John Deere PowerTech 6101 10.1L Diesel Engine Component Technical Manual CTM61 PDF

Contents
Safety
HANDLE FLUIDS SAFELY—AVOID FIRES
PREVENT BATTERY EXPLOSIONS
PREPARE FOR EMERGENCIES
PREVENT ACID BURNS
AVOID HIGH-PRESSURE FLUIDS
WEAR PROTECTIVE CLOTHING
SERVICE MACHINES SAFELY
WORK IN VENTILATED AREA
WORK IN CLEAN AREA
REMOVE PAINT BEFORE WELDING OR HEATING
AVOID HEATING NEAR PRESSURIZED FLUID LINES
ILLUMINATE WORK AREA SAFELY
USE PROPER LIFTING EQUIPMENT
PRACTICE SAFE MAINTENANCE
USE PROPER TOOLS
DISPOSE OF WASTE PROPERLY
LIVE WITH SAFETY
General Information
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES
METRIC BOLT AND CAP SCREW TORQUE VALUES
ENGINE MODEL DESIGNATION
ENGINE SERIAL NUMBER PLATE INFORMATION
ENGINE APPLICATION CHART
Fuels, Lubricants, and Coolant
DIESEL FUEL
DIESEL ENGINE OIL
OILSCAN® AND COOLSCAN™
GREASE
ENGINE COOLANT REQUIREMENTS
ENGINE COOLANT REQUIREMENTS—CONTINUED
ENGINE COOLANT SPECIFICATIONS
ENGINE COOLANT SPECIFICATIONS—CONTINUED
ENGINE COOLANT SPECIFICATIONS—CONTINUED
JOHN DEERE ENGINE COOLING FLUID
CHECK EFFECTIVENESS OF COOLANT SOLUTION
REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCA’S) BETWEEN COOLANT CHANGES
FLUSHING AND SERVICING COOLING SYSTEM
DISPOSING OF COOLANT
Engine Mounting
ENGINE REPAIR STAND
SAFETY PRECAUTIONS
INSTALL 500 SERIES ENGINE ADAPTERS ON REPAIR STAND
ENGINE LIFTING PROCEDURE
CLEAN ENGINE
DISCONNECT TURBOCHARGER OIL INLET LINE
MOUNT ENGINE ON REPAIR STAND
Engine Rebuild Guide
6101 ENGINE DISASSEMBLY SEQUENCE
SEALANT APPLICATION GUIDELINES
SEALANT APPLICATION GUIDELINES—CONTINUED
6101 ENGINE ASSEMBLY SEQUENCE
Cylinder Head and Valves
SPECIAL OR ESSENTIAL TOOLS
CYLINDER HEAD AND VALVES SPECIFICATIONS
CYLINDER HEAD AND VALVES SPECIFICATIONS—CONTINUED
CYLINDER HEAD AND VALVES SPECIFICATIONS—CONTINUED
SERVICE EQUIPMENT AND TOOLS
OTHER MATERIAL
CHECK AND ADJUST VALVE CLEARANCE
CHECK VALVE LIFT
REMOVE CYLINDER HEAD AND VALVES
DISASSEMBLE AND INSPECT ROCKER ARM SHAFT ASSEMBLY
ASSEMBLE ROCKER ARM SHAFT ASSEMBLY
MEASURE VALVE RECESS IN CYLINDER HEAD
DIAGNOSING MALFUNCTIONS
REMOVE VALVE ASSEMBLY
INSPECT AND MEASURE VALVE SPRINGS
INSPECT WEAR CAPS AND VALVE ROTATORS
CLEAN VALVES
INSPECT AND MEASURE VALVES
GRIND VALVES
INSPECT AND CLEAN CYLINDER HEAD
CHECK CYLINDER HEAD COMBUSTION FACE FLATNESS
MEASURE CYLINDER HEAD THICKNESS
CLEAN VALVE GUIDES
MEASURE VALVE GUIDES
KNURL VALVE GUIDES
REPLACE VALVE GUIDES
CLEAN AND INSPECT VALVE SEATS
MEASURE VALVE SEATS
GRIND VALVE SEATS
REMOVE VALVE SEAT INSERTS
MEASURE VALVE SEAT BORES IN CYLINDER HEAD
INSTALL VALVE SEAT INSERTS (STANDARD OR OVERSIZE)
INSPECT AND CLEAN CYLINDER HEAD NOZZLE BORE
CLEAN AND INSPECT PUSH RODS
CLEAN AND INSPECT CRANKCASE VENTILATION ASSEMBLY
CLEAN AND INSPECT TOP DECK OF CYLINDER BLOCK
MEASURE CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)
ASSEMBLE VALVE ASSEMBLY
INSTALL CYLINDER HEAD
TIGHTEN FLANGED-HEAD CYLINDER HEAD CAP SCREWS (WITH FLAT WASHERS)
TORQUE-TURN FLANGED-HEAD CYLINDER HEAD CAP SCREWS
INSTALL ROCKER ARM ASSEMBLY
COMPLETE FINAL ASSEMBLY ON INJECTION PUMP SIDE
COMPLETE FINAL ASSEMBLY ON EXHAUST MANIFOLD SIDE
PERFORM ENGINE BREAK-IN
Cylinder Block, Liners, Pistons and Rods
SPECIAL OR ESSENTIAL TOOLS
OTHER MATERIAL
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS—CONTINUED
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS—CONTINUED
CYLINDER BLOCK, LINERS, PISTONS, AND RODS SPECIFICATIONS—CONTINUED
PRELIMINARY LINER, PISTON, AND ROD CHECKS
REMOVE PISTONS AND CONNECTING RODS
MEASURE CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)
REMOVE CYLINDER LINERS
REMOVE PISTON RINGS
CLEAN PISTONS
VISUALLY INSPECT PISTONS
CLEAN CYLINDER LINERS
VISUALLY INSPECT CYLINDER LINERS
PISTON AND LINER IDENTIFICATION MARKINGS
CHECK PISTON RING GROOVE WEAR
INSTALL PISTON PIN IN PISTON
MEASURE PISTON SKIRT OD
