约翰迪尔 6068T/H 6.8T/H 活塞（米）RE515037 排放 2 & 3

（1）1件组合式密封和穿套; 替换TRE59810，RE538097。

（2）曲轴加工过程中必须保持适当的轴承轴颈半径，以保证正确的操作。

（3）曲轴（m）R116076，直鼻。

（4）曲轴（m）R503470，锥形鼻。

（5）检查应用程序是否正确使用。

（6）线路连接都是线程化的。

（7）线路连接是一个软管倒钩＆amp; 一个线程。

（8）线路连接是两个软管倒钩。

（9）机器分体式和断裂式分体式连杆均可用于同一台发动机，但每个连杆必须使用正确的连杆螺栓。
美国强鹿JOHN DEERE柴油机配件、发动机配件、发电机组： 3029DF120、3029TF158、3029TFU80、3029HFU70、4045HF280、4045TF002、3029DF128、30294045TF258、4045TF275、4045TF220、4045HF285、4045TF258、4045TFU70、4045HF285V07、4045TF220、4045TF120、6068HF120、6068HF475、6068TF220、6068TF001、6068HF158、6135HF485
GRID PAGE GRID PAGE
6E21 OPTION 3002 STARTER (ESN (CD) AND 7D5 OPTION 3101 ALTERNATOR
(T0) -XXXXXX) (DF150) -................ 3000 - 3013A (HF120/HF150/HF250)-....................3100 - 3102
6E19 OPTION 3002 STARTER (ESN (CD) AND 7D4 OPTION 3101 ALTERNATOR
(T0) -XXXXXX) (HF150/HF250) -.... 3000 - 3012 (TF150/TF220/TF250) -....................3100 - 3101
6E17 OPTION 3002 STARTER (ESN (CD) AND 7D6 OPTION 3101 ALTERNATOR (DF150/TF120) ................ 3100 - 3103
(T0) -XXXXXX) (TF150/TF250) -...... 3000 - 3010 7D9 OPTION 3104 ALTERNATOR
6F3 OPTION 3002 STARTER (ESN (PE) ALL, (CD) (DF150/TF120/TF151) -....................3100 - 3106
AND (T0) XXXXXX- ) (DF150) -...... 3000 - 3017A 7D8 OPTION 3104 ALTERNATOR
6F1 OPTION 3002 STARTER (ESN (PE) ALL, (CD) (HF120/HF150/HF250)-....................3100 - 3105
AND (T0) XXXXXX- ) (HF150/HF250) - 3000 - 3016 7D7 OPTION 3104 ALTERNATOR
6E23 OPTION 3002 STARTER (ESN (PE) ALL, (CD) (TF150/TF220/TF250) -....................3100 - 3104
AND (T0) XXXXXX- ) (TF150/TF250)-.. 3000 - 3014 7D12 OPTION 3107 ALTERNATOR
6F9 OPTION 3003 STARTER (DF150/TF120)- 3000 - 3021A (DF150/TF120/TF151) -....................3100 - 3109
6F7 OPTION 3003 STARTER (HF120/HF150/HF250) .......... 3000 - 3020 7D11 OPTION 3107 ALTERNATOR
6F5 OPTION 3003 STARTER (TF150/TF220/TF250) ............ 3000 - 3018 (HF120/HF150/HF250)-....................3100 - 3108
6F15 OPTION 3006 STARTER (ESN (CD) AND 7D10 OPTION 3107 ALTERNATOR
(T0) -XXXXXX) (DF150) -................ 3000 - 3025A (TF150/TF220/TF250) -....................3100 - 3107
6F11 OPTION 3006 STARTER (ESN (CD) AND 7D15 OPTION 3108 ALTERNATOR
(T0) -XXXXXX) (TF150/TF250) -...... 3000 - 3022 (DF150/TF120/TF151) -....................3100 - 3112
6F13 OPTION 3006 STARTER (ESN (CD) AND 7D14 OPTION 3108 ALTERNATOR
(T0) -XXXXXX) (TF150/TF250) -...... 3000 - 3024 (HF120/HF150/HF250)-....................3100 - 3111
6F21 OPTION 3006 STARTER (ESN (PE) ALL, (CD) 7D13 OPTION 3108 ALTERNATOR
AND (T0) XXXXXX- ) (DF150/TF120) - 3000 - 3029A (TF150/TF220/TF250) -....................3100 - 3110
6F19 OPTION 3006 STARTER (ESN (PE) ALL, (CD) 7D18 OPTION 3109 ALTERNATOR
AND (T0) XXXXXX- ) (HF120/HF150/HF250) ............ 3000 - 3028 (DF150/TF120/TF151) -....................3100 - 3115
6F17 OPTION 3006 STARTER (ESN (PE) ALL, (CD) 7D17 OPTION 3109 ALTERNATOR
AND (T0) XXXXXX- ) (TF150/TF220/TF250) .............. 3000 - 3026 (HF120/HF150/HF250)-....................3100 - 3114
6F23 OPTION 3007 STARTER (DF150) -.... 3000 - 3030 7D16 OPTION 3109 ALTERNATOR
6G5 OPTION 3010 STARTER (ESN (CD) AND (TF150/TF220/TF250) -....................3100 - 3113
(T0) -XXXXXX) (DF150) -................ 3000 - 3035A 7D19 OPTION 3110 ALTERNATOR (TF151) (3110) ................ 3100 - 3116
6G3 OPTION 3010 STARTER (ESN (CD) AND 7D22 OPTION 3111 ALTERNATOR
(T0) -XXXXXX) (HF150/HF250) -.... 3000 - 3034 (DF150/TF120/TF151) -....................3100 - 3119
6G1 OPTION 3010 STARTER (ESN (CD) AND 7D21 OPTION 3111 ALTERNATOR
(T0) -XXXXXX) (TF150/TF250) -...... 3000 - 3032 (HF120/HF150/HF250)-....................3100 - 3118
6G11 OPTION 3010 STARTER (ESN (PE) ALL, (CD) 7D20 OPTION 3111 ALTERNATOR
AND (T0) XXXXXX- ) (DF150/TF120) - 3000 - 3039A (TF150/TF220/TF250) -....................3100 - 3117
6G9 OPTION 3010 STARTER (ESN (PE) ALL, (CD) 7D23 OPTION 3111 ALTERNATOR
AND (T0) XXXXXX- ) (HF120/HF150/HF250) ............ 3000 - 3038 (TF150/TF220/TF250) -....................3100 - 3120
6G7 OPTION 3010 STARTER (ESN (PE) ALL, (CD) 7D25 OPTION 3111 ALTERNATOR (DF150/TF120) ................ 3100 - 3122
AND (T0) XXXXXX- ) (TF150/TF220/TF250) .............. 3000 - 3036 7D24 OPTION 3122 ALTERNATOR
6G17 OPTION 3011 STARTER (DF150/TF120)- 3000 - 3043A (HF120/HF150/HF250)-....................3100 - 3121
6G15 OPTION 3011 STARTER (HF120/HF150/HF250) .......... 3000 - 3042 7E3 OPTION 3135 ALTERNATOR (12V ISKRA)
6G13 OPTION 3011 STARTER (TF150/TF220/TF250) ............ 3000 - 3040 (DF150/TF120/TF151) -....................3100 - 3125
6G23 OPTION 3013 STARTER (DF150/TF120)- 3000 - 3047A 7E2 OPTION 3135 ALTERNATOR (12V ISKRA)
6G21 OPTION 3013 STARTER (HF120/HF150/HF250) .......... 3000 - 3046 (HF120/HF150/HF250)-....................3100 - 3124
6G19 OPTION 3013 STARTER (TF150/TF220/TF250) ............ 3000 - 3044 7E1 OPTION 3135 ALTERNATOR (12V ISKRA)
6H5 OPTION 3025 STARTER (DF150/TF120)- 3000 - 3051A (TF150/TF220/TF250) -....................3100 - 3123
6H3 OPTION 3025 STARTER (HF120/HF150/HF250) .......... 3000 - 3050 7E11 OPTION 3517 FUEL FILTER (DF150) -.... 3500 - 3505A
6H1 OPTION 3025 STARTER (TF150/TF220/TF250) ............ 3000 - 3048 7E9 OPTION 3517 FUEL FILTER AND FUEL LINES
