DOWNLOAD PDF John Deere 8R MY11-13 & 8R MY14 9.0 L Power Cylinder Installation Instruction Manual

9.0 L Power Cylinder Update MPRG32334 15RW625; DTAC Solution Number: 100717

PRODUCT IMPROVEMENT PROGRAM 9.0 L Power Cylinder Update RG40055 31JUL20

(ENGLISH)

8R MY11-13 (000182 — 071270) and 8R MY14 (000064 — 003679)

John Deere Waterloo Works RG40055 (31JUL20) PRINTED IN U.S.A. COPYRIGHT © 2019 DEERE & COMPANY Moline, Illinois All rights reserved.

A John Deere ILLUSTRUCTION ™ Manual RG40055-19-31JUL20

MPRG32334 / 15RW625; DTAC Solution Number: 100717

Recognize Safety Information This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

T81389 —UN—28JUN13

Follow recommended precautions and safe operating practices.

DX,ALERT -19-29SEP98-1/1

Understand Signal Words DANGER; The signal word DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

TS187 —19—30SEP88

WARNING; The signal word WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION; The signal word CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events which could lead to personal injury.

A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General

precautions are listed on CAUTION safety signs.

CAUTION also calls attention to safety messages in this manual.

DX,SIGNAL -19-05OCT16-1/1

Carefully read all safety messages in this instruction. Read the product operators manual for operating instructions and safety messages. Do not let anyone operate without instruction. (A copy of the operators manual may also be available from the Service ADVISOR™ application.)

TS201 —UN—15APR13

Follow Safety Instructions

Service ADVISOR is a trademark of Deere & Company DX,READ,INS -19-23JUN09-1/1

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Park Machine Safely Before working on the machine:

TS230 —UN—24MAY89

• Lower all equipment to the ground.

• Stop the engine and remove the key.

• Disconnect the battery ground strap.

• Hang a "DO NOT OPERATE" tag in operator station.

DX,PARK -19-04JUN90-1/1

Notice To Technician

additional information is required, reference TM110319, Interim Tier 4 CTM104819, or Final Tier 4 CTM117719.

PIP: 15RW625

If repairing a Final Tier 4 series engine (engine serial number U000064 — U003679), also order MPRG32335 Final Tier 4 HPCR Delivery Line Kit.

Title: 9.0L Power Cylinder Update Problem: Piston rings breaking.

Solution: Update engine with new piston rings.

Pictures in this document cover repair of an Interim Tier 4 series engine. Final Tier 4 series engines will be similar. If

Different tractor configurations require different parts, all of which are included in the part kits. Upon completion of update, there will be some left over parts.

CB33994,0000D53 -19-06FEB15-1/1

Essential, Recommended, and Fabricated Tools

JDG861 Torque Wrench Adapter JDG11258 Rear Lifting Bracket

NOTE: Order tools according to information given in the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC).

JDG11252 Front Lifting Bracket JDG451 Gauge Block or KJD10123 Gauge

Below are tools listed in this group.

D17526CI (SAE) or D17527CI (METRIC)

JT07336 Lift Sling

JDG10998 Liner Shim Installation Tool

JDG820 Flywheel Rotation Tool

D1062 or D01073AA Liner Pullers CB33994,0000D54 -19-03FEB15-1/1

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Engine Repair Stand NOTE: Only the 2722 kg (6000 lb) heavy-duty engine repair stand No. D05223ST manufactured by Owatonna Tool Co., Owatonna, Minnesota is referenced in this manual. When any other repair stand is used, consult the manufacturer's instructions for mounting the engine.

RG15800 —UN—03OCT08

Refer to steps in this document to remove engine from machine before installing it on repair stand.

D05223ST Engine Repair Stand CB33994,0000D55 -19-03FEB15-1/1

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

MPRG32334 Power Cylinder Update Kit Contents Part Number

Description

Quantity

RE538581

BEARING, CONNECTING ROD

6

R542878

CAP SCREW, CONNECTING ROD

12

DZ100946

CAP SCREW, CYLINDER HEAD

26

R521261

CAP SCREW, ROCKER ARM HOLD DOWN

6

R528196

CAP SCREW, TURBOCHARGER

4

R534121

CAP SCREW, TURBOCHARGER

4

RE292067

CLAMP

1

RE568261

CLAMP, EGR

1

RE285844

CLAMP, TURBOCHARGER

1

RE289839

CLAMP, TURBOCHARGER

3

RE509672

FILTER ELEMENT, OIL

1

R526831

GASKET, EGR (3 BOLT-PATTERN)

3

R525541

GASKET, ENGINE CYLINDER HEAD

1

R529510

GASKET, EXHAUST PIPE

2

R318954

GASKET, AIR FLOW TUBE

2

R320564

GASKET, AIR FLOW TUBE

1

RE554856

GASKET, DOSER

1

R532724

GASKET, INTAKE MANIFOLD

1

R533894

GASKET, OIL PAN

1

R535094

GASKET, TURBO MOUNTING

1

R529141

GASKET, TURBO OIL RETURN

1

R521158

GASKET, TURBOCHARGER

1

RE547771

HPCR DELIVERY LINES (Fuel lines)

1

RE547772

HPCR DELIVERY LINES (Fuel lines)

1

RE547773

HPCR DELIVERY LINES (Fuel lines)

1

RE547774

HPCR DELIVERY LINES (Fuel lines)

1

RE547775

HPCR DELIVERY LINES (Fuel lines)

1

RE547776

HPCR DELIVERY LINES (Fuel lines)

1

51M7047

O-RING, ACCUMULATOR (ILS)

2

R47153

O-RING, BY-PASS TUBE

2

T77613

O-RING, DOSER FUEL LINE/FUEL PUMP RETURN

6

T77814

O-RING, FAN DRIVE CONTROLLER

1

R63548

O-RING, FUEL INJ INLET/TURBO LINES

10

R505452

O-RING, INJECTOR NOZZLE

6

R74354

O-RING, INJECTOR SEALING

6

R31378

O-RING, IVT INPUT SHAFT AUX

1

R528247

O-RING, TURBO AIR TUBE

1

R86588

O-RING, TURBO AIR TUBE

2

R56466

O-RING, TURBO DRAIN LINE

3

R71732

O-RING, TURBO DRAIN LINE/OIL COOLER Continued on next page

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O-RING, TURBO LINE/EGR LINE

7

R63185

O-RING, TURBOCHARGER

1

R56905

O-RING, VENTURI

3

DZ110134

PISTON-LINER KIT

6

R528112

SEAL, EXHAUST TUBE SEAL

2

RE158066

SEAL, HUB, INPUT ASSEMBLY (PST)

1

R119207

SEAL, IVT INPUT SHAFT AUX

1

RE32442

SEAL, IVT INPUT SHAFT AUX

1

R526607

SEAL, ROCKER ARM COVER

1

R528237

SEALING RING, EGR COOLER

1

R519640

SNAP RING, PISTON PIN

12

R548750

WASHER, SEALING, AIR INTAKE MANIFOLD

7

R131051

WASHER, SPECIAL (VERT NOZZ SEALING)

6 CB33994,00001F5 -19-26JUN19-2/2

MPRG32335 Final Tier 4 HPCR Delivery Lines Kit Contents (Engine Serial Numbers U000064 — U003679) Part Number

Description

Quantity

RE553111

HPCR DELIVERY LINES

1

RE553112

HPCR DELIVERY LINES

1

RE553113

HPCR DELIVERY LINES

1

RE553114

HPCR DELIVERY LINES

1

RE553115

HPCR DELIVERY LINES

1

RE553116

HPCR DELIVERY LINES

1 CB33994,0000D57 -19-03FEB15-1/1

Disconnect Battery and Lower ILS 1. Remove side shield (A) and battery cover (B).

A— Side Shield

RXA0146413 —UN—26NOV14

2. Disconnect negative (—) battery cable.

B— Battery Cover

CB33994,0000D58 -19-03FEB15-1/1

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Lower ILS™ (If Equipped) 1. Remove skid plate and position yourself away from any moving suspension parts.

CAUTION: Before any repair or removal of ILS components, pressure in system must be relieved.

When manually relieving pressure in suspension system, the tractor lowers. Position yourself away from any moving suspension parts to prevent serious injury.

RXA0108299 —UN—01SEP10

NOTE: Bleeding system releases all system pressure from cylinders, accumulators, and lines for suspension system.

2. Push in and turn spring rate decrease and rod side drain valve (B).

3. Push in and turn lower and head side manual drain valve (A) slowly until tractor starts to lower.

4. Once tractor is lowered, continue with repair.

A— Lower and Head Side Manual Drain Valve

B— Spring Rate Decrease and Rod Side Drain Valve CB33994,0000D59 -19-03FEB15-1/1

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A— Starter Wiring D— Steering Line B— Rear Hood Spreader E— Aspirator Pipe C— Steering Line Clamps (qty 2) F— Start Aid Solenoid

RXA0107086 —UN—22JUL10

RXA0107084 —UN—22JUL10

Remove Engine From Tractor

G— Removable Air Diverting Shield H— Radiator Upper Hose

I— Cover

1. Remove hood.

8. Remove steering line clamps (C).

2. Remove engine side shields.

9. For tractors equipped with ILS™, disconnect steering line (D) and remove cover (I).

3. If equipped, remove front fenders.

10. Remove aspirator pipe (E).

4. Drain coolant from engine and radiator into an approved container.

5. Remove dipstick, oil filter, and drain engine oil into an approved container.

6. Disconnect starter wiring (A) and move to rear of tractor.

11. Disconnect start aid solenoid connector (F) and move harness to rear of tractor.

12. Remove air diverting shield (G).

13. Remove upper radiator hose (H).

7. Remove left-hand hood spreader (B).

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14. Remove radiator supports (A).

RXA0147042 —UN—27JAN15

A— Radiator Supports

Continued on next page

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A— Front Hood Seal

RXA0147044 —UN—27JAN15

RXA0147043 —UN—27JAN15

MPRG32334 / 15RW625; DTAC Solution Number: 100717

B— Line Bundle Clamp

15. Remove front hood seal (A).

16. Remove line bundle clamp (B).

RXA0107089 —UN—22JUL10

RXA0146662 —UN—05JAN15

CB33994,0000D89 -19-06FEB15-3/18

17. Remove lower radiator hose (A).

18. Disconnect coolant hose (B) from engine.

RXA0146666 —UN—06JAN15

19. Remove deaeration tank (C) and bracket.

20. Disconnect CAC pipe (G).

21. Disconnect fuel cooler hose.

NOTE: Hose may have to be cut off to remove. Replace with hose from dealer stock.