DETERMINE PISTON-TO-LINER CLEARANCE
MEASURE OIL CONTROL RING GROOVE
MEASURE CYLINDER LINERS
DEGLAZE CYLINDER LINERS
INSPECT AND MEASURE CONNECTING ROD BEARINGS
INSPECT ROD AND CAP
INSPECT PISTON PINS AND BUSHINGS
REMOVE PISTON PIN BUSHING
CLEAN AND INSPECT PISTON PIN BUSHING BORE IN CONNECTING ROD
INSTALL PISTON PIN BUSHING IN CONNECTING ROD
COMPLETE DISASSEMBLY OF CYLINDER BLOCK (IF REQUIRED)
REMOVE AND CLEAN PISTON COOLING ORIFICES
INSPECT AND CLEAN CYLINDER BLOCK
CLEAN CYLINDER LINER O-RING BORE
MEASURE CYLINDER BLOCK
INSTALL PISTON COOLING ORIFICES AND GALLEY PLUGS
RECHECK CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK)
MEASURE LINER FLANGE THICKNESS
INSTALL LINER SHIMS—IF REQUIRED
INSTALL CYLINDER LINER O-RINGS AND PACKINGS
CYLINDER LINER MANUFACTURING DATE CODE EXPLANATION
INSTALL CYLINDER LINERS
INSTALL PISTONS AND CONNECTING RODS
USE TORQUE-TURN METHOD FOR PROPER TORQUE
CHECK ENGINE ROTATION FOR EXCESSIVE TIGHTNESS
MEASURE PISTON PROTRUSION
COMPLETE FINAL ASSEMBLY
Crankshaft, Main Bearings and Flywheel
SPECIAL OR ESSENTIAL TOOLS
OTHER MATERIAL
GROUP 15—CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS
GROUP 15—CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS—CONTINUED
GROUP 15—CRANKSHAFT, MAIN BEARINGS, AND FLYWHEEL SPECIFICATIONS—CONTINUED
FAILURE ANALYSIS
DISCONNECT TURBOCHARGER OIL INLET LINE
REMOVE CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE (WITH OIL SEAL HOUSING INSTALLED)
INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE ASSEMBLY (WITHOUT ENGINE DISASSEMBLY)
INSPECT VIBRATION DAMPER
REMOVE VIBRATION DAMPER AND PULLEY
REMOVE CRANKSHAFT FRONT OIL SEAL (WITH TIMING GEAR COVER INSTALLED ON ENGINE)
REMOVE CRANKSHAFT FRONT WEAR SLEEVE (WITH TIMING GEAR COVER INSTALLED OR REMOVED)
INSTALL CRANKSHAFT FRONT WEAR SLEEVE (WITH TIMING GEAR COVER INSTALLED ON ENGINE)
INSTALL CRANKSHAFT FRONT OIL SEAL (WITH TIMING GEAR COVER INSTALLED ON ENGINE)
REMOVE TIMING GEAR COVER
CHECK CRANKSHAFT END PLAY
INSPECT, MEASURE, AND REPAIR FLYWHEEL
CHECK FLYWHEEL HOUSING FACE RUNOUT
CHECK FLYWHEEL FACE FLATNESS
CHECK PILOT BEARING BORE CONCENTRICITY
REMOVE FLYWHEEL AND FLYWHEEL HOUSING
REPLACE FLYWHEEL RING GEAR
REMOVE REAR OIL SEAL HOUSING AND WEAR SLEEVE (WITH ENGINE DISASSEMBLED)
REMOVE CRANKSHAFT MAIN BEARINGS
CHECK MAIN BEARING CLEARANCE
REMOVE CRANKSHAFT
REPLACE CRANKSHAFT GEAR
INSPECT CRANKSHAFT
MEASURE ASSEMBLED I.D. OF BEARINGS AND O.D. OF CRANKSHAFT JOURNALS
MEASURE ASSEMBLED I.D. OF MAIN BEARING CAPS (WITHOUT BEARINGS)
CRANKSHAFT GRINDING GUIDELINES
CRANKSHAFT GRINDING GUIDELINES—CONTINUED
CRANKSHAFT GRINDING SPECIFICATIONS
THRUST BEARING NEW PART SPECIFICATIONS
REPLACE CRANKSHAFT OIL PUMP DRIVE GEAR
INSPECT THRUST BEARINGS
REMOVE AND CLEAN PISTON COOLING ORIFICES
INSTALL MAIN BEARING INSERTS IN BLOCK
INSTALL CRANKSHAFT
INSTALL OIL PUMP AND CHECK DRIVE GEAR-TO-CRANKSHAFT CLEARANCE
INSTALL CRANKSHAFT REAR OIL SEAL HOUSING
CHECK OIL SEAL HOUSING RUNOUT
CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE HANDLING PRECAUTIONS
INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE ASSEMBLY
INSTALL CRANKSHAFT FRONT WEAR SLEEVE
INSTALL TIMING GEAR COVER
INSTALL CRANKSHAFT FRONT OIL SEAL (WITH TIMING GEAR COVER INSTALLED ON ENGINE)
INSTALL DAMPER PULLEY AND VIBRATION DAMPER
INSTALL FLYWHEEL HOUSING AND FLYWHEEL
COMPLETE FINAL ASSEMBLY
Camshaft and Timing Gear Train
SPECIAL OR ESSENTIAL TOOLS
OTHER MATERIAL
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS—CONTINUED
CHECK VALVE LIFT
CHECK CAMSHAFT END PLAY
REMOVE VIBRATION DAMPER AND PULLEY
REMOVE TIMING GEAR COVER
MEASURE CAMSHAFT DRIVE GEAR-TO-CRANKSHAFT GEAR BACKLASH
REMOVE CAMSHAFT
REMOVE CAMSHAFT GEAR, SPACER, AND THRUST PLATE
MEASURE THRUST PLATE AND SPACER
INSPECT AND MEASURE CAMSHAFT
MEASURE CAMSHAFT JOURNAL O.D. AND BUSHING I.D.