6H11 OPTION 3026 STARTER (DF150/TF120)- 3000 - 3053C (HF120/HF150)--.. 3500 - 3504
6H9 OPTION 3026 STARTER (HF120/HF150/HF250) .......... 3000 - 3053A 7E7 OPTION 3517 FUEL FILTER AND FUEL LINES
6H7 OPTION 3026 STARTER (TF150/TF220/TF250) ............ 3000 - 3052 (TF150/TF250) --.. 3500 - 3502
6H17 OPTION 3041 STARTER (DF150/TF120)- 3000 - 3057A 7E17 OPTION 3518 FUEL FILTER AND FUEL LINES
6H15 OPTION 3041 STARTER (HF120/HF150/HF250) .......... 3000 - 3056 (DF150/TF120/TF151) -....................3500 - 3510
6H13 OPTION 3041 STARTER (TF150/TF220/TF250) ............ 3000 - 3054 7E15 OPTION 3518 FUEL FILTER AND FUEL LINES
6H19 OPTION 3044 STARTER (TF151) -.... 3000 - 3058 (HF120/HF150/HF250)-....................3500 - 3508
6H23 OPTION 3060 STARTER (HF120/HF150/HF250) .......... 3000 - 3062 7E13 OPTION 3518 FUEL FILTER AND FUEL LINES
6I1 OPTION 3060 STARTER (TF150) -.... 3000 - 3063A (TF150/TF220/TF250) -....................3500 - 3506
6H21 OPTION 3060 STARTER (TF150/TF220/TF250) ............ 3000 - 3060 7E23 OPTION 3521 FUEL FILTER AND FUEL LINES
6I7 OPTION 3061 STARTER (DF150) -.... 3000 - 3067A (DF150/TF120)--.. 3500 - 3515A
6I5 OPTION 3061 STARTER (HF120/HF150/HF250) .......... 3000 - 3066 7E21 OPTION 3521 FUEL FILTER AND FUEL LINES
6I3 OPTION 3061 STARTER (TF150/TF220/TF250) ............ 3000 - 3064 (HF120/HF150)--.. 3500 - 3514
6I11 OPTION 3073 STARTER (DF150/TF120)- 3000 - 3070 7E19 OPTION 3521 FUEL FILTER AND FUEL LINES
6I10 OPTION 3073 STARTER (HF120/HF150/HF250) .......... 3000 - 3069 (TF150/TF250) --.. 3500 - 3512
6I9 OPTION 3073 STARTER (TF150/TF220/TF250) ............ 3000 - 3068 7F5 OPTION 3522 FUEL FILTER AND FUEL LINES
6I12 OPTION 3075 STARTER (DF150) -.... 3000 - 3071 (DF150/TF120)--.. 3500 - 3519A
GRID PAGE GRID PAGE
7F3 OPTION 3522 FUEL FILTER AND FUEL LINES 7I12 OPTION 4102 CRANKSHAFT PULLEY -.. 4100 - 4105
(HF120/HF150)--..3500 - 3518 7I13 OPTION 4102 CRANKSHAFT PULLEY -.. 4100 - 4106
7F1 OPTION 3522 FUEL FILTER AND FUEL LINES 7I14 OPTION 4103 CRANKSHAFT PULLEY -.. 4100 - 4107
(TF150/TF220/TF250) -....................3500 - 3516 7I15 OPTION 4103 CRANKSHAFT PULLEY -.. 4100 - 4108
7F7 OPTION 3526 FUEL FILTER AND FUEL LINES 7I16 OPTION 4103 CRANKSHAFT PULLEY -.. 4100 - 4109
(TF250)--.............. 3500 - 3520 7I19 OPTION 4303 AIR INTAKE HEATER- 4300 - 4301
7F11 OPTION 3527 FUEL FILTER AND FUEL LINES 7I20 OPTION 4303 AIR INTAKE HEATER- 4300 - 4302
(HF250) --............ 3500 - 3524 7I21 OPTION 4303 AIR INTAKE HEATER- 4300 - 4303
7F9 OPTION 3527 FUEL FILTER AND FUEL LINES 7I22 OPTION 4311 AIR INTAKE HEATER- 4300 - 4304
(TF220/TF250) --..3500 - 3522 7I23 OPTION 4311 AIR INTAKE HEATER- 4300 - 4305
7F13 OPTION 3532 FUEL FILTER -............ 3500 - 3526 7I24 OPTION 4311 AIR INTAKE HEATER- 4300 - 4306
7F15 OPTION 3532 FUEL FILTER -............ 3500 - 3528 7I25 OPTION 4312 AIR INTAKE HEATER- 4300 - 4307
7F17 OPTION 3533 FUEL FILTER -............ 3500 - 3530 7J1 OPTION 4312 AIR INTAKE HEATER- 4300 - 4308
7F19 OPTION 3536 FUEL FILTER -............ 3500 - 3532 7J2 OPTION 4312 AIR INTAKE HEATER- 4300 - 4309
7F21 OPTION 3536 FUEL FILTER -............ 3500 - 3534 8D5 OPTION 4401 TIMING GEAR COVER AND WATER
7F23 OPTION 3537 FUEL FILTER -............ 3500 - 3536 PUMP W/O AUX DRIVE (TF151)(ESN -XXXXX)........4400 - 4402
7G1 OPTION 3545 FUEL FILTER -............ 3500 - 3538 8D11 OPTION 4403 TIMING GEAR COVER AND WATER
7G3 OPTION 3545 FUEL FILTER -............ 3500 - 3540 PUMP W/O AUX DRIVE (DF150/TF120) .................... 4400 - 4408
7G7 OPTION 3601 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3601 8D9 OPTION 4403 TIMING GEAR COVER AND WATER
7G8 OPTION 3601 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3602 PUMP W/O AUX DRIVE (HF120/HF150/HF250) ........4400 - 4406
7G9 OPTION 3601 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3603 8D7 OPTION 4403 TIMING GEAR COVER AND WATER
7G10 OPTION 3602 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3604 PUMP W/O AUX DRIVE (TF150/TF220/TF250) ........4400 - 4404
7G11 OPTION 3602 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3605 8D17 OPTION 4404 TIMING GEAR COVER AND WATER
7G12 OPTION 3602 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3606 PUMP W/AUX DRIVE (DF150/TF220) - 4400 - 4414
7G13 OPTION 3603 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3607 8D15 OPTION 4404 TIMING GEAR COVER AND WATER
7G14 OPTION 3603 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3608 PUMP W/AUX DRIVE (HF120/HF150/HF250) ............ 4400 - 4412
7G15 OPTION 3604 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3609 8D13 OPTION 4404 TIMING GEAR COVER AND WATER
7G16 OPTION 3604 CRANKSHAFT UPPER IDLER GEAR ....3600 - 3610 PUMP W/AUX DRIVE (TF150/TF220/TF250).............. 4400 - 4410
7G19 OPTION 3701 FUEL TRANSFER PUMP - 3700 - 3701 8D23 OPTION 4425 TIMING GEAR COVER AND WATER
7G20 OPTION 3701 FUEL TRANSFER PUMP - 3700 - 3702 PUMP W/AUX DRIVE (DF150/TF120/TF151) ............ 4400 - 4420
7G21 OPTION 3701 FUEL TRANSFER PUMP - 3700 - 3703 8D21 OPTION 4425 TIMING GEAR COVER AND WATER
7H5 OPTION 3701 FUEL TRANSFER PUMP - 3700 - 3701 PUMP W/AUX DRIVE (HF120/HF150/HF250) ............ 4400 - 4418