22. Remove air deflector panel (D).

23. Remove fan blade.

24. Disconnect control unit connector (E) from engine.

A— Lower Radiator Hose B— Coolant Hose C— Deaeration Tank D— Air Deflector Panel

IMPORTANT: Label and identify all connectors and sensors for reassembly.

E— Controller Connector F— Main Harness G— CAC Pipe

25. Identify, label, and disconnect main harness connectors (F) and place on right-hand side of tractor.

Continued on next page

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26. For MFWD tractors only: Remove cap screws (A) from harness (B).

B— Wire Harness RXA0147041 —UN—27JAN15

A— Cap Screws

CB33994,0000D89 -19-06FEB15-5/18

27. Remove right-hand hood spreader (A) and disconnect fuel lines (B).

28. Remove exhaust pipe (C).

29. Remove air intake pipe (G.).

RXA0107090 —UN—22JUL10

30. For tractors equipped with air trailer brakes, perform the following steps:

• Disconnect air compressor lube line (D) and compressor oil return line (F).

• Disconnect air compressor clean air supply line (E).

A— Rear Hood Spreader B— Fuel Lines C— Exhaust Pipe D— Air Compressor Pressure Lube Line

E— Air Compressor Clean Air Supply Line F— Air Compressor Oil Return Line G— Air Intake Pipe

CB33994,0000D89 -19-06FEB15-6/18

31. For tractors equipped with ILS:

• Remove upper suspension accumulators from manifold.

RXA0057619 —UN—15OCT01

a. Unscrew upper accumulator (A) from front differential case. b. Remove upper accumulators.

A— Upper Accumulator

Continued on next page

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A— Heater Manifold Fitting

B— Air Cleaner C— Line Clamp

RXA0107094 —UN—22JUL10

RXA0107095 —UN—26JUL10

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D— Drive Coupler Cap Screws (qty 9)

32. Disconnect line from heater manifold fitting (A).

34. Remove cap screws (D) using JDG Flywheel Rotation Tool and disconnect drive coupler.

33. Remove line clamp (C).

RXA0147039 —UN—27JAN15

RXA0147038 —UN—27JAN15

CB33994,0000D89 -19-06FEB15-8/18

35. Remove heat shield (A).

36. Remove cap screws from P-clamps (B).

A— Heat Shield B— P-Clamps

RXA0147040 —UN—27JAN15

37. Disconnect fuel line (D) from fuel filter housing and fitting (C). Remove fuel line (D).

C— Fitting D— Fuel Line

Continued on next page

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A— Power Steering Line

RXA0146693 —UN—06JAN15

RXA0146692 —UN—06JAN15

MPRG32334 / 15RW625; DTAC Solution Number: 100717

B— Power Steering Line

38. For ILS Equipped Tractors Only: Disconnect power steering lines (A and B).

CB33994,0000D89 -19-06FEB15-10/18

39. Remove alternator (A).

RXA0146661 —UN—05JAN15

40. Remove turbo oil drain line, manifold, and OCV oil supply line.

A— Alternator

Continued on next page

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RXA0146664 —UN—28JAN15

RXA0146414 —UN—06JAN15

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41. Detach line bundle clamps (A and B).

42. Remove bracket (C) from rear hood barrier.

RXA0146415 —UN—06JAN15

43. Remove rear hood barrier.

44. Remove line bundle clamp (D).

45. Disconnect line bundle hose (E).

D— Line Bundle Clamp E— Line Bundle Hose

RXA0146669 —UN—06JAN15

A— Line Bundle Clamps B— Line Bundle C— Bracket

Continued on next page

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46. Unhook latches on front coolers and move line bundle (A) towards left-hand side of tractor.

RXA0147045 —UN—27JAN15

A— Line Bundle

A— Line B— Fitting

RXA0146676 —UN—06JAN15

RXA0111766 —UN—05NOV10

CB33994,0000D89 -19-06FEB15-13/18

D— Wire Harness

C— Starting Fluid Hose

47. Remove line (A) and fitting (B).

49. Separate wire harness (D) from engine.

48. Separate starting fluid line (C) from wire harness (D).

Continued on next page

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50. Disconnect line (B) from EGR fitting (C) leaving the line clamps in place to line (A).

A— Line B— Line

RXA0146677 —UN—06JAN15

51. Remove shield (D).

C— EGR Fitting D— Shield

RXA0147046 —UN—27JAN15

RXA0147047 —UN—27JAN15

CB33994,0000D89 -19-06FEB15-15/18

A— Crossover Tube

B— Doser Injector

52. Remove crossover tube (A).

54. Remove air filter housing.

53. Remove doser injector (B).

Continued on next page

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C— Upright of JDG11258 Rear A— Lower Mount of JDG11258 Rear Lifting Bracket Lifting Bracket B— Mounting Cap Screws (qty 2) D— Rear Mounting Cap Screw (qty 4)

RXA0125462 —UN—28MAR12

RXA0118385 —UN—28JUN11

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E— JDG11252 Front Lifting Bracket F— Front Mounting Cap Screw

55. Using suggested lifting brackets, perform the following:

• Install upright of JDG11258 rear lifting bracket (C)

• Attach lower mount of JDG11258 Rear Lifting

• Install JDG11252 Front Lifting Bracket (E) with cap

using cap screws (D).

Bracket (A) to engine block with M20 cap screws (B) and tighten.

screw (F) and tighten.

NOTE: Install upright of JDG11258 Rear Lifting Bracket by inserting from underside upward between turbos first.

CB33994,0000D89 -19-06FEB15-17/18

IMPORTANT: Make sure that chains are vertical between lifting brackets and lifting sling.

56. Attach JT07336 Lift Sling (A) with chains (B) as shown to lifting brackets (C) and hoist.

57. Remove engine-to-front frame (differential case on ILS™) cap screws (qty 24).

IMPORTANT: Reference diagram later in this manual for removal order of engine to frame cap screws.

RXA0107104 —UN—05NOV10

58. Lift engine (D) rearward and remove out right-hand side of tractor.

IMPORTANT: Avoid damage to oil pickup tube by carefully lifting and removing engine from tractor.

A— JT07336 Lift Sling B— Chain Hooks

C— Lift Brackets D— Engine

CB33994,0000D89 -19-06FEB15-18/18

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Safety Precautions The engine repair stand should be used only by qualified service technicians familiar with this equipment.

center of balance is generally located a few millimeters above the crankshaft.

To maintain shear strength specifications, alloy steel SAE Grade 8, Class 12.9, or higher cap screws must be used to mount adapters and engine to repair stand. Torque cap screws to specification given.

To prevent possible personal injury due to engine slippage, recheck to make sure that engine is solidly mounted before releasing support from engine lifting device.

For full thread engagement, be certain that tapped holes in adapters and engine blocks are clean and not damaged. A thread length engagement equal to 1-1/2 screw diameters minimum is required to maintain strength requirements.

To avoid structural or personal injury, do not exceed the maximum capacity rating of 2722 kg (6000 lb). Maximum capacity is determined with the center of the engine located not more than 330 mm (13 in.) from the mounting hub surface of the engine stand.

The center of balance of an engine must be located within 51 mm (2 in.) of the engine stand rotating shaft. Engine

Never permit any part of the body to be positioned under a load being lifted or suspended. Accidental slippage may result in personal injury.

The lifting jack is to be used when it is necessary to lift the engine for rotation. When working on the engine, the jack should be at its lowest position to keep the center of gravity low and the possibility of tipping low.

To prevent possible personal injury due to sudden engine movement, lower engine by operating jack release valve slowly. Do not unscrew release valve knob more than two turns from its closed position.

CB33994,0000D5B -19-03FEB15-1/1

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Mount Engine on Repair Stand

Consumables: • M16 — Capscrews

RG8770 —UN—08DEC97

Special Tools: •JT07336 — Engine Load Leveling Lifting Strap

Mounting Engine on Repair Stand

Continued on next page

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CAUTION: NEVER remove the overhead lifting equipment until the engine is securely mounted onto the repair stand and all mounting hardware is tightened to specified torque. Always release the overhead lifting equipment slowly.

NOTE: If starter motor or crankshaft driven auxiliary drive accessory is to be removed from engine, remove before mounting engine onto repair stand.

RG16530 —UN—22OCT08

NOTE: Open crankcase ventilation separator may have to be removed from left side of cylinder block before mounting engine on stand, depending on application.

1. Mount the starter side of the engine to the engine adapter with four M16 x 2 x 110 mm Grade 8 (or higher class) cap screws.

2. Torque cap screws to 225 N·m (165 lb.-ft.).

3. Carefully remove lift sling from engine.

To remove engine from repair stand, reverse the installation procedure.

Engine Mounted on Stand

To install engine in vehicle, refer to machine technical manual.

CB33994,0000D5C -19-03FEB15-2/2

A— Engine Wire Harness

RXA0146377 —UN—18NOV14

RXA0146376 —UN—18NOV14

Engine Disassembly

B— ECU C— Turbo Assembly

1. Label, disconnect, and remove engine wire harness (A).

3. On engine models with series turbocharger option, disconnect and remove both turbocharger oil supply lines.

NOTE: Only disconnect harness from components that are being removed from engine for repair.

4. Remove turbine and compressor interstage pipes.

2. Remove ECU (B) and bracket.

5. Remove turbocharger assembly (C) and oil drain line.

Continued on next page

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6. Remove cap screw and oil drain line (A).

RXA0146667 —UN—06JAN15

A— Cap Screw and Oil Drain Line

RXA0146679 —UN—06JAN15

RXA0146678 —UN—06JAN15

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A— Turbo Oil Drain Tube

7. When removing turbocharger, oil drain line (A) may not come out of bracket and have to be disconnected from turbocharger.

CB33994,0000D8A -19-06FEB15-3/10

8. Label and remove separator (A), line, (B), hose (C), and separator bracket.

C— Hose RXA0146378 —UN—18NOV14

A— Separator B— Line

Continued on next page

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9. Remove fuel lines from fuel pressure rail (A) and injectors (B). Remove fuel line clamps for later use.

B— Injectors RXA0146380 —UN—18NOV14

A— Fuel Pressure Rail

RXA0147048 —UN—27JAN15

RXA0146682 —UN—06JAN15

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A— Caps

10. Prevent contamination to fuel system by capping all fuel fittings (A).

Continued on next page

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A— Air Throttle Actuator Assembly

B— Thermostat Cover

C— Bypass Tube

11. Remove air throttle actuator assembly (A).

12. Remove thermostat cover (B) and bypass tube (C).

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13. Remove EGR cooler supply and return lines and air pipes (A). Disassemble at pipe connections (B).