MEASURE CAMSHAFT LOBE LIFT
REMOVE, INSPECT, AND MEASURE CAMSHAFT FOLLOWERS
ASSEMBLE CAMSHAFT
SERVICE CAMSHAFT BUSHINGS USING JDG602 ADAPTER SET
SERVICE CAMSHAFT BUSHINGS USING JDG606 ADAPTER SET
INSTALL CAMSHAFT
INSTALL TIMING GEAR COVER
INSTALL CRANKSHAFT FRONT WEAR SLEEVE (WITH TIMING GEAR COVER INSTALLED ON ENGINE)
INSTALL CRANKSHAFT FRONT OIL SEAL (WITH TIMING GEAR COVER INSTALLED ON ENGINE)
COMPLETE FINAL ASSEMBLY
Lubrication System
OTHER MATERIAL
LUBRICATION SYSTEM SPECIFICATIONS
LUBRICATION SYSTEM SPECIFICATIONS—CONTINUED
DIAGNOSING LUBRICATION SYSTEM MALFUNCTIONS
DRAIN ENGINE OIL, COOLANT, AND REMOVE OIL PAN
LUBRICATION SYSTEM GENERAL INFORMATION
ENGINE OIL BYPASS VALVE HOUSING, OIL COOLER, AND DUAL FILTER SYSTEM
REPLACE BYPASS OIL CHECK VALVE ON DUAL FILTER SYSTEM
ENGINE OIL BYPASS VALVE HOUSING, OIL COOLER, AND COMBINATION FILTER
REPLACE BYPASS OIL CHECK VALVE ON COMBINATION FILTER SYSTEM
REMOVE OIL BYPASS VALVE HOUSING AND OIL COOLER ASSEMBLY
REMOVE AND INSPECT OIL COOLER BYPASS AND OIL FILTER BYPASS VALVES
ASSEMBLE BYPASS VALVE HOUSING AND OIL COOLER ASSEMBLY
INSTALL OIL BYPASS VALVE HOUSING AND OIL COOLER ASSEMBLY
REMOVE, DISASSEMBLE, INSPECT, AND INSTALL OIL PRESSURE REGULATING VALVE AND HOUSING
CHECK CRANKSHAFT GEAR-TO-OIL PUMP DRIVE GEAR BACKLASH
ENGINE OIL PUMP ASSEMBLY
REMOVE ENGINE OIL PUMP
INSPECT AND CLEAN OIL PUMP
CHECK DRIVE SHAFT END PLAY
CHECK DRIVE SHAFT SIDE MOVEMENT
CHECK PUMPING GEAR BACKLASH
INSPECT OIL PUMP DRIVE GEAR
ADJUST OIL PUMP SET SCREW
INSTALL ENGINE OIL PUMP
INSTALL OIL PAN
Cooling System
SPECIAL OR ESSENTIAL TOOLS
OTHER MATERIAL
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS—CONTINUED
SERVICE EQUIPMENT AND TOOLS
DIAGNOSING COOLING SYSTEM MALFUNCTIONS
GENERAL COOLING SYSTEM INFORMATION
REMOVE AND INSTALL HEAVY DUTY FAN DRIVE ASSEMBLY
REMOVE FAN DRIVE BEARINGS
INSTALL FAN DRIVE BEARINGS
REMOVE WATER PUMP
WATER PUMP ASSEMBLY
DISASSEMBLE WATER PUMP
MEASURE BEARING BORE IN WATER PUMP HOUSING
ASSEMBLE WATER PUMP
INSTALL WATER PUMP
REMOVE WATER MANIFOLD
INSPECT AND CLEAN WATER MANIFOLD
INSTALL WATER MANIFOLD
REMOVE AND TEST THERMOSTATS
INSTALL THERMOSTATS
COOLANT CONDITIONER FILTER GENERAL INFORMATION
INTERGAL (AIR INTAKE) COOLANT FILTER CONDITIONER ASSEMBLY
REMOVE AND INSTALL INTERGAL (AIR INTAKE) COOLANT FILTER CONDITIONER ASSEMBLY
AIR INTAKE MANIFOLD MOUNTED COOLANT FILTER CONDITIONER ASSEMBLY
REMOVE AND INSTALL AIR INTAKE MANIFOLD COOLANT FILTER CONDITIONER ASSEMBLY
WATER MANIFOLD MOUNTED COOLANT FILTER CONDITIONER ASSEMBLY
REMOVE AND INSTALL WATER MANIFOLD MOUNTED COOLANT FILTER CONDITIONER ASSEMBLY
COMPLETE FINAL ASSEMBLY
CHECK AND ADJUST V-BELT TENSION
REPLACE FAN BELT TIGHTENER BEARINGS
REMOVE COOLANT HEATER—IF EQUIPPED
INSTALL COOLANT HEATER—IF EQUIPPED
Air Intake and Exhaust System
SPECIAL OR ESSENTIAL TOOLS
OTHER MATERIAL
AIR INTAKE AND EXHAUST SYSTEM SPECIFICATIONS
AIR INTAKE AND EXHAUST SYSTEM SPECIFICATIONS—CONTINUED
EXTENDING TURBOCHARGER LIFE
REMOVE TURBOCHARGER
DIAGNOSING TURBOCHARGER MALFUNCTIONS
TURBOCHARGER SEVEN-STEP INSPECTION
PERFORM RADIAL BEARING CLEARANCE TEST
PERFORM AXIAL END PLAY BEARING TEST
DISASSEMBLE AND INSPECT TURBOCHARGER
REPLACE CENTER HOUSING AND ROTATING ASSEMBLY
PRELUBE TURBOCHARGER
INSTALL TURBOCHARGER
REMOVE AND INSTALL INTAKE MANIFOLD (6101H ENGINES)
INSPECT AND REPAIR INTAKE MANIFOLD—6101H ENGINES
REMOVE AFTERCOOLER ASSEMBLY AND INTAKE MANIFOLD (6101A ENGINES)
INSPECT AND REPAIR AFTERCOOLER (6101A ENGINES)
INSTALL INTAKE MANIFOLD AND AFTERCOOLER ASSEMBLY (6101A ENGINES)
INSTALL AFTERCOOLER COVER (6101A ENGINES)
REMOVE, INSPECT, AND INSTALL EXHAUST MANIFOLD ASSEMBLY
Fuel System
SPECIAL OR ESSENTIAL TOOLS
OTHER MATERIAL
FUEL SYSTEM SPECIFICATIONS
FUEL SYSTEM SPECIFICATIONS—CONTINUED
RELIEVE SYSTEM PRESSURE
REPLACE RECTANGULAR FINAL FUEL FILTER
REPLACE FUEL CHECK VALVE ASSEMBLY
REPLACE PRIMARY FUEL FILTER/WATER SEPARATOR—IF EQUIPPED
REMOVE FUEL SUPPLY PUMP
TEST FUEL SUPPLY PUMP FOR LEAKS
DISASSEMBLE FUEL SUPPLY PUMP
INSPECT AND REPAIR FUEL SUPPLY PUMP
ASSEMBLE FUEL SUPPLY PUMP
INSTALL FUEL SUPPLY PUMP
GENERAL INFORMATION FOR ANEROID—MECHANICAL GOVERNORS ONLY
REPAIR ANEROID—MECHANICAL GOVERNORS ONLY
REMOVE HYDRAULIC ANEROID ACTIVATOR—MECHANICAL GOVERNORS ONLY
DISASSEMBLE AND CLEAN HYDRAULIC ANEROID ACTIVATOR PARTS—MECHANICAL GOVERNORS ONLY
ASSEMBLE AND INSTALL HYDRAULIC ANEROID ACTIVATOR—MECHANICAL GOVERNORS ONLY