7G22 OPTION 3702 FUEL TRANSFER PUMP - 3700 - 3704 8D19 OPTION 4425 TIMING GEAR COVER AND WATER
7G23 OPTION 3702 FUEL TRANSFER PUMP - 3700 - 3705 PUMP W/AUX DRIVE (TF150/TF220/TF250).............. 4400 - 4416
7G24 OPTION 3702 FUEL TRANSFER PUMP - 3700 - 3706 8E5 OPTION 4426 TIMING GEAR COVER AND WATER
7G25 OPTION 3715 FUEL TRANSFER PUMP - 3700 - 3707 PUMP W/AUX DRIVE (DF150/TF120) - 4400 - 4426
7H1 OPTION 3715 FUEL TRANSFER PUMP - 3700 - 3708 8E3 OPTION 4426 TIMING GEAR COVER AND WATER
7H2 OPTION 3715 FUEL TRANSFER PUMP - 3700 - 3709 PUMP W/AUX DRIVE (HF120/HF150/HF250) ............ 4400 - 4424
7H6 OPTION 3715 FUEL TRANSFER PUMP - 3700 - 3708 8E1 OPTION 4426 TIMING GEAR COVER AND WATER
7H3 OPTION 3799 NO FUEL TRANSFER PUMP.................. 3700 - 3710 PUMP W/AUX DRIVE (TF150/TF220/TF250).............. 4400 - 4422
7H4 OPTION 3799 NO FUEL TRANSFER PUMP.................. 3700 - 3711 8E13 OPTION 4603 CYLINDER BLOCK AND CAMSHAFT
7H9 OPTION 4001 OIL DIPSTICK (LH) -.... 4000 - 4001 (DF150/TF120/TF151) -....................4600 - 4606
7H10 OPTION 4001 OIL DIPSTICK (LH) -.... 4000 - 4002 8E11 OPTION 4603 CYLINDER BLOCK AND CAMSHAFT
7H11 OPTION 4001 OIL DIPSTICK (LH) -.... 4000 - 4003 (HF120/HF150/HF250)-....................4600 - 4604
7H12 OPTION 4002 OIL DIPSTICK (LH) -.... 4000 - 4004 8E9 OPTION 4603 CYLINDER BLOCK AND CAMSHAFT
7H13 OPTION 4002 OIL DIPSTICK (LH) -.... 4000 - 4005 (TF150/TF220/TF250) -....................4600 - 4602
7H14 OPTION 4002 OIL DIPSTICK (LH) -.... 4000 - 4006 8E19 OPTION 4702 CRANKSHAFT AND MAIN BEARINGS
7H15 OPTION 4003 OIL DIPSTICK (LH) -.... 4000 - 4007 (DF150/TF120/TF151) -....................4700 - 4703
7H16 OPTION 4003 OIL DIPSTICK (LH) -.... 4000 - 4008 8E18 OPTION 4702 CRANKSHAFT AND MAIN BEARINGS
7H17 OPTION 4003 OIL DIPSTICK (LH) -.... 4000 - 4009 (HF150/HF250)--.. 4700 - 4702
7H18 OPTION 4009 OIL DIPSTICK (REMOVABLE) ................ 4000 - 4010 8E17 OPTION 4702 CRANKSHAFT AND MAIN BEARINGS
7H19 OPTION 4009 OIL DIPSTICK (REMOVABLE) ................ 4000 - 4011 (TF150/TF220/TF250) -....................4700 - 4701
7H20 OPTION 4009 OIL DIPSTICK (REMOVABLE) ................ 4000 - 4012 8E21 OPTION 4703 CRANKSHAFT AND MAIN BEARINGS
7H21 OPTION 4014 OIL DIPSTICK (LH) -.... 4000 - 4013 (HF120/HF150/HF250)-....................4700 - 4705
7H22 OPTION 4014 OIL DIPSTICK (LH) -.... 4000 - 4014 8E20 OPTION 4703 CRANKSHAFT AND MAIN BEARINGS
7H23 OPTION 4014 OIL DIPSTICK (LH) -.... 4000 - 4015 (TF220/TF250) --.. 4700 - 4704
7H24 OPTION 4017 OIL DIPSTICK (LH) -.... 4000 - 4016 8E24 OPTION 4707 CRANKSHAFT AND MAIN BEARINGS
7H25 OPTION 4017 OIL DIPSTICK (LH) -.... 4000 - 4017 (DF150/TF120/TF151) -....................4700 - 4708
7I1 OPTION 4017 OIL DIPSTICK (LH) -.... 4000 - 4018 8E23 OPTION 4707 CRANKSHAFT AND MAIN BEARINGS
7I2 OPTION 4018 OIL DIPSTICK (LH AND RH) .................. 4000 - 4019 (HF150) --............ 4700 - 4707
7I3 OPTION 4018 OIL DIPSTICK (LH AND RH) .................. 4000 - 4020 8E22 OPTION 4707 CRANKSHAFT AND MAIN
7I4 OPTION 4018 OIL DIPSTICK (LH AND RH) .................. 4000 - 4021 (TF220/TF250) --.. 4700 - 4706
7I5 OPTION 4019 OIL DIPSTICK -............ 4000 - 4022 8F3 OPTION 4805 PISTON, CONNECTING ROD,
7I8 OPTION 4101 CRANKSHAFT PULLEY -.. 4100 - 4101 CYLINDER LINER (DF150)-............ 4800 - 4801
7I9 OPTION 4101 CRANKSHAFT PULLEY -.. 4100 - 4102 8F4 OPTION 4807 PISTON, CONNECTING ROD,
7I10 OPTION 4101 CRANKSHAFT PULLEY -.. 4100 - 4103 CYLINDER LINER (DF150)-............ 4800 - 4802
7I11 OPTION 4102 CRANKSHAFT PULLEY -.. 4100 - 4104
POWERTECH 6.8L ENGINES; TORREON(PE)(ESN 010000-), SARAN(CD)(ESN 500000-), DUBUQUE(TO)(ESN 700000-) PC2522 (06-JUN-02) I-49绍兴上虞沃尔沃D12C发动机配件厂家销售中心,泉州南安帕金斯4缸发动机.高压油泵联系询价,河北沧州河间劳斯莱斯发电机P1400E零配件原厂专卖,攀枝花仁和强鹿发动机配件特约经销商,邵阳新宁县P780321唐纳森滤清器纯正配件,伊春南岔P827653唐纳森滤清器大概的价钱,台州仙居县沃尔沃VOLVO手动抽油泵查询中心,咸阳旬邑县卡特发动机风扇叶采购批发平台,misaligned/broken valve springs   ? worn/distorted valve seats   ? insufficient lubrication   warped, worn,/distorted valve guides: ? lack of lubrication   ? cylinder head distortion   ? excessive heat   ? unevenly tightened cylinder head cap screws   distorted cylinder head&gasket leakage: ? loss of cylinder head cap screw torque   ? broken cylinder head cap screw(s)   ? overheating from low coolant level operation   ? insufficient liner standout   ? coolant leakage into cylinder causing hydraulic failure of gasket   ? leaking aftercooler   ? cracked cylinder head   ? cracked cylinder liner   ? damaged/incorrect gasket   ? overpowering/overfueling   ? damaged cylinder head/block surfaces   ? improper surface finish on cylinder head   ? improperly tightened cylinder head cap screws   ? faulty gasket installation (misaligned)   worn/broken valve seats: ? misaligned valves   ? distorted cylinder head   ? carbon deposits on seats due to incomplete combustion   ? valve spring tension too weak   ? excessive heat   ? improper valve clearance   ? improper valve timing   ? incorrect valve/seat installed   burned, pitted, worn,/broken valves: ? worn/distorted valve seats   ? loose valve seats   ? worn valve guides   ? insufficient cooling   ? cocked/broken valve springs   ? improper