14. Remove venturi and EGR valve assembly.

A— EGR Assembly

RXA0146383 —UN—28JAN15

15. Remove EGR cooler and bracket assembly.

B— Pipe Connections

Continued on next page

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NOTE: DO NOT damage option code label (if equipped), when removing rocker arm cover.

RXA0146387 —UN—18NOV14

NOTE: The vent hose should be disconnected from the vent elbow. The vent elbow should not be removed from the rocker arm cover unless the intent is to replace the elbow assembly.

16. Remove breather hose from rocker arm cover elbow.

17. Remove rocker arm cover (A).

18. Remove electronic injector wiring harness.

19. Remove rocker arm shaft assembly, push rods (B), and valve bridges. Identify push rods for reassembly.

21. Remove cylinder head (D).

20. Remove air intake manifold (C).

IMPORTANT: Injectors protrude through head, place head on blocks to avoid damage.

IMPORTANT: Do not use screwdrivers, wedges, or pry bars between cylinder head and block to loosen head to block gasket seal.

22. Remove and dispose of head gasket.

Continued on next page

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23. Remove oil pump assembly (A).

25. Remove pistons and connecting rods (C). Identify connecting rods for reassembly. .

26. Proceed to section Cylinder Liner — Removal for removal of liners (D), O-rings, and packings.

C— Pistons and rods D— Liners

RXA0146391 —UN—18NOV14

A— Oil Pump B— Rod End Caps

RXA0146390 —UN—18NOV14

24. Remove connecting rod end caps (B).

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Cylinder Liner — Removal

B

1. Use D1062AA or D01073AA Cylinder Liner Puller (B) to remove cylinder liner (A).

IMPORTANT: When using D01062AA (or D01073AA) Cylinder Liner Puller (B) to remove liners (A), be sure jaw (C) of puller is correctly positioned before attempting to remove liner.

DO NOT over-tighten liner puller to remove liners. Doing so could easily break liners.

RG17557 —UN—31AUG09

A

C

D01062AA or D017073AA Cylinder Liner Puller CB33994,0000D5E -19-03FEB15-1/2

2. Remove packing (A) from cylinder if it does not come out with liner (E).

3. Remove orange O-ring (B) and white O-ring (C) from cylinder block (D).

A— Square Packing (Neoprene) B— Orange O-ring (Silicone) C— White O-ring (Viton)

D— Cylinder Block E— Cylinder Liner F— Coolant Passage — Cylinder Liner to Block

F

RG16872 —UN—23MAR09

E D A B C Cylinder Liner to Block Assembly CB33994,0000D5E -19-03FEB15-2/2

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Cylinder Block — Cleaning and Inspection

C

B

Tools:

• D17015BR O-ring Bore Cleaning Brush • JDG681 Tap 9/16-12 UNC-2A

RG16887 —UN—23MAR09

A

NOTE: All components (including piston cooling orifices), coolant gallery plugs and oil gallery plugs must be removed from the cylinder block for inspection and cleaning. Refer to the proper group for removal of all external and internal mounted components.

1. Use D17015BR O-ring Bore Cleaning Brush or an equivalent brush to thoroughly clean all debris from cylinder liner O-ring bores.

2. Clean out all threaded holes for cylinder head mounting cap screws in top deck of cylinder block.

Use JDG681 Tap or an equivalent 9/16-12 UNC-2A tap approximately 88.9 mm (3.5 in.) long. Use compressed air to remove any debris or fluid which may be present in the cap screw hole.

IMPORTANT: If cylinder block is cleaned in a hot tank, be sure to remove any aluminum parts. Aluminum parts can be damaged or destroyed by hot tank solutions. Remove all serial number plates.

Measure Liner Counterbore in Block A— Cylinder Block Liner Counterbore Depth B— Cylinder Block Top Deck Surface

C— Liner Support Flange

and allow an improper liner fit. Thoroughly clean all filings from cylinder block.

5. Measure liner flange counterbore depth (A) in block and compare with specification.

Specification Cylinder Block Flange Counterbore—Depth.................. 11.973—12.023 mm (0.471—0.473 in.)

3. Clean block thoroughly using cleaning solvent, pressure steam, or a hot tank.

4. Inspect liner support flange (C) for burrs. If burrs are present, use a small half-moon file and LIGHTLY file (in a circular motion) burr off at approximately a 60° angle. DO NOT let file hit top deck of cylinder block (B) while filing.

Carefully inspect block for cracks or any other physical damage. If a cracked block is suspected, pressure-test the block. Replace block if there is evidence of a crack or physical damage.

NOTE: DO NOT file liner support flange excessively.

Excess filing can damage liner support flange CB33994,0000D5F -19-03FEB15-1/2

6. Clean turbo drain and exhaust surfaces (A and B).

B— Turbo Exhaust Surface

RXA0146684 —UN—07JAN15

A— Turbo Drain Surface

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Cylinder Liner — Installation and Height Measurement Tools:

• JDG451 Gauge Block or KJD10123 Gauge • D17526CI (SAE) or D17527CI (Metric) • JDG10998 Liner Shim Installation Tool Consumable:

• AR54749 Soap Lubricant

A— Cylinder Liner B— Liner Shim C— Square Packing for Liner Pilot OD — Green

RG16683 —UN—22DEC08

It is not necessary to remove piston from liner during height measurement.

D— Top Cylinder Block O-ring Packing — Orange E— Bottom Cylinder Block O-ring Packing — Black F— Cylinder Block

Install Cylinder Liner and Packings CB33994,0000D8B -19-06FEB15-1/3

RG15975 —UN—15SEP09

RG15895 —UN—19MAY09

Liner Shim — Installation

Install Liner Shim JDG10998 — Liner Shim Installation Tool A— Liner Shim B— Liner Flange

C— JDG10998 — Shim Installation Tool

1. Turn liner upside down to rest on top of flange.

specification, based on initial measurement.

Shims are available in 0.051 mm (.002 in.), 0.102 mm (.004 in.), and 0.152 mm (.006 in.) thickness.

IMPORTANT: Liner shims are one time use only.

IMPORTANT: Use care when installing shim so it does not twist or kink. Double check to be sure shims are positioned squarely to flange.

2. Carefully install liner shim over OD of liner and slide past the packing step to liner body.

IMPORTANT: A maximum of 2 liner shims may be used to achieve liner standout specification. Select the shim or shims provided in this kit to meet

3. Use JDG10998 Shim Installation tool to help guide shim over liner until seated to underside of liner flange.

Remove tool and set aside.

Continued on next page

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RG16870 —UN—07MAY09

RG16868 —UN—07MAY09

Install Cylinder Liners without Packings for Initial Liner Height Measurement

Cylinder Liner Secured in Block

Check Liner Standout using JDG451 Gauge Block

NOTE: While orientation of liner date code is not a requirement, installation of liners with date code to front of engine makes it easier in the future to rotate liners 90° if pitting or cavitation is present.

4. Measure each liner in four places, approximately at 1:30, 5:30, 7:30, and 10:30 clock positions as viewed from the rear of the engine (flywheel end). Record all measurements.

IMPORTANT: Remove all old gasket material, rust, carbon, and other foreign material from top deck of block. Gasket surface MUST BE CLEAN. Use compressed air to remove all loose foreign material from cylinder block combustion deck.

Specification Cylinder Liners—Standout (Height Above Block)..........................................................................0.102 —0.204 mm (0.004—0.008 in.)

5. If liner standout is high: 1. Install number 1 cylinder liner, with one 0.004 inch shim installed but without packings on liner or in block.

Install liner with manufacturing date code toward front of engine. Seat liner firmly in place in cylinder block.

2. Bolt liners down in 4 places, as shown, using 9/16-12 UNC-2B cap screws and flat washers. Flat washers should be at least 3.18 mm (1/8 in.) thick. Torque cap screws to specification.

Specification Cylinder Liner Cap Screws (For Checking Liner Standout)—Torque........................................................................50 N·m (37 lb.-ft.)

3. Use JDG451 Gauge Block (B) along with D17526CI (English, in.) or D17527CI (Metric, mm) Dial Indicator or KJD10123 Gauge to measure the height (A) of bolted down liners for correct liner stand out.

• Remove liner and check for debris, nicks, or burrs in block counterbore or on underside of liner flange.

• Reinstall liner and measure again.

• If still out of specification, set liner aside and repeat inspection with a new liner and shim.

• If measurement is still too high, block counterbore may be out of specification.

6. If liner standout is low:

• Remove 0.004 inch shim and replace with 0.006 inch shim to liner flange.

• If still out of specification, set liner aside and repeat inspection with a different liner and shim from kit.

• If measurement is still too low, block counterbore may be out of specification.

7. Repeat liner installation and height measurement process for cylinders 2 — 6.

NOTE: Variations in measurement readings may occur within one cylinder and/or between adjacent cylinders.

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RXA0147049 —UN—27JAN15

Connecting Rod — Assembly

IMPORTANT: Orientation of the piston is not required on 9.0L engines. Only the connecting rod has orientation (front) markings.

RXA0147051 —UN—28JAN15

1. Place top of piston liner (A) down.

2. Slide piston (B) to bottom of liner to expose pin bores as shown.

3. Remove original connecting rod (C) from original piston.

4. Install one R519640 snap ring into piston (B) pin bore groove.

5. Lubricate piston pin, piston, and rod bores with clean TY26661 10W30 John Deere Break-in Plus engine oil.

7. Install second R519640 snap ring into piston pin bore groove, securing piston pin. Be sure that both snap rings are seated securely in the piston bore grooves.

8. Check for free movement of the piston pin in rod and piston by pushing pin back and forth against snap rings.

RXA0147053 —UN—27JAN15

9. Install RE538581 connecting rod bearings to connecting rod and cap. Install cap back onto connecting rod with R542878 cap screws.

RXA0147052 —UN—27JAN15

6. Install connecting rod (C) to piston (D). Install and seat piston pin against previously installed snap ring.

Continued on next page

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10. Turn liners upside down to rest on top of flange.

11. Pour AR54749 Soap Lubricant into a suitable container.

B— Liner OD

RG16889 —UN—23MAR09

A— Green Packing

Install Liner Packing CB33994,00012D6 -19-15FEB16-2/5

IMPORTANT: DO NOT use oil or other petroleum-based lubricants on cylinder liner packing or O-rings.

Oil can cause the orange packing to swell, which squeezes liner and could possibly cause a scored piston.

C

12. Dip new packings and O-rings in soap before installation. Do not leave packings or O-ring in soap to soak.

13. Install green square neoprene liner packing over OD of liner and seat firmly against second shoulder of liner.

RG16888 —UN—23MAR09

IMPORTANT: Use care when installing packings so they do not twist or kink. Double check to be sure that both shim and packing are positioned squarely to flange and liner step, respectively.