SERVICE OVERFLOW VALVE
REMOVE FUEL SHUT-OFF SOLENOID—MECHANICAL GOVERNORS ONLY
INSTALL FUEL SHUTOFF SOLENOID—MECHANICAL GOVERNORS ONLY
REMOVE FUEL INJECTION PUMP
REPAIR FUEL INJECTION PUMP
INSTALL FUEL INJECTION PUMP
REMOVE FUEL INJECTION NOZZLES
DIAGNOSE INJECTION NOZZLE MALFUNCTION
DIAGNOSE INJECTION NOZZLE MALFUNCTION—CONTINUED
TEST FUEL INJECTION NOZZLES
PERFORM OPENING PRESSURE TEST
FUEL INJECTION NOZZLE SPECIFICATIONS
PERFORM LEAKAGE TEST
MAKE CHATTER AND SPRAY PATTERN TEST
DISASSEMBLE FUEL INJECTION NOZZLE
CLEAN AND INSPECT FUEL INJECTION NOZZLE ASSEMBLY
PERFORM NOZZLE SLIDE TEST
CLEAN SPRAY ORIFICES
INSPECT NOZZLE HOLDER
INSPECT GLAND NUT
ASSEMBLE FUEL INJECTION NOZZLE
ADJUST FUEL INJECTION NOZZLES
INSPECT AND CLEAN CYLINDER HEAD NOZZLE BORE
INSPECT AND CLEAN NOZZLE SEATING SURFACE
INSTALL FUEL INJECTION NOZZLES
INSTALL FUEL LEAK-OFF AND FUEL DELIVERY LINE ASSEMBLIES
Engine Tune-Up and Break-In
ALTITUDE COMPENSATION GUIDELINE
PRELIMINARY ENGINE TESTING
GENERAL TUNE-UP RECOMMENDATIONS
DYNAMOMETER TEST
DYNAMOMETER TEST SPECIFICATIONS*
ENGINE BREAK-IN GUIDELINES
PERFORM ENGINE BREAK-IN
CHECK CRANKCASE VENTILATION SYSTEM
CHECK AIR INTAKE SYSTEM
CHECK EXHAUST SYSTEM
CHECK AND SERVICE COOLING SYSTEM
CHECK ELECTRICAL SYSTEM
Engine System Operation and Test
SPECIAL OR ESSENTIAL TOOLS
ENGINE TEST SPECIFICATIONS
ENGINE SECTIONAL VIEW
GENERAL ENGINE DESCRIPTION
HOW THE LUBRICATION SYSTEM WORKS
HOW THE LUBRICATION SYSTEM WORKS—CONTINUED
HOW THE COOLING SYSTEM WORKS
HEAD GASKET JOINT CONSTRUCTION AND OPERATION
HEAD GASKET JOINT CONSTRUCTION AND OPERATION—CONTINUED
DIAGNOSING HEAD GASKET JOINT FAILURES
HEAD GASKET INSPECTION AND REPAIR SEQUENCE
DIAGNOSING ENGINE MALFUNCTIONS
DIAGNOSING ENGINE MALFUNCTIONS—CONTINUED
TEST ENGINE COMPRESSION PRESSURE
CHECK ENGINE OIL PRESSURE
MEASURE ENGINE CRANKCASE PRESSURE (BLOW-BY)
PRESSURE TEST COOLING SYSTEM AND RADIATOR CAP
INSPECT THERMOSTAT AND TEST OPENING TEMPERATURE
Air Intake System Operation and Test
SPECIAL OR ESSENTIAL TOOLS
AIR INTAKE AND EXHAUST SYSTEM TEST SPECIFICATIONS
DIAGNOSING AIR INTAKE MALFUNCTIONS
HOW THE AIR INTAKE AND EXHAUST SYSTEM WORKS
AIR CLEANER OPERATION
DIAGNOSING TURBOCHARGER MALFUNCTIONS
HOW THE TURBOCHARGER WORKS
HOW THE TURBOCHARGER IS LUBRICATED
HOW THE AFTERCOOLER WORKS—6101A ENGINES
CHECK INTAKE MANIFOLD PRESSURE (TURBO BOOST)
Fuel System Operation and Tests
SPECIAL OR ESSENTIAL TOOLS
FUEL SYSTEM TEST SPECIFICATIONS
FUEL SYSTEM TEST SPECIFICATIONS—CONTINUED
FUEL INJECTION PUMP SPECIFICATIONS*
FUEL SYSTEM OPERATION
DIAGNOSE FUEL SYSTEM MALFUNCTIONS
MECHANICAL FUEL SUPPLY PUMP OPERATION
MECHANICAL FUEL SUPPLY PUMP OPERATION—(CONTINUED)
DIAGNOSING MECHANICAL FUEL SUPPLY PUMP MALFUNCTIONS
TEST MECHANICAL FUEL SUPPLY PUMP FOR LEAKS
CHECK MECHANICAL FUEL SUPPLY PUMP OPERATION
SERVICE MECHANICAL FUEL SUPPLY PUMP
FUEL SHUT-OFF SOLENOID OPERATIONAL CHECK
FUEL SHUT-OFF SOLENOID RESISTANCE TEST
FUEL SHUT-OFF SOLENOID LINKAGE ADJUSTMENT
RECTANGULAR FINAL FUEL FILTER OPERATION
ROUND PRIMARY FUEL FILTER/WATER SEPARATOR OPERATION
BLEED THE FUEL SYSTEM
IN-LINE FUEL INJECTION PUMP OPERATION
DIAGNOSE IN-LINE FUEL INJECTION PUMP MALFUNCTIONS
CHECK AND ADJUST INJECTION PUMP TIMING
CHECK FAST IDLE SPEED
CHECK AND ADJUST ENGINE SLOW IDLE SPEED
HOW THE ANEROID WORKS—MECHANICAL GOVERNORS ONLY
DIAGNOSE ANEROID MALFUNCTION
HOW THE HYDRAULIC ANEROID ACTIVATOR WORKS—MECHANICAL GOVERNORS ONLY
DIAGNOSE MALFUNCTIONS—HYDRAULIC ANEROID ACTIVATOR
FUEL INJECTION NOZZLES—GENERAL INFORMATION
FUEL INJECTION NOZZLE OPERATION
DIAGNOSE MALFUNCTIONS—FUEL INJECTION NOZZLE
TEST FUEL INJECTION NOZZLES (ENGINE RUNNING)
FUEL DRAIN BACK TEST PROCEDURE
Dealer Fabricated Tools
HOW TO MAKE TOOLS
FABRICATED TOOLS—CYLINDER LINER HOLDING FIXTURE
Index
A
Additives
Coolant
Aftercooler
Inspect and repair
Install
Aftercooler assembly
Remove
Aftercooler cover
Install
Air cleaner
Operation
Air intake
Specifications
Air intake manifold pressure
Aneroid
Air intake system
Check
Diagnostics
General information
Specifications
Altitude compensation guideline
Aneroid
Diagnostics
General information
General information
Repair
Aneroid activator
Remove
Aneroid, hydraulic
Clean
Disassemble
Aneroid, hydraulic activator
Assemble
Diagnostics
General information
Install
Application chart
Engine
B
Bearing caps, main
Measure assembled ID
Bearing, main
Check clearance
