John Deere PowerTech™ 13.5L OEM Diesel Engines Base Engine Repair - (Worldwide Edition) Component Technical Manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnosis & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

This manual contains high quality images, circuit diagrams, instructions to help you to maintenance, troubleshoot, diagnose, and repair. This document is printable, without restrictions, contains searchable text, bookmarks, crosslinks for easy navigation.

CTM415 English - PowerTech™ 13.5L OEM Diesel Engines Base Engine Repair - (Worldwide Edition) Component Technical Manual (CTM).pdf
ctm418 German - PowerTech™ 13,5-l-OEM-Dieselmotoren Reparatur des Grundmotors -: (Weltweite Ausgabe).pdf

TABLE OF CONTENTS
Section 01: General Information................20
  Group 000: Safety................20
    Avoid Heating Near Pressurized Fluid Lines................24
    Avoid High-Pressure Fluids................25
    Avoid Hot Exhaust................26
    Avoid Static Electricity Risk When Refueling................27
    Construct Dealer-Made Tools Safely................29
    Decommissioning — Proper Recycling and Disposal of Fluids and Components................30
    Follow Safety Instructions................31
    Handle Agricultural Chemicals Safely................32
    Handle Fluids Safely—Avoid Fires................34
    Handling Batteries Safely................35
    Illuminate Work Area Safely................37
    Install All Guards................38
    Live With Safety................39
    Park Machine Safely................40
    Practice Safe Maintenance................41
    Precautions for Welding................43
    Prepare for Emergencies................45
    Prevent Acid Burns................46
    Prevent Battery Explosions................48
    Prevent Machine Runaway................49
    Protect Against High Pressure Spray................50
    Protect Against Noise................51
    Recognize Safety Information................52
    Remove Paint Before Welding or Heating................53
    Replace Safety Signs................54
    Service Cooling System Safely................55
    Service Machines Safely................56
    Stay Clear of Rotating Drivelines................57
    Support Machine Properly................58
    Understand Signal Words................59
    Use Proper Lifting Equipment................60
    Use Proper Tools................61
    Use Steps and Handholds Correctly................62
    Wait Before Opening High-Pressure Fuel System................579
    Wear Protective Clothing................64
    Work in Clean Area................65
    Work In Ventilated Area................66
  Group 001: Engine Identification and Applications................21
    Engine Model Designation................69
    Engine Serial Number Plate Information................71
    Engine Option Code Label................72
  Group 002: Fuels, Lubricants and Coolant................21
    Diesel Fuel................75
    Diesel Fuel Additive Products................77
    BioDiesel Fuel................78
    Minimizing the Effect of Cold Weather on Diesel Engines................80
    Handling and Storing Diesel Fuel................82
    Lubricity of Diesel Fuel................83
    Testing Diesel Fuel................84
    Fuel Filters................85
    Engine Oil and Filter Service Intervals................86
    Diesel Engine Oil — Tier 3 and Stage III................87
    Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III................89
    Oil Filters................91
    Grease................92
    Alternative and Synthetic Lubricants................93
    Lubricant Storage................94
    Mixing of Lubricants................95
    Diesel Engine Coolant (engine with wet sleeve cylinder liners)................96
    Supplemental Coolant Additives................98
    Operating in Warm Temperature Climates................99
    Additional Information About Diesel Engine Coolants and John Deere LIQUID COOLANT CONDITIONER................100
    Diesel Engine Coolant................102
    Testing Diesel Engine Coolant................103
    Drain Intervals for Diesel Engine Coolant................104
Section 02: Repair and Adjustments................105
  Group 010: Engine Rebuild Guide, Break-In and Tune-Up................105
    Engine Overhaul Guidelines................113
    Engine Repair Stand................114
    Safety Precautions................115
    Disconnect Turbocharger Oil Inlet Line................116
    Install Adapter on Repair Stand................118
    Engine Lifting Procedure................119
    Mount Engine on Repair Stand................121
    Clean Engine................123
    6135 Engine Disassembly Sequence................105