B

14. Install black O-ring (A) into lower O-ring groove of cylinder block (C).

15. Install orange silicone O-ring (B) into upper O-ring groove of cylinder block.

A Cylinder Liner to Block Packing Installation

16. Install liner assembly into engine block (E).

A— O-ring (Black) B— O-ring (Orange)

17. Remove connecting rod cap.

C— Cylinder Block

18. Rotate crankshaft to allow installation of connecting rod onto crankshaft.

20. Verify connecting rod and cap numbers.

19. Lubricate rod bearings, connecting rod journals 360°, and cylinder liner bore with clean 10W30 John Deere Break-in Plus engine oil.

Continued on next page

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A

When installing caps, make sure stamped numbers (A and B) on rod and cap are positioned on the same side.

C

IMPORTANT: Before installing rod caps and bolts, visually check cylinder liner ID for any nicks, scratches, or other damage from installation of connecting rod and piston assembly.

D

E

Connecting Rod Identification A— Connecting Rod Identification B— Connecting Rod Cap Identification C— Supplier Identification and Date Code

21. Install connecting rod caps.

Continued on next page

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B

RG16908 —UN—25MAR09

IMPORTANT: On connecting rods, make sure that cap is properly aligned on rod with interlocking surfaces sealing tightly and edges aligned. Be sure that the rod cap is seated correctly on to the rod, then install rod cap bolts. DO NOT use the rod bolts to seat the cap to the rod.

Mismatch problems can occur. DO NOT reverse cap on rod. Match pads on side of rod and cap.

30

D— Factory Identification E— Part Number, Serial Number, Weight Class

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Connecting Rod Joint

Torque Turn Connecting Rod Cap Screws A— Tighten This Cap Screw First

IMPORTANT: NEVER use connecting rod cap screws more than once for final engine assembly. Once rod cap screws have been tightened to final torque-turn specifications, they cannot not be reused for another final assembly.

22. Dip R542878 cap screws in clean John Deere 10W30 Break-in Plus engine oil. Make sure bore threads and all threads on cap screws are thoroughly oiled.

23. Install cap screws finger tight.

clockwise until handle of wrench is perpendicular to center line of engine crankshaft axis as shown.

24. Starting with the cap screw closest to piston end (A), torque both cap screws to initial torque specification.

Specification Connecting Rod Cap Screws—Initial Torque...................................................................60 N·m (44 lb.-ft.)

Starting with same cap screw (A), torque turn both cap screws the final 90-100°. Feel rod-to-cap joint to check for proper alignment.

IMPORTANT: DO NOT use pneumatic wrenches to install connecting rod cap screws.

Doing so may damage threads. Use speed-handle wrench instead.

Specification Connecting Rod Cap Screws—Torque Turn........................................ 90–100° Turn Clockwise

NOTE: When applying torque turn to cap screws, position handle of wrench parallel to center line of engine crankshaft axis. Tighten 1/4 turn (90–100°)

25. Repeat procedure for all liners.

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Oil Pump — Installation

1. Install oil pump (A) with original cap screws. Torque to specification.

RXA0147068 —UN—28JAN15

Specification Oil Pump Cap Screws—Torque............................................................................63 N·m (46 lb.-ft.)

2. Install oil tubes (B and C) into adaptor, pump, and block with R71732 O-rings.

3. Install original washers and cap screws (D). Torque to specification.

Specification Oil Tube Adaptor—Torque...........................................................................54 N·m (40 lb.-ft.)

A— Oil Pump B— Oil Tube

C— Oil Tube D— Cap Screws CB33994,0000D62 -19-03FEB15-1/1

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Cylinder Head — Installation Special Tools:

• JDG11256 — Lift Strap, Rear • JDG11252 — Lift Strap, Front Consumable Materials:

• Cylinder Head Cap Screws • Head Gasket • SAE30 Diesel Engine Oil Install Cylinder Head IMPORTANT: ALWAYS thoroughly inspect new cylinder head gasket for possible manufacturing imperfections. Return any gasket that does not pass inspection.

Using Lint free towel, wipe cylinder block combustion surface to remove residual assembly fluids and other contaminants.

RG16676 —UN—25MAY09

1. If necessary, install two hollow dowels (C) into the cylinder block top deck surface.

2. Install a new head gasket (D) on cylinder block. Do not use sealant on gasket; install dry.

IMPORTANT: If cylinder head is lowered onto cylinder block and the head is not positioned correctly on locating dowels, remove cylinder head and install a new gasket. DO NOT try to reposition cylinder head on the same gasket again since the fire ring may be damaged.

NOTE: It may be beneficial to use additional guide pins to locate gasket to cylinder block combustion surface.

3. Install cylinder head (B) on gasket on cylinder block, using locating dowels as a guide. Make sure that head is positioned correctly over dowels and sits flat on cylinder block top deck.

Cylinder Head Assembly A—Cylinder Head Cap Screw B—Cylinder Head

C—Hollow Dowels D—Cylinder Head Gasket

NOTE: Excess oil will not allow cap screws to reach proper clamp load using torque to yield strategy.

4. Dip entire cap screw in clean SAE30 diesel engine oil.

Allow excess oil to drip off cap screws.

Continued on next page

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IMPORTANT: Only ASTM Grade 180 Flanged-Head cap screws marked “NO REUSE” are recommended for use on 6090 engines. ALWAYS use NEW cap screws when installing cylinder head. Cap screws may be used only one time.

DO NOT use multi-viscosity oils to lubricate cap screws. SAE30 is recommended.

RG13904 —UN—09MAY05

NOTE: All cylinder head cap screws are the same length.

5. Install 26 special cylinder head cap screws through head and gasket and into block.

Cap Screw Identification IMPORTANT: Always use the cap screws listed in the relevant parts catalog.

Special Cap Screws for Cylinder Head

Identify which type of cap screw is being used on the application and refer to correct torque procedure.

B—Type “B” Cap Screw

RG30937 —UN—12NOV18

A—Type “A” Cap Screw

Cylinder Head Cap Screws Continued on next page

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Torque Procedure for Cap Screw “A”

Cylinder Head Cap Screw Torque Sequence A—Front of Engine

1. Tighten the cap screw shown as number 17 in the torque sequence to initial torque specification.

NOTE: If a cap screw is accidentally tightened more than 90° in any one sequence, DO NOT loosen cap screw but make adjustments in the next tightening sequence.

Specification Type A Cylinder Head Cap Screw—Torque (initial)............................................................................................80 N·m (60 lb·ft)

4. First pass, sequentially tighten all cap screws an additional 90°. Line on cap screw will be perpendicular to crankshaft.

2. Sequentially tighten all cap screws to the initial torque specification.

5. Second pass, sequentially tighten all cap screws an additional 90°. Line on cap screw will be parallel to crankshaft.

Specification Type A Cylinder Head Cap Screw—Torque (initial)............................................................................................80 N·m (60 lb·ft)

IMPORTANT: Cap screw MUST NOT be tightened more than a total of 270° ± 5°.

3. Using an oil proof pen, pencil, or marker, draw a line parallel to the crankshaft across the entire top of each cap screw. This line is used as a reference mark.

6. Final pass, sequentially tighten all cap screws an additional 90°. Line on cap screw will be perpendicular to crankshaft.

Continued on next page

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Torque Procedure for Cap Screw “B”

Cylinder Head Cap Screw Torque Sequence A—Front of Engine

loosen cap screw but make adjustments in the next tightening sequence.

1. Tighten the cap screw shown as number 17 in the torque sequence to initial torque specification.

Specification Type B Cylinder Head Cap Screw—Torque (initial)..........................................................................................120 N·m (88 lb·ft)

2. Sequentially tighten all cap screws to the initial torque specification.

Specification Type B Cylinder Head Cap Screw—Torque (initial)..........................................................................................120 N·m (88 lb·ft)

3. Using an oil proof pen, pencil, or marker, draw a line parallel to the crankshaft across the entire top of each cap screw. This line is used as a reference mark.

4. First pass, sequentially tighten all cap screws an additional 90°. Line on cap screw will be perpendicular to crankshaft.

5. Second pass, sequentially tighten all cap screws an additional 90°. Line on cap screw will be parallel to crankshaft.

6. Third pass, sequentially tighten all cap screws an additional 90°. Line on cap screw will be perpendicular to crankshaft.

IMPORTANT: Cap screw MUST NOT be tightened more than a total of 360° ± 5°.

7. Final pass, sequentially tighten all cap screws an additional 90°. Line on cap screw will be parallel to crankshaft.

NOTE: If a cap screw is accidentally tightened more than 90° in any one sequence, DO NOT CB33994,0000090 -19-13NOV19-4/4

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Intake Manifold — Installation

Consumable: None

Special Tools: 120 mm, 90 mm, and 65 mm Threaded Guide Pin.

RG20398A —UN—16FEB12

RG20397 —UN—27JUN11

NOTE: Guide pins can be made by cutting heads off M8 cap screws of sufficient length, as noted.

Intake Manifold Gasket and Guide Pins

Intake Manifold Installation A— 90 mm Threaded Guide Pin E— Gasket B— 120 mm Threaded Guide Pin F— 110 mm Flange Head Cap C— Cylinder Head Screws D— 65 mm Threaded Guide Pin G— 55 mm Flange Head Cap Screw H— 80 mm Flange Head Cap Screws

I— 80 mm Flange Head Cap Screw J— 95 mm Flange Head Cap Screw K— Sealing Washers

L— Right Side of Intake Manifold

1. Install R532724 intake manifold gasket (E) on the cylinder head (C).

5. Install intake manifold over guide pins and place on gasket (E) and cylinder head (C).

2. Install one 90 mm threaded guide pin (A) through gasket (E) into left rear side of the cylinder head.

6. Install six 80 mm flange head cap screws (H) through intake manifold on right-hand side into cylinder head.

3. Install one 120 mm threaded guide pin (B) through gasket (E) into left-hand front side of cylinder head.

7. Remove guide pins (A), (B) and (D) from cylinder head. Install one 55 mm flange head cap screw (G) where guide pin (D) was removed.

4. Install one 65 mm threaded guide pin (D) through gasket into right side of the cylinder head.

NOTE: Intake manifold gasket (E) has a specially designed hole and slot in 90 mm and 120 mm pin locations to improve gasket alignment on the cylinder head.

8. Remove original sealing washers. Install seven R548750 sealing washers (K): five 110 mm flange head cap screws (F), one 80 mm flange head cap screw (I), and one 95 mm flange head cap screw (J) and lubricate all with SAE 30 diesel engine oil.