Install
Bearing, pilot bore
Check concentricity
Bearing, thrust
Specifications
Bearings, connecting rod
Inspect and measure
Bearings, fan drive
Install
Remove
Bearings, main
Measure assembled ID
Remove
Bearings, thrust
Inspect
Belt tightener bearings
Replace
Belt, V
Check and adjust tension
Block, cylinder
Clean and inspect
Clean and inspect
Disassembly
Measure
Bore, piston pin bushing
Clean and inspect
Break-in, engine
Guidelines
Perform
Perform
Bushing bore, piston pin
Clean and inspect
Bushing, piston pin
Inspect
Install
Remove
Bushings, camshaft
Service with JDG602
Service with JDG606
C
Camshaft
Assemble
Check end play
Install
Measure and inspect
Remove
Service bushings using JDG602
Specifications
Camshaft bushing ID
Measure
Camshaft bushings
Service with JDG606
Camshaft drive gear
Measure backlash
Camshaft followers
Inspect
Camshaft gear
Remove
Camshaft journal OD
Measure
Camshaft lobe lift
Measure
Camshaft spacer
Measure
Remove
Camshaft thrust plate
Measure
Remove
Cap screws, cylinder head
Tighten
TORQUE-TURN
Caps, main bearing
Measure assembled ID
Check valve, oil bypass
Check
Compression pressure, engine
Test
Conditioner filter, coolant
General information
Connecting rod
Cap screw tightening procedure
Inspect rod and cap
Connecting rod bearings
Inspect and measure
Connecting rods
Install
Remove
Coolant
Additives
Check effectiveness
Disposing
Drain
Engine
Specifications
Coolant conditioner filter
General information
Coolant filter conditioner
Assembly
Remove and install
Coolant heater
Install
Remove
Cooling fluid
Cooling orifices
Install
Remove and clean
Remove and clean
Cooling system
Flush
Flushing and servicing
How it works
Pressure test
Cover, aftercooler
Install
Cover, timing gear
Install
Remove
Crankcase
Blow-by
Crankcase ventilation system
Check
Crankshaft
Grinding guidelines
Grinding specifications
Inspect
Install
Remove
Crankshaft end play
Check
Crankshaft gear
Measure backlash
Replace
Crankshaft gear-to oil pump drive gear
Check backlash
Crankshaft journals
Measure OD
Crankshaft rear oil seal
Handling precautions
Remove
Crankshaft, oil pump drive gear
Replace
Crankshaft, rear oil seal
Install
Install
Cylinder block
Clean and inspect
Clean and inspect
Disassembly
Measure
Cylinder head
Check flatness
Clean and inspect
Clean and inspect push rods
Clean valve seats
Inspect rotators and wear caps
Inspect valve springs
Install
Knurl guides
Remove
Cylinder head Diagnosing malfunctions
Cylinder head cap screws
Tighten
TORQUE-TURN
Cylinder head gasket
Failure diagnostics
Cylinder head nozzle bore
Inspect and clean
Inspect and clean
Cylinder head thickness
Measure
Cylinder liner
Identification markings
Manufacturing date code
Cylinder liner flange thickness
Measure
Cylinder liner height
Measure
Cylinder liner O-ring bore
Clean
Cylinder liner O-rings and packings
Install
Cylinder liner standout
Measure
Measure
Recheck
Cylinder liners
Clean
Deglaze
Inspect
Install
Measure
Remove
D
Damper
Remove
Remove
Damper, vibration
Inspect
Install
Diagnostics
Air intake system
Engine
Head gasket failure
Diesel fuel
Dynamometer test
Procedure
Specifications
E
Electrical system
Check
Elevations
Compensation guideline
Engine
Application chart
Assembly sequence
Blow-by
Cleaning
Coolant
Coolant
Coolant
Coolant, check effectiveness
Cooling fluid
Diagnostics
Disassembly sequence
Dynamometer test
General description
Lifting procedure
Mounting on repair stand
Oil
Repair stand
Sealant guidelines
Serial number plate
Engine break-in
Perform
Perform
Engine break-in guidelines
Engine compression pressure
Test
Engine coolant
Drain
Engine oil
Drain
Engine oil pressure
Check
Engine rotation
Check excessive tightness
Engine specifications
Block, liners, pistons, and rods
Crankshaft
Flywheel
Lubrication
Main bearings
Engine test specifications
Engine, specifications
Cylinder head and valves
Exhaust manifold
Remove, inspect, and install
Exhaust system
Check
General information
Specifications
Specifications
F
Failure analysis
Head gasket
Fan belt tightener bearings
Replace
Fan drive
Install bearings
Fan drive assembly
Remove and install
Fan drive bearings
Install
Remove
Filter, coolant conditioner
General information
Filter, final fuel
Replace
Filter, primary fuel
Replace
Filter, rectangular fuel
Operation
Filter, round primary fuel
Operation
Fluid, engine cooling
Flywheel
Check face flatness
