John Deere PowerTech 6090 9.0L Tier 3 Stage IIIA Base Diesel Engine Component Technical Manual CTM400 PDF

Contents
General
Safety
Handle Fluids Safely—Avoid Fires
Handle Starting Fluid Safely
Handling Batteries Safely
Prepare for Emergencies
Avoid High-Pressure Fluids
Wear Protective Clothing
Service Machines Safely
Work In Ventilated Area
Work in Clean Area
Install Fan Guards
Avoid Hot Parts
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Illuminate Work Area Safely
Use Proper Lifting Equipment
Construct Dealer-Made Tools Safely
Practice Safe Maintenance
Use Proper Tools
Dispose of Waste Properly
Live With Safety
Engine Identification
Engine Model Designation
Engine Serial Number Plate Information
Engine Option Code Label
Engine Application Chart (OEM) (Outside Equipment Manufacturers)
Fuels, Lubricants and Coolant
Diesel Fuel
Bio-Diesel Fuel
Lubricity of Diesel Fuel
Dieselscan Fuel Analysis
Diesel Engine Break-In Oil
Extended Diesel Engine Oil Service Intervals
Extended Diesel Engine Oil Service Intervals
Alternative and Synthetic Lubricants
Mixing of Lubricants
Oilscan and Coolscan
Grease
Diesel Engine Coolant
Diesel Engine Coolants, Supplemental Additive Information
Testing Diesel Engine Coolant
Replenishing Supplemental Coolant Additives (SCAs) Between Coolant Changes
Operating in Warm Temperature Climates
Flush and Service Cooling System
Disposing of Coolant
Repair and Adjustments
Engine Rebuild
Engine Overhaul Guidelines
Engine Repair Stand
Safety Precautions
Install Adapters on Engine Repair Stand
Engine Lifting Procedure
Clean Engine
Disconnect Turbocharger Oil Inlet Line
Mount Engine on Repair Stand
Engine Disassembly Sequence for Overhaul
Sealant Application Guidelines
Engine Assembly Sequence After Overhaul
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
General Tune-Up Recommendations
Cylinder Head and Valves Repair and Adjustment
Adjust Valve Clearance
Check Valve Lift
Remove Cylinder Head
Diagnosing Head Gasket Joint Failures
Head Gasket Diagnostic Charts
Head Gasket Inspection and Repair Sequence
Inspect Rocker Arm Assembly
Disassemble and Assemble Rocker Arm Assembly
Measure Valve Recess
Preliminary Cylinder Head and Valve Checks
Remove Valve Assembly
Inspect and Measure Valve Springs
Inspect Valve Spring Caps, Wear Caps, and Retainer Locks Serial Number
(200,000— )
Clean Valves
Inspect and Measure Valves
Grind (Reface) 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 – Serial Number
Clean and Inspect Valve Seats
Measure Valve Seats – Serial Number
Grind Valve Seats
Remove Valve Seat Inserts and Measure Bores in Cylinder Head
Install Valve Seat Inserts
Inspect and Clean Cylinder Head Nozzle Bore
Clean and Inspect Push Rods
Clean and Inspect Top Deck of Cylinder Block
Measure Cylinder Liner Standout (Height Above Block)
Assemble Valve Assembly
Install Cylinder Head and Cap Screws
Torque-to-Yield Flanged-Head Cap Screws—Grade 180 Marked “NO REUSE”
Install Intake Manifold
Install Rocker Arm Assembly
Inspect and Clean Ventilator Outlet Hose
Complete Final Assembly of Fuel Pump Side of Engine
Complete Final Assembly on Exhaust Manifold Side of Engine
Perform Engine Break-In
Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment
Preliminary Liner, Piston, and Rod Checks
Remove Pistons and Connecting Rod Assemblies
Measure Cylinder Liner Standout (Height Above Block)
Remove Cylinder Liners
Deglaze Cylinder Liners
Clean Cylinder Liners
Disassemble Piston and Rod Assembly