    Sealant Application Guidelines................127
    6135 Engine Assembly Sequence................105
    Engine Break-In Guidelines................132
    Perform Engine Break-In................133
    Check Crankcase Ventilation System................135
    Check Air Intake System................136
    Check Exhaust System................138
    Check and Service Cooling System................139
    Check Electrical System................140
  Group 020: Cylinder Head and Valves................105
    Remove and Install Rocker Arm Cover................144
    Clean and Inspect Crankcase Ventilation Assembly................146
    Replace Rocker Arm Cover Gasket................147
    Check and Adjust Valve Assembly Clearances and Injector Preload................148
    Remove Rocker Arm Assembly................157
    Remove Cylinder Head................159
    Diagnosing Head Gasket Joint Failures................163
    Head Gasket Inspection and Repair Sequence................165
    Disassemble and Inspect Rocker Arms and Shaft Assembly................167
    Preliminary Cylinder Head and Valve Checks................169
    Assemble Rocker Arms and Shaft Assembly................171
    Check Valve Height in Relation to Head Surface (Valve Recess)................172
    Remove Valve Assembly................173
    Inspect and Measure Valve Springs................175
    Inspect Valve Rotators................176
    Clean, Inspect, and Measure Valves................177
    Grind Valves................178
    Clean and Inspect Cylinder Head................179
    Check Cylinder Head Flatness................181
    Measure Cylinder Head Thickness................182
    Measure Valve Guide ID................183
    Replace Valve Guides................184
    Clean and Inspect Valve Seats................186
    Valve Seat — Grinding................187
    Remove Valve Seat Inserts................189
    Measure Valve Seat Bore in Cylinder Head................190
    Install Valve Seat Inserts................191
    Install Valves................192
    Replace Unit Injector Sleeve in Cylinder Head Using JDG981................732
    Replace Unit Injector Sleeve in Cylinder Head Using JDG1184................742
    Remove Unit Injector Sleeve Using JDG10014................746
    Clean and Inspect Top Deck of Cylinder Block................213
    Measure Cylinder Liner Standout (Height Above Block)................241
    Install Cylinder Head................216
    Torque-Turn Cylinder Head Cap Screws................218
    Install Rocker Arm Assembly................221
    Complete Final Assembly for Cylinder Head Installation................225
  Group 030: Cylinder Block, Liners, Pistons, and Rods................106
    Remove and Install Cylinder Block Front Plate................229
    Preliminary Liner, Piston, and Rod Checks................232
    Connecting Rods—General Information................234
    Remove Piston Spray Jets................235
    Remove Pistons and Connecting Rods................237
    Measure Cylinder Liner Standout (Height Above Block)................241
    Remove Cylinder Liners Using D01062AA or D01073AA Cylinder Liner Puller................243
    Remove Cylinder Liners Using JDG1145 Cylinder Liner Service Set................245
    Visually Inspect Cylinder Liners................248
    Deglaze Cylinder Liners................251
    Clean Cylinder Liners................252
    Cylinder Liner Manufacturing Date Code Explanation................253
    Disassemble Piston/Rod Assembly and Clean Piston................255
    Check Piston Oil Control Ring Groove Wear................257
    Inspect Piston Pin and Pin Bore in Piston................258
    Determine Piston-to-Liner Clearance................260
    Measure Liner Flange Thickness................262
    Inspect and Measure Connecting Rod Bearings................263
    Inspect Connecting Rod and Cap................265
    Inspect Piston Pins and Rod Bushings................269
    Complete Disassembly of Cylinder Block (If Required)................271
    Inspect and Clean Cylinder Block................273
    Cylinder Block — Inspect and Reclaim................275
    Cylinder Block — Measurements................289
    Install Cylinder Liner Shim................290
    Install Cylinder Liner O-Rings and Packings................291
    Install Cylinder Liners................293
    Assemble Pistons and Connecting Rods................295
    Install Pistons and Connecting Rods................297
    Torque-Turn Connecting Rod Cap Screws................301
    Check Engine Rotation for Excessive Tightness................303
    Install Piston Spray Jets................304
    Measure Piston Protrusion................306