Inspect, measure, and repair
Install
Remove
Ring gear, replace
Flywheel housing
Check face runout
Install
Remove
Fuel
Diesel
Fuel check valve
Replace
Fuel delivery line assembly
Install
Fuel filter, final
Replace
Fuel filter, primary
Replace
Fuel filter, rectangular
Operation
Fuel filter, round primary
Operation
Fuel injection nozzle
Make chatter and spray test
Operation
Perform leakage test
Perform opening pressure test
Specifications
Fuel injection nozzle holder
Inspect
Fuel injection nozzles
Adjustment
Assemble
Clean
Clean
Diagnostics
Disassemble
Inspect
Inspect
Install
Remove
Slide test
Test
Test, engine running
Fuel injection pump
Diagnostics
Fast idle speed, check
General information
Install
Repair
Slow idle speed, check and adjust
Specifications
Timing, check and adjust
Fuel leak-off line assembly
Install
Fuel shut-off solenoid
Linkage adjustment
Operational check
Remove
Resistance test
Fuel shutoff solenoid
Adjustment, check
Bracket, install
Install
Fuel supply pump
Assemble
Check operation
Diagnostics
Disassemble
General information
Inspect
Install
Remove
Service
Test for leaks
Fuel supply pump, mechanical
Test
Fuel system
Diagnostics
Fuel drain back test
Operation
Specifications
Torques
Fuel system—Nippondenso
Bleed
G
Galley plugs
Install
Gear
Flywheel ring, replace
Gear, camshaft
Remove
Gear, crankshaft
Measure backlash
Replace
Gear, crankshaft oil pump drive
Replace
Gear, oil pump drive
Inspect
Replace
Grease
Extreme pressure and multipurpose
Guides, valve
Clean
Knurl
Measure
Replace
H
Head, cylinder
Check flatness
Clean and inspect
Clean and inspect push rods
Clean valve seats
Gasket failure diagnostics
Inspect rotators and wear caps
Install
Knurl guides
Measure thickness
Remove
Head, cylinder Diagnosing malfunctions
Heater, coolant
Install
Remove
Housing, flywheel
Check face runout
Install
Remove
Housing, rear oil seal
Check runout
Install
I
Inch torque values
Injection nozzle
Adjustment
Diagnosis
Make chatter and spray test
Operation
Perform leakage test
Perform opening pressure test
Specifications
Test, engine running
Injection nozzle holder
Inspect
Injection nozzle seating surface
Inspect and clean
Injection nozzles
Assemble
Clean
Clean
Diagnostics
Disassemble
Inspect
Inspect
Install
Remove
Slide test
Test
Injection pump
Diagnostics
Fast idle speed, check
General information
Remove
Slow idle speed, check and adjust
Timing, check and adjust
Inserts, valve seat
Install
Remove
Intake manifold
Remove
Intake manifold pressure
Check
Check
Intake manifold,
Inspect
Repair
Intake manifold, 6101A Engines
Install
Intake manifold, 6101H Engines
Remove and install
Intake system, air
Check
J
Journals, crankshaft
Measure OD
L
Leak-off line assembly
Install
Liner flange thickness
Measure
Liner height
Measure
Liner O-rings and packings
Install
Liner shims
Install
Liner standout
Measure
Measure
Recheck
Liner, cylinder
Identification markings
Liner, Cylinder
Manufacturing date code
Liner, O-ring bore
Clean
Liners, cylinder
Clean
Deglaze
Inspect
Install
Measure
Remove
Lubrication system
How it works
M
Main bearing
Check clearance
Main bearing caps
Measure assembled ID
Main bearings
Install
Measure assembled ID
Remove
Manifold pressure, intake
Check
Manifold, exhaust
Remove, inspect, and install
Manifold, intake
Inspect
Install
Remove
Remove and install
Repair
Manifold, intake pressure
Check
Manifold, water
Inspect and clean
Remove
Metric torque values
N
Nozzle bore
Inspect and clean
Inspect and clean
Nozzle holder
Inspect
Nozzle seating surface
Clean and inspect
Inspect and clean
Nozzle, fuel injection
Make chatter and spray test
Operation
Perform leakage test
Perform opening pressure test
Specifications
Nozzles, fuel injection
Install
Remove
Test
O
Oil
Drain
Engine
Oil bypass valve
Check
Oil bypass valve housing
Assemble
Install
Remove
Oil control ring groove
Measure
Oil cooler assembly
Assemble
Install
Remove
Oil cooler bypass valve
Remove and inspect
Oil filter bypass valve
Remove and inspect
Oil pan
Install
Remove
Oil pressure
Check
Oil pressure regulating valve
Remove, disassemble, and install
Oil pressure regulating valve housing
Remove, disassemble, and install
Oil pump
Check drive shaft end play
Check drive shaft side movement
Check pumping gear backlash
Inspect and clean
Inspect drive gear
Install
Install
Remove
Oil pump assembly
Oil pump drive gear
Replace
Oil pump drive gear-to-crankshaft gear