Continued on next page

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9. Torque all intake manifold to cylinder head cap screws to specification as per sequence. Numbers are cast into intake manifold for torquing sequence.

Specification Intake Manifold to Cylinder Head Cap Screws—Torque............................................................................20 N·m (177 lb.-in.)

RG20399 —UN—27JUN11

10. Individually back out each cap screw 180° and torque to specification as per sequence.

Specification Intake Manifold to Cylinder Head Cap Screws—Torque Turn.......................................................... 20 N·m + 90° (177 lb.-in. + 90°) Tightening Sequence

11. Then back out cap screw number 1 to 180° and retorque to specification.

Specification Intake Manifold to Cylinder Head Cap Screws# 1—Torque Turn..................................................................................... 20 N·m + 90° (177 lb.-in. + 90°)

NOTE: If a bolt is missed or out of sequence repeat steps.

CB33994,0000D8E -19-06FEB15-2/2

Push Rod — Cleaning and Inspection Special Tools: • None

T81233 —UN—01NOV88

Consumables: • None 1. Clean push rods with solvent and compressed air.

2. Check push rods for straightness by rolling on a flat surface.

3. Inspect contact ends for wear and damage.

Checking Valve Push Rods for Straightness

4. Replace defective push rods.

5. Install push rods.

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Rocker Arm Shaft Assembly — Installation

RG17172 —UN—19AUG09

IMPORTANT: When possible, install rocker arm assembly PRIOR to installing fuel injectors.

It is easier to adjust valve clearances, and it eliminates the chance of damaging the injectors when installing rocker arm assembly.

1. Rocker Arm Assembly Installation Special Tools: • None Consumables: • Mounting Screws, SAE 30 Engine Oil

Rocker Arm Shaft Assembly Torque Sequence

NOTE: Cylinder no. 1 can be verified by looking for “T” mark on backside of cam fuel pump drive gear in fuel pump opening in block, or removing plug on right-hand side of timing gear cover and looking for notch on cam fuel pump drive gear tooth. a. Rotate engine to number 1 cylinder top dead center (TDC). Lock to position by inserting timing pin through rear block flange into hole in flywheel.

IMPORTANT: Push rods should be installed to same position in cylinder head from which they were removed. b. If removed, install (12) push rods to cylinder head with cup end up.

NOTE: Index of valve bridges to valve stems is immaterial. c. If removed, install valve bridges to valve stems.

IMPORTANT: Rocker arm mounting screws cannot be reused. Replace rocker arm mounting screws removed from engine with new screws.

g. Seat rocker arm balls in push rod seats before torquing of rocker arm pedestal cap screws. h. In the sequence shown, torque six rocker pedestal-to-cylinder head cap screws to initial specification.

Specification Rocker Arm Shaft Pedestal Cap Screws (qty 6)—Initial Torque....................................................................20 N·m (177 lb.-in.)

i. Individually, in the sequence shown, loosen one cap screw at a time 90° minimum. j. Then final tighten and torque-turn the same cap screw to specification: Specification Rocker Pedestal-toCylinder Head Cap Screw—Torque Turn........................................................... 40 N·m +120° (30 lb.-ft. +120°)

k. Repeat previous two steps for remaining five cap screws.

d. Lubricate rocker arm pedestal cap screws under head with SAE 30 diesel engine oil. e. Carefully install rocker arm assembly. Verify rocker arms, push rods, and valve bridges are in proper position.

2. Proceed to section: Valve — Clearance Adjustment.

f. Install six R521261 rocker arm shaft assembly hold down cap screws through pedestals into cylinder head finger tight.

CB33994,0000D8F -19-06FEB15-1/1

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Valve — Clearance Adjustment

cooling system does not have time to take place, causing burned valves and low power.

Tools: • JDG820 — Flywheel Turning Tool • JDE81-4 — Flywheel Timing Pin

Too much valve clearance causes a lag in valve timing, causing engine valve train imbalance. Fuel-air mixture enters cylinders late during intake stroke. Exhaust valve closes early and prevents waste gases from being removed from cylinders. Also, valves close with a great deal of impact, which may crack or break valves and scuff camshaft and followers.

Consumables: • None Too little valve clearance throws valves out of time. Valves open too early and close too late. This causes valves to overheat due to hot combustion gases rushing past valves when out of time. Overheating lengthens valve stems which prevents proper seating of valves. Valves seat so briefly or poorly that normal heat transfer into the

IMPORTANT: Valve clearance MUST BE checked and adjusted with engine COLD.

RG18318 —UN—31MAR10

RG18317 —UN—31MAR10

1. Install JDG820 Flywheel Turning Tool and JDE81-4 Timing Pin.

Timing Gear Cover Plug

Notched Gear Tooth

2. Rotate engine with flywheel turning tool until timing pin engages timing hole in flywheel.

Rotate engine one full revolution (360°) to No. 1 top dead center compression.

NOTE: If rocker arms for No. 1 (front) cylinder are loose, engine is at No. 1 top dead center compression.

NOTE: Engine can also be checked for #1 top dead center (TDC) by removing plug on right-hand side of timing gear cover. If engine is at #1 TDC, a notched tooth on camshaft gear is visible through the timing gear cover hole.

NOTE: If rocker arms for No. 6 (rear) cylinder are loose, engine is at No. 6 top dead center.

EJE2PTA,0000D2C -19-31JUL20-1/4

3. To help adjusting valve clearance, push rocker arm foot (A) forward for easier feeler gauge access (B).

B— Clearance for Feeler Gauge

RG17174 —UN—19AUG09

A— Rocker Arm Foot

Rocker Arm Foot Position Continued on next page

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RG16813 —UN—31AUG09

MPRG32334 / 15RW625; DTAC Solution Number: 100717

Valve Clearance Adjustment — #1 TDC Exhaust Valve Clearance (Rocker Arm-to-Valve Bridge With Engine Cold)—Clearance....................................................................... 0.64 mm (0.025 in.)

Valve Adjusting Screw Lock Nut—Torque..........................................................................27 N·m (20 lb.-ft.)

4. With engine lock-pinned at “TDC” of No. 1 pistons compression stroke, use a bent feeler gauge to check valve clearance on Nos. 1, 3, and 5 exhaust valves and Nos. 1, 2, and 4 intake valves. If out of specification, loosen lock nut on rocker arm adjusting screw. Turn adjusting screw until feeler gauge slips with a slight drag. Hold the adjusting screw from turning with 4 mm hex key wrench and torque lock nut to specifications.

Recheck clearance again after torquing lock nut.

Readjust clearance as necessary.

Specification Intake Valve Clearance (Rocker Arm-to-Valve Bridge With Engine Cold)—Clearance....................................................................... 0.35 mm (0.014 in.)

Continued on next page

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RG16812 —UN—31AUG09

MPRG32334 / 15RW625; DTAC Solution Number: 100717

Valve Clearance Adjustment — #6 TDC

5. Rotate flywheel 360° until No. 6 piston is at “TDC” of its compression stroke. Rocker arms for No. 6 piston should be loose.

7. When finished adjusting valves, install sight plug back into timing cover.

6. Check and adjust valve clearance to the same specifications on Nos. 2, 4, and 6 exhaust and Nos. 3, 5, and 6 intake valves.

EJE2PTA,0000D2C -19-31JUL20-4/4

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RG17238A —UN—17JUN09

Injector Wiring Harness — Installation

Install Injector Wiring Harness A— Injector Harness B— Harness Carrier Captured Cap Screws (qty 5)

C— Harness Carrier Clips (qty 5) D— Wiring Harness Tab Housing

1. Lay fuel injector wiring harness carrier assembly (A) inside intake manifold.

2. Start five captured screws (B) in wiring harness carrier into intake manifold.

Specification Captured Screws — Harness Carrier to Intake Manifold—Torque..........................................................................20 N·m (177 lb.-in.)

3. Place 3 mm thick spacers between each harness carrier clip (C) and intake manifold boss. Torque captured screws to specification and remove spacers.

Continued on next page

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Wiring Harness Tab Housing Assembly

RG17240 —UN—17JUN09

RG17239A —UN—17JUN09

MPRG32334 / 15RW625; DTAC Solution Number: 100717

Assembled Wiring Harness Tab Housing

4. Verify that O-ring is on wiring harness tab housing (D).

Lubricate with SAE 30W engine oil.

5. Press wiring harness tab housing (D) through hole in intake manifold.

RG17241A —UN—17JUN09

NOTE: Retaining clip bumps (F) should “click” and fasten behind wiring harness tab housing notches.

6. Install tab housing retaining clip (E).

7. Check wiring harness tab housing (D) on inside of intake manifold. Ensure that tab housing is oriented properly with intake manifold alignment feature (G), as shown.

D— Tab Housing E— Retaining Clip

Tab Housing to Intake Manifold Alignment

F— Bumps on Retaining Clip G— Intake Manifold Alignment Feature CB33994,0000D68 -19-03FEB15-2/3

8. Apply LOCTITE® 242 medium strength thread locker to injector terminal studs. Install 2 wire lead eyelets (H) of wiring harness to each fuel injector. Finger start nuts to terminal studs, then torque to specification.

RG17242A —UN—17JUN09

Specification Wiring Harness Nuts to Injector Terminal Studs—Torque Turn.......................................1 N·m + 18° additional turn (9.0 lb.-in. + 18° additional turn) H— Injector Terminal Wiring Leads Injector Terminal Wiring Leads LOCTITE is a trademark of Loctite Corp.

CB33994,0000D68 -19-03FEB15-3/3

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

Rocker Arm Cover — Installation

Consumables: • None

RG17181 —UN—19AUG09

Special Tools: • None

RG17711 —UN—15OCT09

Rocker Arm Cover Torque Sequence

Rocker Arm Cover B— Rocker Arm Cover

IMPORTANT: Always use a new rocker arm cover seal when reinstalling cover.

2. Install vent hose to elbow on rocker arm cover.

1. Install R526607 rocker arm cover seal and rocker arm cover (B). Torque rocker arm cover cap screws to specifications in sequence as shown.

3. Install any wiring harness connections removed from sensors.

Specification Rocker Arm Cover-to-Cylinder Head Cap Screw—Torque......................................................................35 N·m (26 lb.-ft.)