    Complete Final Assembly................383
  Group 040: Crankshaft, Main Bearings, and Flywheel................107
    Crankshaft Rubber Damper Torque Sequence................310
    Inspect Crankshaft Vibration Damper................311
    Check Crankshaft End Play................313
    Remove Crankshaft Rubber Damper and Pulley................314
    Remove Viscous Damper and Front Crankshaft Oil Seal................316
    Remove Timing Gear Cover................319
    Check Flywheel Housing Face Runout................321
    Check Flywheel Face Flatness................323
    Remove Flywheel................324
    Inspect and Repair Flywheel................325
    Replace Flywheel Ring Gear................326
    Remove and Install Flywheel Housing................327
    Install Flywheel................329
    Remove Rear Crankshaft Oil Seal and Housing Assembly................332
    Crankshaft Unitized Rear Oil Seal — Removal................335
    Crankshaft Unitized Rear Oil Seal and Housing — Installation................337
    Crankshaft and Main Bearing Failure Analysis................342
    Remove Crankshaft Main Bearings................343
    Check Main Bearing-to-Journal Oil Clearance................345
    Remove Crankshaft................346
    Inspect Crankshaft................348
    Measure Assembled ID of Bearings and OD of Crankshaft Journals................350
    Measure Assembled ID of Main Bearing Caps (Without Bearings)................351
    Replace Crankshaft Drive Gear................352
    Inspect Thrust Bearings................354
    Thrust Bearing New Part Specifications................355
    Install Main and Thrust Bearing Inserts in Block................356
    Install Crankshaft................358
    Install Crankshaft Rear Oil Seal Housing................362
    Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly................364
    Install Timing Gear Cover................366
    Install Crankshaft Rubber Damper and Front Oil Seal................372
    Install Viscous Damper Assembly and Front Oil Seal................377
    Complete Final Assembly................383
  Group 050: Camshaft and Timing Gear Train................108
    Camshaft Timing Pin................385
    Check and Adjust Camshaft-to-Crankshaft Timing................386
    Adjust Front Timing Gear Backlash Using JDG993................735
    Adjust Front Timing Gear Backlash Without Using JDG993................735
    Remove and Install Camshaft................399
    Replace Fuel Supply Pump Drive Pin................406
    Visually Inspect Camshaft and Roller Followers................407
    Inspect and Measure Camshaft Bushing ID and Journal OD................408
    Measure Camshaft Lobe Lift Height................409
    Inspect Camshaft Position Sensor Lobe................410
    Replace Camshaft Bushings................411
    SAE “A” (Front) and SAE “B” (Rear) Auxiliary Drive Assembly................417
    SAE B Rear Auxiliary Drive — Removal and Installation................419
    Align SAE “A” Front Auxiliary Drive Adapter................421
  Group 060: Lubrication System................109
    Oil Filter and Oil Conditioning Housing Assembly................425
    Remove Oil Filter and Valve Housing/Oil Cooler Cover and Valve Housing................427
    Inspect and Replace Oil Filter Adapter................428
    Remove, Inspect, and Install Oil Pressure Regulating Valve................429
    Remove, Inspect, and Install Oil Cooler and Oil Filter Bypass Valves................430
    Remove, Inspect, and Install Oil Pressure Relief Valve................432
    Remove, Clean, and Inspect Engine Oil Cooler................433
    Install Oil Cooler/Oil Filter Valve Housing Assembly or Oil Cooler Cover/Valve Housing Assembly................436
    Remove Engine Oil Pump................439
    Clean and Inspect Oil Pump and Drive Gear................441
    Install Engine Oil Pump................442
    Remove Engine Oil Pan................445
    Remove and Install Oil Pickup Tube................446
    Install Engine Oil Pan................447
    Oil Dipstick Tube Assembly — Installation................451
    Oil Dipstick Tube Assembly — Removal................454
  Group 070: Cooling System................109
    Replace Bearings in Fan Drive Assembly................459
    Inspect and Check Belt Tensioner Spring Tension................463
    Replace Belt Tensioner Assembly................465
    Remove Coolant Pump................467
    Clean and Inspect Coolant Pump Parts................469
    Install Coolant Pump................471
    Remove and Install Thermostat Cover and Thermostats................472
    Test Thermostat Opening Temperature................474
    Remove and Install Thermostat Housing and Coolant Tubes................476