Check backlash
Oil seal housing
Check runout
Oil seal housing, rear
Install
Oil seal, crankshaft rear
Handling precautions
Install
Install
Oil seal, front
Install (timing cover installed)
Install (timing cover installed)
Install (timing cover installed)
Remove (timing cover installed)
Orifices, piston cooling
Remove and clean
Remove and clean
P
Pan, oil
Install
Pin bushing in rod
Install
Pin bushing, piston
Remove
Pin, piston
Install
Piston
Identification markings
Measure protrustion
Piston cooling orifices
Install
Remove and clean
Remove and clean
Piston pin
Install
Piston pin bushing
Install
Remove
Piston pin bushing bore
Clean and inspect
Piston pins and bushings
Inspect
Piston ring groove Check wear
Piston Rings
Remove
Piston skirt OD
Measure
Piston-to-liner
Clearance
Pistons
Clean
Inspect
Install
Remove
Plate
Engine serial number
Plugs, galley
Install
Pressure, engine compression
Test
Pressure, engine oil
Check
Pressure, intake manifold
Check
Check
Pulley, vibration damper
Install
Remove
Remove
Pump, fuel injection
Install
Repair
Pump, fuel supply
Install
Remove
Test for leaks
Pump, injection
Remove
Pump, oil
assembly
Check drive shaft end play
Check drive shaft side movement
Check pumping gear backlash
Inspect and clean
Inspect drive gear
Install
Install
Remove
Pump, water
Assemble
Disassemble
Install
Remove
Push rods
Clean and inspect
R
Radiator cap
Pressure test
Radiator, cap
Pressure test
Rear oil seal
Remove
Relieve system pressure—Nippondenso
Repair stand
Ring gear, flywheel
Replace
Ring groove, oil control
Measure
Rings, Piston
Remove
Rocker arm assembly
Install
Rocker arm shaft assembly
Assemble
Disassemble and inspect
Rod bearings
Inspect and measure
Rod, connecting
Cap screw tightening procedure
Inspect rod and cap
Rods, connecting
Install
Remove
S
Seal housing, rear oil
Check runout
Install
Seal, crankshaft rear oil
Handling precautions
Install
Install
Remove
Seal, front oil
Install (timing cover installed)
Install (timing cover installed)
Install (timing cover installed)
Remove (timing cover installed)
Sealant guidelines
Seats, valve
Clean and inspect
Grind
Measure
Separator, water
Operation
Replace
Serial number plate
Shaft, rocker arm assembly
Assemble
Disassemble and inspect
Shims, liner
Install
Shut-off solenoid, fuel
Linkage adjustment
Operational check
Remove
Resistance test
Sleeve, front wear
Install (timing cover installed)
Install (timing cover installed)
Remove (timing cover installed)
Sleeve, wear
Remove
Solenoid, fuel shut-off
Linkage adjustment
Operational check
Remove
Resistance test
Solenoid, fuel shutoff
Install
Specifications
Air intake and exhaust
Air intake system
Block, liners, pistons, and rods
Camshaft and timing gear train
Coolant
Crankshaft
Cylinder head and valves
Dynamometer test
Engine test
Exhaust system
Flywheel
Fuel injection pump
Fuel system
Intake manifold pressure
Lubrication
Main bearings
Springs, valve
Inspect
Supply pump, fuel
Assemble
Check operation
Diagnostics
Disassemble
General information
Inspect
Install
Service
Supply pump, mechanical fuel
Test
System, air intake
Check
System, cooling
Flush
How it works
System, crankcase ventilation
Check
System, electrical
Check
System, exhaust
Check
System, fuel
Torques
System, lubrication
How it works
T
Test specifications
Engine
Thermostat
Inspect and test
Thermostats
Install
Remove and test
Replace
Thrust bearing
Specifications
Thrust bearings
Inspect
Tightener, fan belt
Replace bearings
Timing gear cover
Install
Install
Remove
Remove
Timing gear train
Specifications
Torque values
Inch
Metric
TORQUE-TURN procedure
Connecting rod cap screws
Cylinder head cap screws
Tune-up
Preliminary engine testing
Tune-Up Recommendations
Turbocharger
Axial End Play Bearing Test
Boost pressure at aneroid
Diagnostics
Diagnostics
General information
General information
How it is lubricated
Install
Prelube
Radial bearing clearance test
Remove
Replace center housing
Replace rotating assembly
V
V-belt tension
Check and adjust
Valve assembly
Assemble
Remove
Valve guides
Clean
Knurl
Measure
Replace
Valve lift
Check
Check
Valve recess
Measure
Valve seat inserts
Install
Remove
Valve seats
Clean and inspect
Grind
Measure
Valve springs
Inspect
Measure
Specifications
Valve, fuel check
Replace
Valve, oil bypass
Check
Valve, overflow
Service
Valve, rotators
Inspect
Valves
Check and adjust clearance