Clean Pistons
Visually Inspect Pistons
Check Piston Ring Groove Wear
Inspect Piston Pin and Bore
Visually Inspect Cylinder Liners
Cylinder Liner Manufacturing Date Code Explanation
Determine Piston-to-Liner Clearance
Inspect Rod and Cap
Inspect Piston Pins and Bushings
Remove Piston Pin Bushing, Clean and Inspect Pin Bore
Measure Liner Flange
Inspect and Measure Connecting Rod Bearings
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
Measure Cylinder Block
Install Piston Cooling Orifices
Recheck Cylinder Liner Standout
Install Packing on Cylinder Liner and O-Rings in Block
Install Cylinder Liner in Block
Install Piston and Connecting Rod
Torque-Turn Connecting Rod Cap Screws
Check Engine Rotation for Excessive Tightness
Complete Final Assembly
Crankshaft, Main Bearings and Flywheel Repair and Adjustment
Crankshaft and Main Bearing Failure Analysis
Crankshaft Rear Oil Seal and Wear Sleeve General Information
Remove Crankshaft Rear Oil Seal and Wear Sleeve
Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions
Install Crankshaft Rear Oil Seal Housing
Install Crankshaft Rear Oil Seal & Wear Sleeve Assembly
Inspect Vibration Damper
Check Crankshaft End Play
Remove Crankshaft Vibration Damper
Remove Crankshaft Front Oil Seal and Wear Sleeve
Remove Timing Gear Cover—Engine Removed
Inspect and Measure Flywheel
Check Flywheel Housing Face Runout
Check Flywheel Face Flatness
Check Pilot Bearing Bore Concentricity
Remove Flywheel
Remove SAE 1 Flywheel Housing
Remove SAE 2 and 3 Flywheel Housing
Replace Flywheel Ring Gear
Remove Rear Oil Seal Housing—Engine Removed
Remove Main Bearing Caps
Check Main Bearing Oil Clearance
Remove Connecting Rod Caps and Remove Crankshaft
Inspect Crankshaft
Measure Assembled I.D. of Bearings and O.D. of Crankshaft Journals
Main Bearing Cap Line Bore Specifications
Thrust Bearing New Part Specifications
Replace (Crankshaft) Oil Pump Drive Gear
Replace Crankshaft Gear
Inspect Thrust Bearings
Install Main Bearings and Crankshaft
Check Crankshaft Rear Oil Seal Housing Runout
Install Thrust Washer and Timing Gear Cover
Install Front Wear Sleeve
Install Crankshaft Front Oil Seal
Install Vibration Damper
Install SAE 2 and 3 Flywheel Housing
Install Flywheel
Install SAE 1 Flywheel Housing
Complete Final Assembly
Camshaft and Timing Gear Train Repair and Adjustment
Check Camshaft End Play and Measure Gear Backlash
Remove Vibration Damper and Timing Gear Cover
Remove, Inspect, and Install Crankshaft Gear-Driven Auxiliary Drive—If Equipped
Remove Camshaft
Remove Camshaft Gears
Measure Thrust Washer Thickness
Inspect and Measure Camshaft Followers
Visually Inspect Camshaft
Measure Camshaft Journal O.D. and Bushing I.D.
Measure Camshaft Lobe Lift
Install Camshaft Gears
Service Camshaft Bushings Using JDG602 Adapter Set
Service Camshaft Bushings Using JDG606 Adapter Set
Install Camshaft
Install Thrust Washer and Timing Gear Cover
Complete Final Assembly
Lubrication System Repair and Adjustment
Diagnosing Lubrication System Malfunctions
Top-Load Oil Filter Assembly
Top Load Oil Filter – Theory of Operation
Changing Top-Load Oil Filter
Engine Oil Cooler Assembly
Remove, Inspect, and Install Engine Oil Cooler
Remove Engine from Tractors for Access to Engine Oil Pump
Remove Oil Pan
Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash
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
Install Engine Oil Pump
Remove and Install Oil Pump Outlet Tube and Oil Cooler Crossover Tube Adapter