engine operation   ? improper valve train timing   ? faulty valve rotators   ? warped/distorted valve stems   ? “stretched” valves due to excessive spring tension   ? warped cylinder head   ? bent push rods   ? carbon build-up on valve seats   ? rocker arm failure   ? incorrect valve/seat installed   ? incorrect piston-to-valve clearance   improper valve clearance: ? inefficient use of fuel   ? engine starts harder   ? maximum engine power will not be achieved   ? shorter service life of valve train   ? greater chance for engine to overheat   excessive recession: ? worn valve guides   ? bent valves   ? debris passed through valve train   ctm104 (11jul02) 02-021-23 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=151 cylinder head&valves (four-valve head engines) 02 021 24 ouo1089,0000210 –19–05jun02–1/1 remove valve assembly rg12378a –un–07jun02 valve spring removal tool rg12379a –un–07jun02 valve spring&components a—retainer locks b—valve retainer c—valve spring d—valve stem seal note: identify all parts for assembly in same location   a small magnet may be used to aid removal of valve retainer locks   1   using jde138 valve spring compres***, compress valve springs far enough to remove retainer locks (a)   2   release spring tension&remove valve retainer (b) and valve spring (c)   3   remove valves from cylinder head   4   remove valve stem seal (d) from valve guide towers   ctm104 (11jul02) 02-021-24 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=152 cylinder head&valves (four-valve head engines) 02 021 25 ouo1089,000020f –19–04jun02–1/1 inspect&measure valve springs rg2732 –un–04dec97 valve spring rg7427 –un–21may98 valve spring compression tester important: intake valves, exhaust valves, valve seat inserts, springs&retainers must be replaced in pairs to maintain proper valve bridge alignment   also, replace bridge if any of these parts are replaced   1   inspect valve springs for alignment, wear,&damage   2   using d01168aa spring compression tester, check valve spring tension   compressed height must be within specification given below   valve springs—specification spring free length 0 n (0 lb-force)1—height        46  15 mm (1  82 in  ) spring compressed 166 n (37  32 lb-force)—height       37  21 mm (1  46 in  ) spring compressed 356 n (80  03 lb-force)—height       27  01 mm (1  06 in  ) 1free length may vary slightly between valve springs   ouo1089,0000215 –19–06jun02–1/1 clean valves 1   hold each valve firmly against a soft wire wheel on a bench grinder   important: do not use a wire wheel on plated portion of valve stem   polish the valve stem with steel wool/crocus cloth to remove any scratch marks left by the wire brush   2   make sure all carbon is removed from valve head, face and unplated portion of stem   ctm104 (11jul02) 02-021-25 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=153 cylinder head&valves (four-valve head engines) 02 021 26 ouo1089,0000216 –19–06jun02–1/3 inspect&measure valves rg7429 –un–03nov97 valve stem rg12380a –un–07jun02 intake/exhaust valve identification a—retainer lock groove b—raised letter “i” important: intake valves, exhaust valves, valve seat inserts, springs&retainers must be replaced in pairs to maintain proper valve bridge alignment   also, replace bridge if any of these parts are replaced   1   clean&inspect valves, valve stems, stem tips, and retainer lock groove (a)   replace worn/damaged valves in pairs   specification intake valve head—od 36  87—37  13 mm (1  452—1  462 in  )      exhaust valve head—od 35  87—36  13 mm (1  412—1  422 in  )        note: intake valve has a larger head od&is also identified with a raised letter “i” on valve head   ouo1089,0000216 –19–06jun02–2/3 rg7430 –un–23nov97 valve stem measurement 2   measure valve stem od   record measurements and compare with valve guide id   (see measure valve guides later in this group  ) specification intake valve stem—od 6  987—7  013 mm (0  2750—0  2761 in  )      exhaust valve stem—od 6  984—7  000 mm (0  2749—0  2756 in  )        ctm104 (11jul02) 02-021-26 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=154 continued on next page cylinder head&valves (four-valve head engines) 02 021 27 ouo1089,0000216 –19–06jun02–3/3 rg4234 –un–05dec97 valve inspection center 3   using a valve inspection center, determine if valves are out of round, bent,/warped   specification valve face—maximum runout (intake&exhaust)      0  038 mm (0  0015 in  ) ouo1089,000020e –19–04jun02–1/1 grind valves important: intake valves, exhaust valves, valve seat inserts, springs&retainers must be replaced in pairs to maintain proper valve bridge alignment   also, replace bridge if any of these parts are replaced   do not grind valves   if valve face is warped, pitted, burnt, worn/damaged, replace intake/exhaust valves in pairs   ctm104 (11jul02) 02-021-27 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=155 cylinder head&valves (four-valve head engines) 02 021 28 ouo1089,0000217 –19–06jun02–1/2 head gasket inspection&repair sequence rg8117 –un–15jan98 head gasket inspection a—combustion seals b—gasket body d—elastomer beading strip e—front of