CB33994,0000D69 -19-03FEB15-1/1

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RG17237A —UN—17JUN09

Injection Lines — Installation

Fuel Rail and Injection Lines A— High-Pressure Common Rail D— Pressure Relief Line G— Injector Line Clamp to B— Mounting Bolts — Fuel Rail Connector — Cylinder Head Cylinder Head Cap Screw to Cylinder Block E— Pressure Relief Line and H— Injector Line Clamps C— Mounting Studs — Fuel Rail Connector — Fuel Rail I— Fuel Line — High-Pressure to Cylinder Block F— High-Pressure Injection Line Pump to Fuel Rail — three sets of two

IMPORTANT: It is recommended that injection lines be replaced anytime the lines are disconnected.

There are two main reasons:

and if lines are not replaced it is unlikely a good seal will be made.

IMPORTANT: Remove all fuel system caps previously installed!

• Fuel pressures for Interim Tier 4 engines have increased 20%. The higher fuel pressures are more difficult to seal.

• High-pressure lines are softer than mating parts (inlet connector, high-pressure common rail, high-pressure fuel pump, etc.) and are made to deform to the shape of the harder components. This deformation is permanent

1. For Interim Tier 4 series engines, install fuel lines supplied with kit MPRG32334 to fuel rail (A) and flow dampers (D).

2. For Final Tier 4 series engines, install fuel lines supplied with kit MPRG32335.

Continued on next page

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J— High-Pressure Fuel Pump

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NOTE: When tightening fuel supply line to rail, tighten fuel rail end of line first.

RG18303 —UN—30MAR10

3. Install and finger-start high-pressure injection lines in three sets of two lines (F) to inlet connectors (cylinder head end) and flow dampers (fuel rail end). Do not torque now.

Specification Interim Tier 4 Fuel Inlet Line Fittings—Torque....................................................................50 N·m (37 lb.-ft.)

Specification Final Tier 4 Fuel Inlet Line Fittings—Torque............................................................................60 N·m (44 lb.-ft.)

Fuel Line Wrench

Specification Interim Tier 4 High-Pressure Injection Line Fittings—Torque....................................................................50 N·m (37 lb.-ft.)

IMPORTANT: While tightening the fuel delivery line fitting, do not allow the inlet connector to turn. If the inlet connector is allowed to turn, galling might occur on the injector sealing surface. This could cause fuel leaks.

Specification Final Tier 4 High-Pressure Injection Line Fittings—Torque....................................................................60 N·m (44 lb.-ft.)

4. Using a backup wrench, tighten the fuel line fittings to the inlet connectors and to the flow dampers.

5. Torque each end of all high-pressure lines to specification.

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RXA0146686 —UN—06JAN15

RXA0146685 —UN—06JAN15

MPRG32334 / 15RW625; DTAC Solution Number: 100717

Specification Fuel Line Clamp Cap Screws (E)—Torque........................................................................8 N·m (71 lb.-in.)

Clamp Cap Screws (E)—Torque...................................................................................30 N·m (22 lb.-ft.)

D— Clamp and Cap Screw E— Clamp Cap Screw

RXA0146689 —UN—06JAN15

RXA0146688 —UN—06JAN15

A— Fuel Line Position B— Fuel Line Position C— Fuel Line Position

RXA0146687 —UN—06JAN15

6. Install previously removed fuel line clamps (D) in positions (A, B, and C) with cap screw supplied with fuel line. Install original clamp cap screws (E). Torque to specification.

CB33994,0000D6A -19-03FEB15-3/3

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EGR Cooler Assembly — Installation

RG20349 —UN—19MAY11

RG20350 —UN—19MAY11

EGR Cooler Assembly and Coolant supply Line — Installation

EGR Cooler on Coolant Supply Line

EGR Coolant Supply Line

1. Install R71732 O-rings on both ends of the EGR cooler coolant supply line (A).

NOTE: Lubricate O-rings with AMOGEL or equivalent grease before installation.

RG20351 —UN—19MAY11

2. Install the EGR cooler coolant supply line (A) into the coolant manifold (B).

3. Install EGR cooler onto intake manifold while inserting EGR coolant supply line (A) into the EGR cooler coolant inlet port (C).

4. Install one cap screw (D) through the EGR cooler coolant supply line flange into the EGR cooler inlet port. Torque to specification.

EGR Cooler on Exhaust Manifold

Specification Cap Screw (D)—Torque................................................................15 N·m (133 lb.-in.)

A— EGR Cooler Coolant Supply Line B— Coolant Manifold C— EGR Cooler Coolant Inlet Port D— Cap Screw

5. Install R528237 sealing ring (F) into groove of bellow (G).

E— EGR Cooler F— C-Seal G— Bellow Groove H— EGR Bellow

6. Connect EGR cooler (E) to EGR bellow (H) making sure that sealing ring is in bellow groove.

IMPORTANT: Exhaust gas bellow must be able to pass 0.5 mm gauge between all bellow convolutions to verify that alignment is correct.

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RG20352 —UN—19MAY11

RG20353 —UN—19MAY11

MPRG32334 / 15RW625; DTAC Solution Number: 100717

EGR Cooler Clamping Straps EGR Cooler Clamp I— Clamp J— Clamp Nut K— EGR Clamp Pad

L— Clamping straps N— Bottom Side Clamp Cap M— Top Side Clamp Cap Screws Screws O— EGR Cooler

7. Install three clamping straps (L) over EGR clamp pads (K) onto EGR cooler (O).

NOTE: Position the clamp with the part number at the top.

11. Torque three bottom side clamp cap screws (N) then three top side cap screws (M) from rear to front to specification.

Specification Cap Screws (N and M)—Torque....................................................................................40 N·m (30 lb.-ft.)

8. Install three bottom side clamp cap screws (N) then three top side cap screws (M).

9. Torque three bottom side cap screws (N) to specification from rear to front.

NOTE: Do not reuse clamps after thermal cycle.

Specification

12. Install RE568261 clamp (I) to EGR cooler and EGR bellow at 20 +/- 10° below horizontal. Torque clamp nut (J) to specification. Verify that clamp nut on rear clamp is also torqued to specification.

Cap Screws (N)—Torque.....................................................................................5 N·m (45 lb.-in.)

10. Torque three top side cap screws (M) to specification from rear to front.

Specification Clamp Nut (J)—Torque....................................................................7 N·m (62 lb.-in.)

Specification Cap Screws (M)—Torque....................................................................................5 N·m (45 lb.-in.)

IMPORTANT: Verify that clamping straps are seated in clamp pads and both ends are seated in intake manifold.

Continued on next page

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RXA0147059 —UN—28JAN15

RXA0147058 —UN—28JAN15

Venturi Assembly — Installation

1. Install two R56905 O-rings (A).

2. Install T77932 O-ring (B).

4. Install T77613 O-ring (D).

RXA0147061 —UN—28JAN15

5. Install venturi into mixture housing (E) with original cap screws (F).Torque cap screws after EGR cold side pipe has been installed.

RXA0147060 —UN—28JAN15

3. Install T77932 O-ring (C).

Continued on next page

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MPRG32334 / 15RW625; DTAC Solution Number: 100717 EGR Cold Side Pipe and EGR Valve — Installation 1. If removed, install elbow on EGR cooler. Install new O-ring under elbow and torque cap screws to specification.

RG20367 —UN—23JUN11

2. Install two R526831 gaskets (B) one on each side of the EGR valve (A).

3. Hold EGR valve assembly (A) with two gaskets (B) onto EGR cooler elbow.

4. Install EGR cold side pipe (D) onto EGR valve (A) and insert three M8 X 65 mm cap screws (C) into EGR cooler through EGR cold side pipe (D) and EGR valve (A).

5. Connect EGR cold pipe (D) to venturi (F) with R526831 gasket (G).

EGR Cold Side Pipe and EGR Valve A— EGR Valve B— Gaskets C— Cap Screws D— EGR Cold Side Pipe

6. Install three cap screws (H) to EGR cold pipe (D) and to venturi (F).

E— Cap Screws F— Venturi G— Gasket H— Cap Screws

7. Torque cap screws (H) to specification.

Specification Cap Screws (H)—Torque.....................................................................................5 N·m (45 lb.-in.)

Specification Three Cap Screws — EGR Cold Side Pipe to Venturi —Torque............................................................................35 N·m (26 lb.-ft.)

8. Torque venturi hold down cap screws (E) to specification.

Specification Two Cap Screws — Venturi Hold Down—Torque...............................................................................35 N·m (26 lb.-ft.)

Specification Cap Screws (E)—Torque.....................................................................................5 N·m (45 lb.-in.)

9. Final torque eight bolts from EGR Cold Side Pipe and EGR Valve — Installation Specification Three Cap Screws — EGR valve to EGR Cooler elbow —Torque.............................................................................35 N·m (26 lb.-ft.)

Continued on next page

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RG20368 —UN—23JUN11

RG20369 —UN—23JUN11

EGR Coolant Return Line, Venturi Coolant Lines — Installation

P-Clamp Cap Screw

EGR Coolant Return Line

1. Lubricate and install R71732 O-rings on both ends of EGR cooler coolant return line (A) with AMOGEL grease. Install EGR cooler coolant return line (A) into EGR cooler outlet port (C) and then into timing gear cover port (B).

RG20370A —UN—02FEB12

2. Install cap screw (D) through EGR cooler coolant return line flange to timing gear cover (B). Torque to specification.

Specification Cap Screw (D)—Torque................................................................15 N·m (133 lb.-in.)

3. Install cap screw (F) through P-clamp (E) onto the EGR cooler. Torque to specification.

Venturi Coolant Supply Elbow Fitting

Specification P-Clamp Cap Screw—Torque..............................................................................35 N·m (26 lb.-ft.)

A— EGR Cooler Coolant Return Line B— Timing Gear Cover Port C— EGR Cooler Coolant Outlet Port D— Cap Screw E— P-Clamp F— Cap Screw

NOTE: Install T77613 O-ring (G) onto EGR cooler coolant return line fitting.

G— O-Ring H— Elbow Fitting I— Coolant Inlet Port J— Fitting K— Dosing Injector Coolant Supply Line

4. Install T77932 O-ring into elbow (H).

5. Install T77613 O-ring into adaptor fitting (J).

Specification Supply Hose (K)—Torque...................................................................................25 N·m (221 lb.-in.)

6. Connect dosing injector coolant supply hose (K) to adaptor fitting (J). Torque to specification.

Continued on next page

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RG20372 —UN—30JUN11

RG20371 —UN—23JUN11

MPRG32334 / 15RW625; DTAC Solution Number: 100717

Venturi Coolant Supply Line

Venturi Coolant Return Line J— Venturi Coolant Return Line K— EGR Coolant Return Line Fitting

L— Fittings M— Venturi N— Venturi Coolant Supply Line

IMPORTANT: Install T77932 O-rings into elbows (O and Q) and fitting (L).