Remove, Inspect, and Install Oil Pump Pickup Tube
Install Engine Oil Pan
Tighten Cap Screws on Front Frame/Oil Sump – Tractors
Cooling System Repair and Adjustment
Inspect Fan Hub & Replace Bearings in Heavy-Duty, Adjustable Fan Drive Assembly
Replace Bearings in Coolant Manifold-Mounted, Fixed Fan Drive Assembly
Fan Drive Assembly
Checking Belt Tensioner Spring Tension and Belt Wear
Inspect and Install Fan Assembly
Visually Inspect Coolant Pump
Remove Coolant Pump Assembly
Install Coolant Pump Assembly
Replace Bypass Tube & O-Rings in Thermostat Housing
Remove and Test Thermostats
Remove Thermostat Housing
Install Thermostats
Install Thermostat Housing
Remove and Install Coolant Temperature Sensor
Servicing of Engine Coolant Heater
Complete Final Assembly
Air Intake and Exhaust System Repair and Adjustment
Extending Turbocharger Life
Remove Turbocharger
Remove Turbocharger Oil Drain Line
Remove Turbocharger Oil Supply Line
Turbocharger Failure Analysis
Turbocharger Inspection
Repair Turbocharger
Prelube Turbocharger
Install Turbocharger
Install Turbocharger Oil Supply Line Brackets
Install Turbocharger Oil Supply Line
Install Turbocharger Oil Drain Line
Install Heat Shield & Turbocharger Oil Supply Line Bracket
Remove and Install Turbocharger Actuator
Install Actuator Coolant Line Fittings
Install Turbocharger Actuator Coolant Return Line
Install Turbocharger Actuator Coolant Supply Line
Remove and Install Actuator Linkage
Remove Exhaust Gas Recirculator (EGR) Assembly
Remove & Install EGR Valve
Remove and Install EGR Coolant Manifold
Remove and Install EGR Cooler Coolant Supply Line
Remove and Install EGR Cooler Return Line
Remove, Inspect, and Install Exhaust Manifold
Remove, Inspect, and Install Intake Manifold
Install EGR
Remove and Install Air Inlet/Heater
OEM Starting and Charging Systems Repair and Adjustment
Remove and Install Alternator (OEM Engines)
Remove and Install Starter Motor (OEM Engines)
Theory of Operation
Base Engine Operation
Engine Sectional View Serial Number
General Engine Operation
Lubrication System Operation
Cooling System Operation
Exhaust Gas Recirculator (EGR) and Variable Geometry Turbocharger (VGT)
Head Gasket Joint Construction and Operation
Air Intake and Exhaust System Operation
Turbocharger Operation
How the Turbocharger is Lubricated
Diagnostics
Observable Diagnostics and Tests
About This Group of the Manual
9.0L – L1 – Excessive Oil Consumption
9 L – L1 – Excessive Oil Consumption

Engine Oil Consumption
9.0L – L2 – Engine Oil Pressure Low
9.0L – L3 – Engine Oil Pressure High
9.0L – C1 – Engine Coolant Temperature Above Normal
9.0L – C2 – Engine Coolant Temperature Below Normal
9.0L – C3 – Coolant In Oil or Oil In Coolant
Test Engine Compression Pressure with Mechanical Gauge
Check Engine Cranking Speed
Check Engine Oil Pressure
Check for Excessive Engine Crankcase Pressure (Blow-by)
Check for Turbocharger Oil Seal Leak
Inspect Thermostat and Test Opening Temperature
Pressure Test Cooling System and Radiator Cap
Pressure Test EGR Cooler for Air Leaks
Check for Head Gasket Failures
Measure Intake Manifold Pressure (Turbo Boost)
Check for Intake and Exhaust Restrictions
Test for Intake Air Leaks
Check for Exhaust Air Leaks
Tools and Other Materials
Repair Tools and Other Materials
Group 021 — Cylinder Head and Valves – Essential Tools
Group 021 — Cylinder Head and Valves – Service Equipment and Tools
Group 021 — Cylinder Head and Valves – Other Materials