    Remove and Install Coolant Heater—if Equipped................478
    Bleed Air from Coolant System................480
  Group 080: Air Intake and Exhaust System................110
    Extending Turbocharger Life................485
    Remove and Install Variable Geometry Turbocharger Actuator................488
    Remove and Install Actuator Linkage................490
    Remove Turbocharger................494
    Turbocharger — Failure Analysis................499
    Turbocharger Seven-Step Inspection................502
    Perform Radial Bearing Clearance Test................508
    Turbocharger — Repair................510
    Prelube Turbocharger................511
    Install Turbocharger................512
    Turbocharger Break-In................517
    Recommendations for Turbocharger Use................518
    Remove, Inspect, and Install EGR Cooler................519
    Exhaust Manifold — Remove................535
    Exhaust Manifold — Install................536
    Remove, Inspect, and Install Intake Manifold................530
    Remove, Inspect, and Install EGR Valve (Tier 3/Stage III A)................532
  Group 081: Air Intake and Exhaust System — PowerTech™ E Engines................110
    Exhaust Manifold — Remove................535
    Exhaust Manifold — Install................536
    Turbocharger — Remove................538
    Turbocharger — Install................540
    Air Intake Manifold — Remove................543
    Air Intake Manifold — Install................544
  Group 082: Air Intake and Exhaust System — Marine Engines................111
    Air Intake Manifold (Marine) — Removal................552
    Air Intake Manifold (Marine) — Installation................558
    Exhaust Manifold (Marine) — Removal................565
    Exhaust Manifold (Marine) — Installation................568
    Turbocharger (Marine) — Removal................571
    Turbocharger (Marine) — Installation................574
  Group 090: Fuel System................579
    Fuel System................579
  Group 100: Starting and Charging Systems................111
    Remove and Install Alternator (OEM Engines)................582
    Remove and Install Starter Motor (OEM Engines)................584
Section 03: Theory of Operation................585
  Group 120: Base Engine Operation — PowerTech Plus................585
    General Engine Operation................611
    Lubrication System Operation................614
    Cooling System Operation................617
    Fuel System Theory of Operation................620
    Head Gasket Joint Construction and Operation................621
    Intake and Exhaust System Operation................623
    Exhaust Gas Recirculator (EGR) Exhaust Gas Recirculator (EGR) & Variable Geometry Turbocharger (VGT) Operation{pgNO}585 Variable Geometry Turbocharger (VGT) Operation................602
    Turbocharger Operation................624
    How the Turbocharger is Lubricated................626
  Group 121: Base Engine Operation — PowerTech & PowerTech E................585
    General Engine Operation................611
    Lubrication System Operation................614
    Cooling System Operation................617
    Fuel System Theory of Operation................620
    Head Gasket Joint Construction and Operation................621
    Intake and Exhaust System Operation................623
    Turbocharger Operation................624
    How the Turbocharger is Lubricated................626
Section 04: Diagnostics................627
  Group 150: Observable Diagnostics and Tests................627
    About this Section of the Manual................629
    13.5L - L1 - Excessive Oil Consumption................627
    13.5L - L2 Engine Oil Pressure High................627
    13.5L - L3 - Engine Oil Pressure Low................627
    13.5L - L4 - Fuel in Oil................627
    13.5L - L5 - Soot or Sludge in the Oil................627
    13.5L - C1 - Engine Coolant Temperature Above Normal................627
    13.5L - C2 - Engine Coolant Temperature Below Normal................627
    13.5L Engines - C3 - Coolant in Oil or Oil in Coolant................627
    13.5L Engines - C4 - Coolant Leaking from Weep Hole................627
    Dynamometer Test................642
    Check Cylinder Compression................643
    Engine Oil Consumption................646
    Check Engine Oil Pressure................647
    Check for Excessive Engine Crankcase Pressure (Blow-By) (Base Pressure)................648
    Check for Turbocharger Oil Seal Leak................659
    Inspect Thermostat and Test Opening Temperature................660
    Cooling System Pressure Test................662
    Charge Air Cooler Test................665