engine (flanges) c—rocker arm oil port the following inspection procedures are recommended whenever a head gasket joint failure occurs,/when joint disassembly takes place   1   review historical data relating to machine operation, maintenance&repair, along with diagnostic observations   note all areas requiring further inspection&analysis   2   remove rocker arm cover&check for presence of coolant in the oil   3   record head cap screw torques prior to removal   upon removal, check cap screw length differences   4   remove cylinder head using appropriate lifting devices to prevent handling damage to head gasket   (see remove cylinder head earlier in this group  ) 5   observe surfaces of removed head gasket   examine combustion seals (a) for the following: ? flange severed/expanded/cracked/deformed   ? adjacent body area burned/eroded   ? fire ring severed/displaced/missing   ? flange sealing pattern eccentric/contains voids   ? discoloration of flange&adjacent body areas   ? flange surfaces rough/abraded/channelled   examine gasket body (b) for the following: ? combustion gas erosion paths/soot deposits originating at combustion seals   ? extreme discoloration/hardening/embrittlement in localized areas   ? o-ring seal missing/damaged in port area (c)   ? elastomer missing/damaged in port area (d)   ? oil/coolant paths from port areas   ? localized areas of low compression   6   before cleaning components, inspect head, block, and liners for evidence of combustion gas&fluid leakage   inspect cylinders&valve ports for unusual deposits   7   clean block, head, liners,&cap screws   (see procedures in this group&in group 030  ) 8   proceed with the following dimensional checks and visual inspections: ctm104 (11jul02) 02-021-28 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=156 continued on next page cylinder head&valves (four-valve head engines) 02 021 29 ouo1089,0000217 –19–06jun02–2/2 cylinder head (see procedures in this group) ? check surface flatness/finish   ? inspect for surface damage   ? check cylinder head thickness, if resurfacing   cylinder block&liners (assembled and clamped) (see group 030) ? check liner standout at four places on each liner   ? check liner standout difference between cylinders   cylinder block (see group 030) ? check surface flatness/finish   ? inspect for surface damage   ? check liner counterbore depth (if liner is removed)   ? check top deck to crankshaft centerline dimension   ? inspect cap screw bosses; must be clean/intact   cylinder liner (see group 030) ? check liner flange flatness/finish   ? check liner flange thickness (if liner is removed)   ? inspect flange for damage   cylinder head cap screws (see procedures in this group) ? inspect for corrosion damage   ? inspect condition of threads   ? inspect for straightness   ? check length   9   when inspections&measurements have been completed, determine most probable causes of joint failure   make all necessary repairs to joint components, cooling system,&fuel injection system   10   reassemble the engine according to procedures and specifications in the repair groups of this manual   ctm104 (11jul02) 02-021-29 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=157 cylinder head&valves (four-valve head engines) 02 021 30 ouo1089,0000218 –19–06jun02–1/1 inspect&clean cylinder head 1   inspect combustion face for evidence of physical damage, oil/coolant leakage,/gasket failure prior to cleaning the cylinder head   repair/replace cylinder head if there is evidence of physical damage, such as cracking, abrasion, distortion,/valve seat “torching”   inspect all cylinder head passages for restrictions   2   scrape gasket material, oil, carbon,&rust from head   use a powered wire brush to clean sealing surfaces   important: be sure to remove all plugs before cleaning head, as parts can be damaged/destroyed by hot tank solutions   3   clean cylinder head in a chemical hot tank,/with solvent&a brush   4   dry with compressed air&blow out all passages   ouo1089,0000219 –19–06jun02–1/1 check cylinder head flatness rg12376 –un–11jun02 cylinder head flatness check check cylinder head flatness using d05012st precision “bevelled edge” straightedge&feeler gauge   check lengthwise, crosswise,&diagonally in several places   specification cylinder head flatness— maximum acceptable out-of-flat for entire length/width        0  08 mm (0  003 in  ) maximum acceptable out-of-flat for every 150 mm (5  90 in  )      0  03 mm (0  001 in  ) if out-of-flat exceeds specifications, the cylinder head must be reconditioned/replaced   (see measure cylinder head thickness later in this group  ) ctm104 (11jul02) 02-021-30 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=158 cylinder head&valves (four-valve head engines) 02 021 31 ouo1089,000021a –19–06jun02–1/1 measure cylinder head thickness rg12377 –un–11jun02 cylinder head thickness check measure head thickness from valve cover gasket rail-to-combustion face   if cylinder head thickness is less than minimum allowable thickness, do not attempt to resurface   install a new cylinder head   when resurfacing cylinder head, remove only what is