshaft, Main Bearings and Flywheel Essential Too326
Group 040 — Crankshaft, Main Bearings and Flywheel Service Equip330
Group 040 — Crankshaft, Main Bearings and Flywheel Other Materia330
Group 050 — Camshaft and Timing Gear Train Essential Tools331
Group 050 — Camshaft and Timing Gear Train Other Materials334
Group 060 — Lubrication System Other Materials334
Group 070 — Cooling System Other Materials334
Group 080 — Air Intake and Exhaust System Other Materials335
Group 100 — Starting and Charging Systems Essential Tools335
Diagnostic Service Tools337
Base Engine Diagnostic Tools337
Dealer Fabricated Service Tools339
How to Make Tools339
DFRG3—Cylinder Liner Holding Fixture339
Specifications341
Repair and General OEM Specifications343
General OEM Engine Specifications343
Unified Inch Bolt and Screw Torque Values344
Metric Bolt and Screw Torque Values345
Group 020 — Cylinder Head and Valves Repair Specifications346
Group 030 — Cylinder Block, Liners, Pistons and Rods Repair Spec348
Group 040 — Crankshaft, Main Bearings and Flywheel Repair Speci351
Group 050 — Camshaft and Timing Gear Train Repair Specifications354
Group 060 — Lubrication System Repair Specifications356
Group 070 — Cooling System Repair Specifications358
Group 080 — Air Intake and Exhaust System Repair Specifications 359
Group 081 — Air Intake and Exhaust System Repair Specifications 360
OEM Starting and Charging Systems360
Diagnostic Specifications361
Base Engine Diagnostic Specifications (Includes Dynamometer Spec361
Dynamometer Test Specifications362
Intake Manifold Pressure (Turbocharger Boost) Specifications363
Effects of Altitude and Temperature on Engine Performance363
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