Clean
Grind
Inspect and measure
Remove
Valves Diagnosing malfunctions
Ventilation assembly
Clean and inspect
Ventilation system, crankcase
Check
Vibration damper
Inspect
Install
Remove
Remove
Vibration damper pulley
Install
Remove
Remove
W
Water manifold
Inspect and clean
Remove
Water pump
Assemble
Disassemble
Install
Remove
Water pump housing
Measure bearing bore
Water separator
Operation
Replace
Wear caps
Inspect
Wear sleeve
Remove
Wear sleeve assembly
Install
Install
Wear sleeve, front
Install (timing cover removed)
Install (timing cover installed)
Install (timing cover installed)
Remove (timing cover installed)
PAGE NUMBERS
GROUP 00
00-0001
00-0002
00-0003
00-0004
00-0005
00-0006
00-0007
00-0008
GROUP 01
01-0001
01-0002
01-0003
01-0004
01-0005
01-0006
GROUP 02
02-0001
02-0002
02-0003
02-0004
02-0005
02-0006
02-0007
02-0008
02-0009
02-0010
02-0011
02-0012
02-0013
02-0014
GROUP 03
03-0001
03-0002
03-0003
03-0004
03-0005
03-0006
GROUP 04
04-0001
04-0002
04-0003
04-0004
GROUP 05
05-0001
05-0002
05-0003
05-0004
05-0005
05-0006
05-0007
05-0008
05-0009
05-0010
05-0011
05-0012
05-0013
05-0014
05-0015
05-0016
05-0017
05-0018
05-0019
05-0020
05-0021
05-0022
05-0023
05-0024
05-0025
05-0026
05-0027
05-0028
05-0029
05-0030
05-0031
05-0032
05-0033
05-0034
05-0035
05-0036
05-0037
05-0038
05-0039
05-0040
05-0041
05-0042
05-0043
05-0044
05-0045
05-0046
GROUP 10
10-0001
10-0002
10-0003
10-0004
10-0005
10-0006
10-0007
10-0008
10-0009
10-0010
10-0011
10-0012
10-0013
10-0014
10-0015
10-0016
10-0017
10-0018
10-0019
10-0020
10-0021
10-0022
10-0023
10-0024
10-0025
10-0026
10-0027
10-0028
10-0029
10-0030
10-0031
10-0032
10-0033
10-0034
10-0035
10-0036
10-0037
10-0038
10-0039
10-0040
10-0041
10-0042
10-0043
10-0044
10-0045
10-0046
10-0047
10-0048
10-0049
10-0050
10-0051
10-0052
GROUP 15
15-0001
15-0002
15-0003
15-0004
15-0005
15-0006
15-0007
15-0008
15-0009
15-0010
15-0011
15-0012
15-0013
15-0014
15-0015
15-0016
15-0017
15-0018
15-0019
15-0020
15-0021
15-0022
15-0023
15-0024
15-0025
15-0026
15-0027
15-0028
15-0029
15-0030
15-0031
15-0032
15-0033
15-0034
15-0035
15-0036
15-0037
15-0038
15-0039
15-0040
15-0041
15-0042
15-0043
15-0044
15-0045
15-0046
15-0047
15-0048
15-0049
15-0050
GROUP 16
16-0001
16-0002
16-0003
16-0004
16-0005
16-0006
16-0007
16-0008
16-0009
16-0010
16-0011
16-0012
16-0013
16-0014
16-0015
16-0016
16-0017
16-0018
16-0019
16-0020
16-0021
16-0022
16-0023
16-0024
16-0025
16-0026
GROUP 20
20-0001
20-0002
20-0003
20-0004
20-0005
20-0006
20-0007
20-0008
20-0009
20-0010
20-0011
20-0012
20-0013
20-0014
20-0015
20-0016
20-0017
20-0018
20-0019
20-0020
20-0021
20-0022
20-0023
20-0024
GROUP 25
25-0001
25-0002
25-0003
25-0004
25-0005
25-0006
25-0007
25-0008
25-0009
25-0010
25-0011
25-0012
25-0013
25-0014
25-0015
25-0016
25-0017
25-0018
25-0019
25-0020
25-0021
25-0022
25-0023
25-0024
25-0025
25-0026
25-0027
25-0028
25-0029
25-0030
25-0031
25-0032
25-0033
25-0034
GROUP 30
30-0001
30-0002
30-0003
30-0004
30-0005
30-0006
30-0007
30-0008
30-0009
30-0010
30-0011
30-0012
30-0013
30-0014
30-0015
30-0016
30-0017
30-0018
30-0019
30-0020
30-0021
30-0022
30-0023
30-0024
30-0025
30-0026
GROUP 35
35-0001
35-0002
35-0003
35-0004
35-0005
35-0006
35-0007
35-0008
35-0009
35-0010
35-0011
35-0012
35-0013
35-0014
35-0015
35-0016
35-0017
35-0018
35-0019
35-0020
35-0021
35-0022
35-0023
35-0024
35-0025
35-0026
35-0027
35-0028
35-0029
35-0030
35-0031
35-0032
35-0033
35-0034
35-0035
35-0036
35-0037
35-0038
35-0039
35-0040
35-0041
35-0042
35-0043
35-0044
35-0045
35-0046
35-0047
35-0048
35-0049
35-0050
35-0051
35-0052
35-0053
35-0054
GROUP 100
100-0001
100-0002
100-0003
100-0004
100-0005
100-0006
100-0007
100-0008
100-0009
100-0010
GROUP 105
105-0001
105-0002
105-0003
105-0004
105-0005
105-0006
105-0007
105-0008
105-0009
105-0010
105-0011
105-0012
105-0013
105-0014
105-0015
105-0016
105-0017
105-0018
105-0019
105-0020
105-0021
105-0022
105-0023
105-0024
105-0025
105-0026
GROUP 110
110-0001
110-0002
110-0003
110-0004
110-0005
110-0006
110-0007
110-0008
110-0009
110-0010
110-0011
110-0012
GROUP 115
115-0001
115-0002
115-0003
115-0004
115-0005
115-0006
115-0007
115-0008
115-0009
115-0010
115-0011
115-0012
115-0013
115-0014
115-0015
115-0016
115-0017
115-0018
115-0019
115-0020
115-0021
115-0022
115-0023
115-0024
115-0025
115-0026
115-0027
115-0028
115-0029
115-0030
115-0031
115-0032
115-0033
115-0034
GROUP 199
199-0001
199-0002