necessary to restore flatness   specification new cylinder head—thickness 104  87—105  13 mm (4  129—4  139 in  )      minimum acceptable thickness       104  24 mm (4  104 in  ) combustion face surface finish (surface grind only) (aa) 0  7—3  2 micrometers (31—125 micro-in  )      maximum wave depth      0  012 mm (0  0005 in  ) maximum material removal for resurfacing       0  76 mm (0  030 in  ) important: after resurfacing cylinder head, check for flatness as described earlier   also check surface finish on combustion face of head   measure&record valve recess in cylinder head   (see measure valve recess in cylinder head earlier in this group  ) ctm104 (11jul02) 02-021-31 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=159 cylinder head&valves (four-valve head engines) 02 021 32 ouo1089,0000234 –19–11jun02–1/1 remove fuel injector sleeves rg12396a –un–13jun02 fuel injection nozzle sleeve removal a—7/8-9 tap 1   tap the inner diameter of the sleeve with a 7/8-9 tap (a)   2   insert a 7/8-9 cap screw&pull out the fuel injection nozzle sleeve   ouo1089,0000232 –19–11jun02–1/1 clean fuel injector bores rg12385a –un–12jun02 clean fuel injection nozzle bore clean fuel injection nozzle bores with a plastic brush before inspection/repair   note: a few drops of light oil/kerosene will help clean the bores   ctm104 (11jul02) 02-021-32 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=160 cylinder head&valves (four-valve head engines) 02 021 33 ouo1089,0000235 –19–11jun02–1/1 install fuel injector sleeves b c a d rg12406 –un–18jun02 fuel injector nozzle sleeve rg12386a –un–19jun02 fuel injection nozzle sleeve installation a—o-ring b—o-ring c—sleeve d—cut-away view of fuel injector sleeve e—jdg1649 injector sleeve installer important: if installing a new fuel injector nozzle sleeve with four-valve head attached to block, make sure piston is not at or near top dead center (tdc)   rotate engine until piston is at bottom dead center (bdc)/piston damage will result   1   support four-valve head so that the lower surface of the head is approximately 50 mm (2  0 in  ) above work bench   2   apply loctite? 592 completely around the lower, outer edge of the fuel injection nozzle sleeve (c)   important: make sure o-rings are installed in their proper positions   failure to do so will result in premature o-ring failure   do not use any petroleum based products to lubricate fuel injector sleeve o-rings/o-rings will swell   3   install o-rings (a&b)&lubricate with liquid soap   4   set fuel injection nozzle sleeve (c) over bore and place jdg1649 injector sleeve installer (d) into the sleeve   5   using a hammer, strike the nozzle installation tool carefully to drive the sleeve fully into the bore   loctite is a trademark of loctite corp   ctm104 (11jul02) 02-021-33 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=161 cylinder head&valves (four-valve head engines) 02 021 34 ouo1089,0000233 –19–11jun02–1/1 clean glow plug bores rg12400a –un–12jun02 clean glow plug bores clean glow plug bores with a 吕梁JohnDeere左平衡轴TRE500449代理,中山约翰迪尔拖拉机发动机全车线束哪里买,武汉美国强鹿发动机大修包厂家供应,果洛约翰迪尔强鹿机油底壳垫片R532464代理商,汉中约翰迪尔强鹿3029柴油机空气加热器厂家供应,金华约翰迪尔6090柴油机加大止推轴承瓦供货商,许昌强鹿柴油发电机组连杆哪里买,临沂约翰迪尔RE521348曲轴代理,佛山约翰迪尔发动机止推片哪里买,东营约翰迪尔风扇皮带张紧轮RE57498诚信推荐,青岛强鹿柴油发动机加大连杆瓦RE57167厂家供货,咸宁强鹿柴油机发电机皮带R503312哪家买,阿克苏约翰迪尔强鹿柴油发动机电子燃油泵市场报价,无堂划分域强鹿柴油机柴滤RE507284厂家供货,牡丹江强鹿柴油发电机组气缸垫多少钱,防城港强鹿缸套阳水圈AR65507厂家批发,徐州强鹿连杆螺丝TR501124厂家价格,黄石JohnDeereRE19507水泵修理包找哪家,信阳约翰迪尔凸轮轴衬套RE504914市场报价,阜新强鹿柴油机电子燃油泵RE539769代理商,锦州强鹿柴油发电机配件批发价,荆门强鹿滤芯滤清器RE35522的价格,东莞约翰迪尔6J-1654拖拉机发动机配件哪家好,阿克苏强鹿柴油机连杆瓦市场报价,乌兰察布约翰迪尔进气门R98062厂家供应,宁波强鹿平衡轴铜套TR115299哪家好,延边强鹿柴油发动机3029衬垫套信息,鄂州约翰迪尔柴油机3029曲轴诚信推荐,荆门强鹿柴油机活塞环RE527844厂家供应,淮安JohnDeereRE65168B止推轴承哪家买,高雄强鹿柴油机加大主轴瓦RE65165B厂家价格,双鸭山强鹿温度传感器el522823价格行情,遂宁JohnDeere水泵RE530194厂家价格,阿里johndeere约翰迪尔强鹿柴油发动机水泵总成RE505980厂家价格,文山强鹿排气门异管RE518083厂家供货,武威约翰迪尔强鹿皮带张紧轮RE68715厂家批发,咸阳约翰迪尔柴油机T26321凸轮轴上衬套代理,怒江强鹿6090柴油发动机曲轴批发,新界约翰迪尔水温度传感器RE51774多少钱,商洛强鹿4045TF120起动机市场报价,乌鲁木齐约翰迪尔凸轮轴铜套R119874厂家供应,伊犁强鹿RE504836机油滤芯厂家价格,陇南约翰迪尔E240挖掘机发动机配件哪里买,赤峰约翰迪尔发动机喷油嘴厂家价格,阿坝强鹿6081柴油机节温器供货商,株洲约翰迪尔6068柴油机燃油泵公司,黔西南约翰迪尔挖掘机单体泵哪家好,黄南约翰迪尔柴油机气门弹簧R502187价格,绍兴强鹿6090柴油机加大止推轴承瓦代理,大同约翰迪尔柴油发电机组缸套厂家供货,宜春JohnDeere气缸室盖垫片R527884公司,杭州约翰迪尔联合收割机发动机止推片厂家价格,柳州约翰迪尔4045柴油机气门室盖螺丝R85363代理商,澳门半岛johndeere约翰迪尔强鹿柴油发动机连杆瓦RE65908批发商,怀化约翰迪尔温度传感器RE51774厂家批发,朔州强鹿传感器RE522794批发价,廊坊johndeere约翰迪尔强鹿柴油机充电发电机代理商,plastic brush before inspection/repair   note: a few drops of light oil/kerosene will help clean the bores   ouo1089,000021c –19–06jun02–1/1 clean valve guides rg12388a –un–07jun02 valve guide cleaning clean valve guides with a plastic brush before inspection or repair   note: a few drops of light oil/kerosene will help clean the guides   ctm104 (11jul02) 02-021-34 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=162 cylinder head&valves (four-valve head engines) 02 021 35 ouo1089,000021d –19–06jun02–1/1 measure valve guides rg12383a –un–07jun02 valve guide wear using a telescopic gauge, measure valve guide wear   specification valve guide bore (new)—id 7  041—7  067 mm (0  277—0  278 in  )      intake valve guide-to-valve stem (new)—clearance 0  03—0  08 mm (0  0012—0  0031 in  )        exhaust valve