    Check for Head Gasket Failures................667
    Check Intake Manifold Pressure (Turbo Boost)................670
    Check Intake Manifold Pressure (Turbo Boost) — Fix Geometry Turbocharger................671
    Check for Intake and Exhaust Restrictions................672
    Check for Intake Air Leaks................674
    Check for Exhaust Air Leaks................676
    Check Camshaft-to-Crankshaft Timing................677
    Check Crankshaft Position Sensor Depth................679
    Check Engine Cranking Speed................681
    EGR Cooler Test................682
    Excessive Engine Vibration................683
Section 05: Tools and Other Materials................774
  Group 170: Special Tools................687
    75240................687
    D01062AA................692
    D01168AA................693
    D01200AA................694
    D01218AA................695
    D01300AA................696
    D05012ST-A................697
    D05104ST................698
    D05223ST................699
    D01073AA................700
    D17006BR................701
    D17015BR................702
    D17024BR................703
    D17525CI................704
    D17526CI................705
    D17527CI................706
    DFRG3................707
    DFRG4................709
    DFRG9................710
    DFRG11................712
    JDE41296................714
    JDG164A................715
    JDG451................716
    JDG782A................717
    JDG820................718
    JDG839................719
    JDG967................720
    JDG968................721
    JDG969A................722
    JDG970B................723
    JDG971................724
    JDG972................725
    JDG973................726
    JDG974A................727
    JDG975................728
    JDG976................729
    JDG977................730
    JDG978................731
    JDG981................732
    JDG981-1................733
    JDG982A................734
    JDG993................735
    JDG996................736
    JDG1020................737
    JDG1069................738
    JDG1144................739
    JDG1145................740
    JDG1167................741
    JDG1184................742
    JDG1333................743
    JDG1334................744
    JDG1847................745
    JDG10014................746
    JDG10194................747
    JDG10199................748
    JDG10200................749
    JDG10246A................750
    JDG10249................751
    JDG10357B................752
    JDG10539A................753
    JDG10668................754
    JDG10996................755
    JDG10997................756
    JDG11008................757
    JDG11056................758
    JDG11084................759
    JDG11334P3................760
    JDG11373................761
    JDG11374................762
    JDG11544................763
    JDG11831................764
    JDG11860................765
    JDG11864................766
    JT01674A................767
    JT05412................768
    JT05697A................769
    JT05993................770
    JT07336................771
  Group 180: Lubricants, Sealants, and Other Materials................774
    Other Materials................774
Section 06: Specifications................776
  Group 200: Repair and General OEM Specifications................776
    General OEM Engine Specifications................778
    Unified Inch Bolt and Screw Torque Values................779
    Metric Bolt and Screw Torque Values................781
    Engine Rebuild Guide, Break-In and Tune-Up (Group 010) Specifications................783
    Cylinder Head and Valves (Group 020) Specifications................784
    Cylinder Block, Liners, Pistons and Rods (Group 030) Specifications................787
    Crankshaft, Main Bearings and Flywheel (Group 040) Specifications................790
    Camshaft and Timing Gear Train (Group 050) Specifications................792
    Lubrication System (Group 060) Specifications................793
    Cooling System (Group 070) Specifications................795
    Air Intake and Exhaust System (Group 080) Specifications — Variable Geometry Turbocharger................796
    Air Intake and Exhaust System (Group 081) Specifications — Fixed Geometry Turbocharger................797
    Starting and Charging Systems (Group 100) Specifications................798
  Group 210: Diagnostic Specifications................776
    Observable Diagnostics and Test Specifications................800
    Dynamometer Test Specifications (OEM Engines)................801
    Intake Manifold Pressure (Turbocharger Boost) Specifications................804

John Deere PowerTech 13.5L OEM Diesel Engines Base Engine Repair Component Technical Manual (CTM415)