Group 030 — Cylinder Block, Liners, Pistons, and Rods Essential Tools
Group 030 — Cylinder Block, Liners, Pistons, and Rods Other Materials
Group 040 — Crankshaft, Main Bearings and Flywheel Essential Tools
Group 040 — Crankshaft, Main Bearings and Flywheel Service Equipment and Tools
Group 040 — Crankshaft, Main Bearings and Flywheel Other Materials
Group 050 — Camshaft and Timing Gear Train Essential Tools
Group 050 — Camshaft and Timing Gear Train Other Materials
Group 060 — Lubrication System Other Materials
Group 070 — Cooling System Other Materials
Group 080 — Air Intake and Exhaust System Other Materials
Group 100 — Starting and Charging Systems Essential Tools
Diagnostic Service Tools
Base Engine Diagnostic Tools
Dealer Fabricated Service Tools
How to Make Tools
DFRG3—Cylinder Liner Holding Fixture
Specifications
Repair and General OEM Specifications
General OEM Engine Specifications–Continued
Unified Inch Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
Group 020 — Cylinder Head and Valves Repair Specifications
Group 030 — Cylinder Block, Liners, Pistons and Rods Repair Specifications
Group 040 — Crankshaft, Main Bearings and Flywheel Repair Specifications
Group 050 — Camshaft and Timing Gear Train Repair Specifications
Group 060 — Lubrication System Repair Specifications
Group 070 — Cooling System Repair Specifications
Group 080 — Air Intake and Exhaust System Repair Specifications
Group 100 — OEM Starting and Charging Systems Repair Specifications
Diagnostic Specifications
Group 150 — Base Engine Diagnostic Specifications (Includes Dynamometer Specifications (OEM) and Turbocharger Boost Specifications)
Dynamometer Test Specifications
Intake Manifold Pressure (Turbocharger Boost) Specifications
Effects of Altitude and Temperature on Engine Performance

Model:

6090AFM75, 6090AFM85, 6090HCQ01, 6090HCQ03, 6090HDW01, 6090HDW02, 6090HDW03, 6090HDW04, 6090HDW07, 6090HDW08, 6090HDW09, 6090HDW13,6090HDW24, 6090HF475, 6090HF484, 6090HF485, 6090HFC47, 6090HFC48, 6090HFG84, 6090HFG86, 6090HFL75, 6090HFL85, 6090HFL95, 6090HFU84, 6090HH001, 6090HH002, 6090HH005, 6090HH006, 6090HH008, 6090HN001, 6090HN002, 6090HN003, 6090HN005, 6090HN006, 6090HRW01, 6090HRW02,6090HRW03, 6090HRW04, 6090HRW05, 6090HRW06,6090HRW08, 6090HRW09, 6090HRW10, 6090HRW11, 6090HRW13, 6090HRW15, 6090HRW16, 6090HRW18,6090HRW20, 6090HRW21, 6090HRW22, 6090HRW23, 6090HRW24, 6090HRW25, 6090HRW26, 6090HRW27, 6090HRW28, 6090HRW29, 6090HRW30, 6090HRW31, 6090HRW32, 6090HRW33, 6090HRW34, 6090HRW35, 6090HRW36, 6090HRW37, 6090HRW38, 6090HRW39, 6090HRW40, 6090HRW41, 6090HRW42, 6090HRW43,6090HRW44, 6090HRW45, 6090HRW46, 6090HRW47,6090HRW48, 6090HRW49, 6090HRW50, 6090HRW51, 6090HRW52, 6090HRW53, 6090HRW54, 6090HRW57, 6090HRW58, 6090HRW59, 6090HRW74, 6090HRW75, 6090HRW76, 6090HRW77, 6090HRW78, 6090HRW79, 6090HRW82, 6090HRW83, 6090HRW84, 6090HRW85, 6090HRW86, 6090HRW87, 6090HT001, 6090HT002, 6090HT003, 6090HT005, 6090HT006, 6090HT009, 6090HT803, 6090HT804, 6090HTJ03, 6090HTJ04, 6090HTJ05, 6090HTJ09, 6090HTJ10, 6090HTJ11, 6090HTJ12, 6090HTJ13, 6090HTJ16, 6090HTJ21, 6090HTJ23, 6090HTJ24, 6090HTJ26, 6090HZ001,6090HZ002, 6090HZ003, 6090HZ003B, 6090HZ003C, 6090HZ003D, 6090RW210, 6090RW211, 6090RW212, 6090RW214, 6090RW215, 6090RW216, 6090RW217, 6090SFM85, 6135HDW07

For complete service information also see:

PowerTech Plus 9.0 L Diesel Engines—Level 14 Diagnostics – Electronic Fuel Systems with Denso HPCR…CTM385
Alternators and Starting Motors…CTM77
OEM Engine Accessories…CTM67