guide-to-valve stem (new)—clearance 0  04—0  09 mm (0  0016—0  0035 in  )      intake&exhaust valve guide-to-valve stem (wear limit)—clearance 0  15 mm (0  0059 in  )        note: valves are available with 0  15 mm (0  006 in  ) oversize stems   if valve guide-to-stem oil clearance exceeds the wear limit, oversize valve stems are available   have a qualified machine shop ream valve guides to ensure guide-to-stem clearance is within specification   if valve guide-to-stem oil clearance exceeds the wear limit, but is less than 0  20 mm (0  008 in  ), it is acceptable to knurl guides&ream to size   however, installing oversize valve stems is preferred   (see knurl valve guides, later in this group  ) important: production valve guides have an m8-1 modified internal thread the entire length of guide with major diameter of 7  181—7  257 mm (0  2827—0  2857 in  )   thread must encompass full circumference for entire length   have qualified machine shop thread valve guides accordingly after reaming for oversize valve stems   ctm104 (11jul02) 02-021-35 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=163 cylinder head&valves (four-valve head engines) 02 021 36 ouo1089,000021e –19–06jun02–1/1 knurl valve guides rg7437 –un–23nov97 knurling valve guides important: valve guide knurling should only be done by experienced personnel familiar with equipment&capable of maintaining required specification   always knurl valve guides before reaming to assure proper valve guide-to-stem clearance   1   use jt05949 valve guide knurler kit to knurl valve guides   use kit exactly as directed by the manufacturer   2   after knurling, ream valve guide to finished size to provide specified stem-to-guide clearance   ouo1089,000021f –19–06jun02–1/1 clean&inspect valve seats rg12384a –un–07jun02 valve seat cleaning&inspection 1   use an electric hand drill with d17024br end brush to remove all carbon on valve seats   2   inspect seats for excessive wear, cracks,/damage   3   check entire combustion face for rust, scoring, pitting, or cracks   ctm104 (11jul02) 02-021-36 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=164 cylinder head&valves (four-valve head engines) 02 021 37 ouo1089,0000220 –19–06jun02–1/1 grind valve seats important: intake valves, exhaust valves, valve seat inserts, springs&retainers must be replaced in pairs to maintain proper valve bridge alignment   also, replace bridge if any of these parts are replaced   do not grind valve seats   if valve seat is pitted, burnt, worn/damaged, replace intake/exhaust valve seats in pairs   ouo1089,0000221 –19–06jun02–1/4 remove valve seat inserts important: be careful not to damage cylinder head when removing valve seats   valve seat removal should only be done by experienced personnel familiar with procedures   do not use an oxy-acetylene torch to remove valve seat inserts, as it alters the hardness of the cylinder head   valve seat inserts are made of sintered (powdered) metal   remove inserts by one of the following methods: continued on next page ctm104 (11jul02) 02-021-37 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=165 cylinder head&valves (four-valve head engines) 02 021 38 ouo1089,0000221 –19–06jun02–2/4 rg12398a –un–12jun02 carbide deburring tool rg12397a –un–12jun02 valve seat a—deburring tool b—burr raising burr on valve seat insert 1   using a carbide deburring tool (a), raise a burr (b) on bottom of valve seat insert   continued on next page ctm104 (11jul02) 02-021-38 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=166 cylinder head&valves (four-valve head engines) 02 021 39 ouo1089,0000221 –19–06jun02–3/4 rg7818 –un–13nov97 chisel for valve seat insert removal rg12399a –un–12jun02 valve seat insert removal c—special ground chisel d—valve seat insert 2   protect surface of cylinder head with cardboard or cloth   using a chisel with special ground end (c), tap handle of chisel with hammer until valve seat insert (d) comes loose   continued on next page ctm104 (11jul02) 02-021-39 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=167 cylinder head&valves (four-valve head engines) 02 021 40 ouo1089,0000221 –19–06jun02–4/4 rg7761 –un–10nov97 weld bead for valve seat insert removal rg7813 –un–13nov97 weld bead location a—welder’s cloth b—weld bead using an arc welder 1   protect the valve guide by installing a cap screw or dowel in guide to protect from weld spatter   2   protect the cylinder head surface with a non-flammable welder’s cloth (a)   apply a thin bead of weld (b) around id of valve seat insert   allow insert to cool and use a screwdriver/similar tool&carefully pry insert from bore   3   after removal of inserts, thoroughly clean area around valve seat bore&inspect for damage/cracks   replace cylinder head as necessary   ctm104 (11jul02) 02-021-40 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=168 cylinder head&valves (four-valve head engines) 02 021 41 ouo1089,0000222 –19–06jun02–1/1 measure valve seat bore in cylinder head rg9101 –un–27mar98 cylinder head valve seat bore if bore dimensions are not within specification, machine head to the following specifications: exhaust