7. Install venturi coolant return line (J) between fittings (L) on venturi (M) and the EGR cooler coolant return line fitting (K). Torque both ends to specification.

Specification Return Line (J)—Torque................................................................45 N·m (33 lb.-ft.)

8. Install venturi coolant supply line (N) between elbow fittings (O) on EGR cooler and venturi (Q). Torque both ends to specification.

O— Elbow Fitting P— Elbow Fitting Lock Q— Elbow Fitting

R— Elbow Fitting Lock

Specification Supply Line (N)—Torque...................................................................................45 N·m (33 lb.-ft.)

9. Torque both elbow fittings lock nuts (R and P) to specification while holding elbow fittings (Q and O).

Specification Lock Nuts (R and P)—Torque....................................................................................69 N·m (51 lb.-ft.)

CB33994,0000D6B -19-03FEB15-6/7

Air Bleed Line — Installation NOTE: Air bleed location varies depending on engine configuration.

RXA0146690 —UN—03FEB15

IMPORTANT: Install T77613 O-rings onto both adapters.

1. Install venturi coolant air bleed line (A) between venturi adapter (C) and thermostat housing adapter.

2. Torque both end nuts (B and D) to specification.

Specification End Nuts (B and D)—Torque....................................................................................25 N·m (221 lb.-in.)

Air Bleed Line Installation A— Air Bleed Line B— Air Bleed Line Nut

C— Venturi Adapter D— Air Bleed Line Nut CB33994,0000D6B -19-03FEB15-7/7

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A— Thermostat Housing

RXA0147063 —UN—28JAN15

RXA0147062 —UN—28JAN15

Thermostat Housing — Installation

B— Bypass Tube

1. Install thermostat housing (A) with original cap screws.

Torque to specification.

Specification Thermostat Housing Cap Screws—Torque............................................................................61 N·m (45 lb.-ft.)

Specification Bypass Tube Cap Screws—Torque............................................................................15 N·m (133 lb.-in.)

2. Install bypass tube (B) with R47153 O-rings. Torque to specification.

CB33994,0000D6C -19-03FEB15-1/1

Air Throttle Actuator — Installation 1. Install air throttle actuator assembly (A) with original gaskets and cap screws.

2. Torque four cap screws to specification.

RXA0144857 —UN—15JAN15

Specification Air Throttle Actuator (A) Cap Screws—Torque....................................................................37 N·m (27 lb.-ft.)

CB33994,0000D6D -19-03FEB15-1/1

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RXA0146775 —UN—09JAN15

RXA0146774 —UN—09JAN15

Turbocharger — Installation

1. Install R529141 gasket (A) and R535094 gasket (B).

2. Install turbocharger (C) with four R534121 cap screws (D and E). Torque to specification.

RXA0146776 —UN—28JAN15

Specification Cap Screws (D)—Torque...................................................................................50 N·m (37 lb.-ft.)

3. Route and connect wire harness (F).

4. Tighten oil drain cap screws.

D— Cap Screws E— Cap Screw F— Wire Harness

RXA0146777 —UN—28JAN15

A— Gasket B— Gasket C— Turbocharger

Continued on next page

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A— Gasket B— Turbocharger

C— Cap Screws

RXA0146779 —UN—28JAN15

RXA0146778 —UN—28JAN15

MPRG32334 / 15RW625; DTAC Solution Number: 100717

D— Cap Screw

5. Install R521158 gasket (A).

7. Connect turbo oil drain with original cap screws (D).

6. Install turbocharger (B) with four R528196 cap screws (C). Torque to specification.

Specification Cap Screws (D)—Torque...................................................................................50 N·m (37 lb.-ft.)

CB33994,0000D6E -19-03FEB15-2/4

8. Install R86588 O-ring (A).

9. Install R528247 O-ring (B).

A— O-Ring B— O-Ring

RXA0146780 —UN—09JAN15

10. Install RE285844 clamp (C).

C— Clamp

Continued on next page

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RXA0146784 —UN—28JAN15

RXA0146783 —UN—28JAN15

MPRG32334 / 15RW625; DTAC Solution Number: 100717

11. Lubricate O-ring (A).

12. Install coupler (C).

14. Install elbow (E) into turbocharger (F) and coupler (G).

15. Tighten clamp (B).

A— O-Ring B— Clamp C— Coupler D— O-Ring

E— Elbow F— Turbocharger G— Coupler

RXA0146785 —UN—28JAN15

13. Install and lubricate R86588 O-ring (D) to elbow (E).

CB33994,0000D6E -19-03FEB15-4/4

Separator — Installation Install bracket and separator (A), line (B), and hose (C).

C— Hose

RXA0146378 —UN—18NOV14

A— Bracket and Separator B— Line

CB33994,0000D6F -19-03FEB15-1/1

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RXA0147055 —UN—27JAN15

RXA0147056 —UN—27JAN15

Transmission Seal — Installation

A— Input Hub

B— Seal

1. Remove input hub (A).

2. For PST, install RE158066 seal (B). For IVT install RE32442 and R119207 seals and R31378 O-ring.

CB33994,0000D70 -19-04FEB15-1/1

Prepare Engine for Installation Reinstall all lifting brackets and slings previously used for engine removal. Remove engine from stand and proceed to section: Install Engine.

CB33994,0000D71 -19-03FEB15-1/1

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Specifications Item

Measurement

Specification

MFWD and Two-Wheel Drive Torque Turn Cap Screws (1—8 and 11—12)

Torque Turn

50 N·m + 60° Turn (37 lb.-ft.+ 60° Turn)

MFWD and Two-Wheel Drive Torque Turn Cap Screws (9—10 and 13—18)

Torque Turn

60 N·m + 90° Turn (45 lb.-ft.+ 90° Turn)

MFWD and Two-Wheel Drive Torque Turn Cap Screws (19—22)

Torque Turn

20 N·m + 90° Turn (177 lb.-in.+ 90° Turn)

MFWD and Two-Wheel Drive Torque Turn Cap Screws (23 and 24)

Torque Turn

45 N·m + 90° Turn (33 lb.-ft. + 90° Turn)

Heavy-Duty MFWD Torque Turn Cap Screws (1—16)

Torque Turn

50 N·m + 60° Turn (37 lb.-ft.+ 60° Turn)

Heavy-Duty MFWD Torque Turn Cap Screws (17 and 18)

Torque Turn

20 N·m + 180° Turn (177 lb.-in.+ 180° Turn)

Heavy-Duty MFWD Torque Turn Cap Screws (19 —22)

Torque Turn

20 N·m + 90° Turn (177 lb.-in. + 90° Turn)

Heavy-Duty MFWD Torque Turn Cap Screws (23 and 24)

Torque Turn

45 N·m + 90° Turn (33 lb.-ft. + 90° Turn)

ILS™ Torque Turn Cap Screws (1—6)

Torque Turn

22 N·m + 45° Turn (194 lb.-in.+ 45° Turn)

ILS™ Torque Turn Cap Screws (7—18)

Torque Turn

50 N·m + 60° Turn (37 lb.-ft.+ 60° Turn)

ILS™ Torque Turn Cap Screws (19 —24)

Torque Turn

20 N·m + 90° Turn (177 lb.-in.+ 90° Turn)

Engine-to-Transmission Drive Shaft Cap Screws

Torque

126 N·m (92 lb.-ft.)

Front Frame-to-Transmission Cap Screws

Torque

500 N·m (369 lb.-ft.)

Front Support-to-Front Frame Cap Screws

Torque

430 N·m (317 lb.-ft.)

Fan Hex Nuts

Torque

25 N·m (221 lb.-in.)

Alternator Cap Screws

Torque

50 N·m (37 lb.-ft.)

CAC Pipe Connection

Torque

20 N·m (177 lb.-in.)

Item

Measurement

Specification

Thermostat Cover Cap Screws

Torque

48 N·m (35 lb.-ft.)

Thermostat Cover Cap Screws

Torque

48 N·m (35 lb.-ft.)

Radiator

Pressure Test

90 kPa (0.9 bar) (13 psi)

Radiator Cap

Pressure Test

103 kPa (1.03 bar) (15 psi) Continued on next page

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Measurement

Specification

Torque

70 N·m (52 lb.-ft.)

Torque

25 N·m (221 lb.-in.)

Torque

25 N·m (221 lb.-in.)

Torque

11 N·m (97 lb.-in.)

Torque

25 N·m (221 lb.-in.)

Torque

25 N·m (221 lb.-in.)

Belt Tensioner Mounting Cap Screw

Torque

35 N·m (26 lb.-ft.)

Fan-to-Drive Assembly Nut

Torque

25 N·m (221 lb.-in.)

Drive Pulley-to-Drive Cap Screw

Torque

37 N·m (27 lb.-ft.)

Vent Adapter

Torque

24 N·m (212 lb.-in.)

Vent Cap Screw

Torque

13 N·m (115 lb.-in.)

Bleed Screw

Torque

25 N·m (221 lb.-in.)

Jam Nut

Torque

25 N·m (221 lb.-in.)

Diverter Panel Cap Screw

Torque

20 N·m (177 lb.-in.)

Bleed Screw Nut

Torque

25 N·m (221 lb.-in.)

Diverter Panel Cap Screws

Torque

20 N·m (177 lb.-in.)

Drive-to-Engine Cap Screw

Torque

73 N·m (54 lb.-ft.)

Driven Assembly-to-Engine Cap Screw

Torque

73 N·m (54 lb.-ft.)

Retaining Nut

Torque

400 N·m (295 lb.-ft.)

Lower Radiator Mounts Nuts Fan Shroud Mounting Cap Screws Cap Screws Upper Radiator Support Nuts Nuts Radiator Hose Clamps Hose Clamps Lower Charge Air Clamp Cap Screws Side Panel Mounting Cap Screws Cap Screws

Continued on next page

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MPRG32334 / 15RW625; DTAC Solution Number: 100717 Item

Measurement

Specification

Cap Screws

Torque

37 N·m (27 lb.-ft.)

Vari-Cool™ Control Valve Cap Screws

Torque

35 N·m (26 lb.-ft.)

Vari-Cool™ Cartridge Valve

Torque

30 N·m (265 lb.-in.)

Solenoid Nut

Torque

7 N·m (62 lb.-in.)

CB33994,0000D72 -19-03FEB15-3/3

Install Engine 1. Install engine noting the following instructions:

• Remove any gasket or oil residue from mating parts and install oil pan gasket R533894.

IMPORTANT: High Flex Form-In-Place Gasket is used on block side of gasket to seal area between flywheel housing, front plate, and timing gear cover.

• Apply PM38657 High Flex Form-In-Place Gasket in A— High Flex Form-In-Place Gasket Location (qty 4) B— Front of Pan Gasket

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location (A) on block side of gasket at front of pan gasket (B) and rear of pan gasket (C).

C— Rear of Pan Gasket

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

2. For tractors with MFWD and Two-Wheel Drive, perform the following: Clean gasket surfaces and install new gasket.

IMPORTANT: Specifications are for dry torque.

Ensure that cap screws and threads are clean of any lubricants before installing and tightening to specification.

3. Install cap screws (A—F) as illustrated.

Key

Quantity

Size (mm)

A

8

12 x 152 mm

B

4

12 x 102 mm

C

6

12 x 64 mm

D

2

10 x 194 mm

E

2

10 x 57 mm

F

2

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RXA0118400 —UN—28JUN11

MPRG32334 / 15RW625; DTAC Solution Number: 100717

MFWD and Two-Wheel Drive Oil Pan Torque A— MFWD and Two-Wheel Drive B— MFWD and Two-Wheel Drive C— MFWD and Two-Wheel Drive Cap Screws (1—8 and 11—12) Cap Screws (9—10 and Cap Screws (19—22) 13—18) D— MFWD and Two-Wheel Drive Cap Screws (23 and 24)

IMPORTANT: Tighten all cap screws using sequence and torque turn strategy.

6. Torque cap screws (C) to the following specifications.

Specification MFWD and Two-Wheel Drive Torque Turn Cap Screws (19—22)—Torque Turn................................................20 N·m + 90° Turn (177 lb.-in.+ 90° Turn)

4. Tighten cap screws (A) to the following specifications.

Specification MFWD and Two-Wheel Drive Torque Turn Cap Screws (1—8 and 11—12)—Torque Turn.................................................50 N·m + 60° Turn (37 lb.-ft.+ 60° Turn)

7. Torque cap screws (D) to the following specifications.

Specification MFWD and Two-Wheel Drive Torque Turn Cap Screws (23 and 24)—Torque Turn........................................................45 N·m + 90° Turn (33 lb.-ft. + 90° Turn)

5. Torque cap screws (B) to the following specifications.

Specification MFWD and Two-Wheel Drive Torque Turn Cap Screws (9—10 and 13—18)—Torque Turn.................................................60 N·m + 90° Turn (45 lb.-ft.+ 90° Turn)

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

8. For tractors with Heavy-Duty MFWD, perform the following: Clean gasket surfaces and install new gasket.

IMPORTANT: Specifications are for dry torque.

Ensure that cap screws and threads are clean of any lubricants before installing and torquing to specification.

9. Install cap screws (A—F) as illustrated.

Key

Quantity

Size (mm)

A

8

12 x 152 mm

B

4

12 x 102 mm

C

6

12 x 64 mm

D

2

10 x 194 mm

E

2

10 x 57 mm

F

2

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

Heavy-Duty MFWD Oil Pan Torque A— Heavy-Duty MFWD Cap Screws (1—16) B— Heavy-Duty MFWD Cap Screws (17 and 18)

C— Heavy-Duty MFWD Cap Screws (19 —22) D— Heavy-Duty MFWD Cap Screws (23 and 24)

IMPORTANT: Tighten all cap screws using sequence and torque turn strategy.

12. Torque cap screws (C) to specification.

Specification Heavy-Duty MFWD Torque Turn Cap Screws (19 —22)—Torque Turn...............................................20 N·m + 90° Turn (177 lb.-in. + 90° Turn)

10. Torque cap screws (A) to the following specifications.

Specification Heavy-Duty MFWD Torque Turn Cap Screws (1—16)—Torque Turn..................................................50 N·m + 60° Turn (37 lb.-ft.+ 60° Turn)

13. Torque cap screws (D) to specification.

Specification Heavy-Duty MFWD Torque Turn Cap Screws (23 and 24)—Torque Turn.............................................................................45 N·m + 90° Turn (33 lb.-ft. + 90° Turn)

11. Torque cap screws (B) to specification.

Specification Heavy-Duty MFWD Torque Turn Cap Screws (17 and 18)—Torque Turn...........................................................................20 N·m + 180° Turn (177 lb.-in.+ 180° Turn)

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

D

E

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D

A B

C 14. For tractors with ILS™, perform the following: Clean gasket surfaces and install new gasket.

Key

Quantity

Size (in.)

IMPORTANT: Specifications are for dry torque.

Ensure that cap screws and threads are clean of any lubricants before installing and torquing to specification.

A

4

12 x 102 mm

15. Install cap screws (A—E) as illustrated.

B

8

12 x 64 mm

C

6

12 x 45 mm

D

4

10 x 57 mm

E

2

10 x 67 mm

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

ILS™ Independent Link Suspension Oil Pan Torque A— Cap Screws (1—6)

B— Cap Screws (7 —18)

C— Cap Screws (19 —24)

IMPORTANT: Tighten all cap screws using sequence and torque turn strategy.

Specification ILS™ Torque Turn Cap Screws (7—18)—Torque Turn.............................................................................50 N·m + 60° Turn (37 lb.-ft.+ 60° Turn)

16. Torque cap screws (A) to specification.

Specification ILS™ Torque Turn Cap Screws (1—6)—Torque Turn.............................................................................22 N·m + 45° Turn (194 lb.-in.+ 45° Turn)

18. Torque cap screws (C) to specification.

Specification ILS™ Torque Turn Cap Screws (19 —24)—Torque Turn.....................................................20 N·m + 90° Turn (177 lb.-in.+ 90° Turn)

17. Torque cap screws (B) to specification.

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19. For All tractors, perform the following:

• Torque engine-to-transmission drive shaft cap

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screws with JDG861 Torque Wrench Adapter (A) using the formula illustrated.

Specification Engine-to-Transmission Drive Shaft Cap Screws—Torque..........................................................................126 N·m (92 lb.-ft.)

Tw

=

Torque setting on the torque wrench

Ta

=

Torque actually being applied to the nut or cap screw

L

=

Length from the point of force (center of the wrench handle) to the center of head of torque wrench

A

=

Application distance from center of torque wrench head to the center of adapter which is 95 mm (3.75 in.)

rearward against transmission oil seal.

20. Remove all engine removal lifting brackets and straps.

21. Close all drain valves and reinstall removed components in reverse order A-V as follows.

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A— JDG861 Torque Wrench Adapter

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• Push engine-to-transmission drive shaft V-ring seal

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

A— Crossover Tube

B— Doser

a. Air filter housing.

l. Coolant hose.

b. Crossover tube (A) with R528112 O-rings and RE289839 clamps.

m. Deaeration tank and brackets.

c. Doser (B) with RE554856 gasket.

n. Install alternator and belt.

d. Doser supply line.

o. Fan blade, air diverting shield, and air deflector panels.

e. Oil plugs, fuel lines, line bundle, and clamps.

p. Main wiring harness.

f. Oil plugs.

q. If equipped, steering line and clamps.

g. Air cleaner and pipes with R320564 and R318954 gaskets..

r. Aspirator pipe.

h. Drive coupler.

s. Fly wheel guards, rear hood barriers, and rear hood separator.

i. If equipped, accumulators with 51M7047 O-rings..

t. Starter aid solenoid.

j. Exhaust pipes with R529510 gaskets. k. Lower and upper radiator hoses and radiator mounts.

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A— Power Steering Line

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

B— Power Steering Line

u. Connect power steering lines (A and B).

v. Connect upper and lower CAC pipe with R318954 and R320564 gaskets.

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A— O-Rings B— Drain Tube

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VGT Oil Drain and Supply Lines — Installation

F— Elbow Fitting

C— Elbow D— Port E— Drain Hose

1. Install three R71732 O-rings onto drain tube (B).

4. Install drain hose (E) with T77613 O-ring to elbow fitting (F).

2. If removed, install elbow (C) with R63185 O-ring.

3. Install drain tube into elbow (C) and port (D).

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

5. Route and install oil supply line (A) as shown.

6. Connect oil supply line (A) to turbo adaptor fitting (B) and block elbow fitting (C).

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7. Connect oil supply line (D) to line port (E) and turbo adaptor fitting (F).

8. Install RE509672 oil filter.

9. Refill coolant system with original coolant.

10. Fill engine with John Deere Break-In oil.

Specification John Deere Break-In Engine Oil—Volume.......................................................................... 27 L (7 gal.)

A— Oil Supply Line B— Turbo Adaptor Fitting

C— Block Elbow Fitting D— Oil Supply Line CB33994,0000D91 -19-06FEB15-2/2

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Perform Engine Break-In Special Tools: • None

Specification Engine Oil—Volume.......................................................................... 27 L (7 gal.)

Consumables: • John Deere Oil Filter

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John Deere ENGINE BREAK-IN OIL

Check Engine Oil Level

Engine Oil Dipstick

2. Use a dynamometer to perform the following preliminary break-in procedure. If necessary, preliminary engine break-in can be performed without a dynamometer if under controlled operating conditions.

1. Connect negative (—) battery cable.

IMPORTANT: DO NOT use John Deere PLUS-50 oil or engine oils meeting API CG4, API CF4, ACEA E3 or ACEA E2, performance levels during break-in period of an engine that has had a major overhaul. These oils will not allow an overhauled engine to properly wear during the break-in period.

3. After break-in period, use John DeerePlus-50™ II engine oil as recommended in owners manual.

IMPORTANT: During engine break-in procedure, check engine for coolant or oil leaks. Stop procedure if any leaks appear.

Do not add makeup oil until the oil level is BELOW the add mark. John Deere Break-In Oil should be used to make up any oil consumed during break-in period.

DO NOT fill above the crosshatch pattern or FULL mark. Oil levels anywhere within the crosshatch are acceptable.

Plus-50 is a trademark of Deere & Company.

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MPRG32334 / 15RW625; DTAC Solution Number: 100717

a. Start tractor and run engine at idle for 2 minutes with no load (A).

c. Run engine 2 minutes at 1200 rpm with 1/4 load (B). d. Run engine 2 minutes at 1800 rpm with 1/2 load (C). e. Run engine 8 minutes at 2100 rpm (full throttle) and full load (D). f. Drag engine down with dynamometer to 1900 rpm for one minute.

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b. Run engine 2 minutes at 1200 rpm with no load (A).

g. Drag engine down with dynamometer to 1600 rpm for one minute.

i. Run engine at idle for one minute with no load (A). j. Remove from dynamometer and inspect for oil or coolant leaks. k. If equipped, install fenders. l. Install hood spreader and side shields. m. Install hood.

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h. Reduce dynamometer to no load (A) and engine rpm to 1500 for two minutes.

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