valve seat insert bore specifications: a      not available b      not available c      not available d      not available e      not available maximum surface finish of bore “a”    not available intake valve seat insert bore specifications: a      not available b      not available c      not available d      not available e      not available maximum surface finish of bore “a”    not available replacement valve seat insert od: intake    47  155—47  181 mm (1  8565—1  8575 in  ) exhaust      43  038—43  064 mm (1  6944—1  6954 in  ) ctm104 (11jul02) 02-021-41 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=169 cylinder head&valves (four-valve head engines) 02 021 42 ouo1089,0000223 –19–06jun02–1/1 install valve seat inserts rg12381a –un–07jun02 valve seat insert in cylinder head installation a—jdg1653-1 valve seat driver b—jdg1653-2 valve seat installer important: intake valves, exhaust valves, valve seat inserts, springs&retainers must be replaced in pairs to maintain proper valve bridge alignment   also, replace bridge if any of these parts are replaced   1   use jdg1653-1 valve seat driver (a)&jdg1653-2 valve seat installer (b) to install valve seat inserts in cylinder head   use one end of jdg1653-2 valve seat installer to install intake valve seat inserts&the other end to install exhaust valve seat inserts   2   install valves&measure valve recess   (see measure valve recess in cylinder head, earlier in this group  ) ctm104 (11jul02) 02-021-42 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=170 cylinder head&valves (four-valve head engines) 02 021 43 ouo1089,0000211 –19–05jun02–1/2 install valves rg12382a –un–07jun02 valve stem seal installation tool a—jdg1651 valve seal installer b—valve stem seal c—valve guide tower important: intake valves, exhaust valves, valve seat inserts, springs&retainers must be replaced in pairs to maintain proper valve bridge alignment   also, replace bridge if any of these parts are replaced   1   coat entire length of valve guide bores&dip valve stem end of valve in ar44402 lubricant before installation   note: valves must move freely in guide&seat properly in head to form an effective seal   2   insert valves in head (if valves are reused, install in same location from which removed)   3   apply clean engine oil to valve stem seal&use jdg1651 valve seal installer (a) to slide valve stem seal (b) over valve stem&onto valve guide tower (c)   note: jdg1651 installer may also be used to install oversize valve stem seals on oversize valve stems   4   install valve springs&retainers   ouo1089,0000211 –19–05jun02–2/2 rg12387a –un–07jun02 valve spring compres***&retainer locks a—spring compres*** b—retainer locks 5   compress valve springs using jde138 valve spring compres*** (a)&install retainer locks (b) on valve stems   6   strike end of each valve three/four times with a soft mallet (non-metallic) to ensure proper positioning of the retainer locks   7   recheck valve recess   (see measure valve recess in cylinder head, earlier in this group  ) ctm104 (11jul02) 02-021-43 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=171 cylinder head&valves (four-valve head engines) 02 021 44 ouo1089,0000224 –19–06jun02–1/1 clean&inspect cylinder head cap screws rg6319 –un–23nov97 cylinder head cap screw 1   clean entire length of cap screws   use a wire brush and solvent to remove rust&scale   dry cap screws with compressed air   2   inspect cap screws for corrosion, damage&overall condition of threads   cap screws with corrosion/other imperfections must be replaced   ouo1089,0000225 –19–06jun02–1/1 inspect&clean exhaust manifold 1   thoroughly clean all passages&gasket surfaces in exhaust manifold&exhaust elbow   2   inspect entire exhaust manifold for cracks/damage   replace parts as necessary   ctm104 (11jul02) 02-021-44 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=172 cylinder head&valves (four-valve head engines) 02 021 45 ouo1089,0000226 –19–06jun02–1/1 clean&inspect top deck of cylinder block rg7444 –un–23nov97 cleaning threaded holes in cylinder block rg7421 –un–23nov97 clean&lube camshaft followers 1   remove gasket material, rust, carbon,&other foreign material from top deck   gasket surface must be clean   2   clean threaded holes in cylinder block using jdg680 tap/any 1/2-13 unc-2a tap about 76 mm (3  0 in  ) long   use compressed air to remove debris&fluids from the cap screw holes   replace block if there is evidence of damage   3   use compressed air to remove all loose foreign material from cylinders&top deck   important: all debris must be cleaned from the camshaft followers before assembling the engine   4   if not previously done, remove camshaft followers from block&wash in solvent   lubricate with clean engine oil&install in the same bore   5   inspect top deck for flatness&serviceability   (see measure cylinder block top deck flatness in group 030  ) ctm104 (11jul02) 02-021-45 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=173 cylinder head&valves (four-valve head engines) 02 021 46 ouo1089,0000227 –19–06jun02–1/1 measure cylinder liner standout (height above block) rg6439 –un–03nov97 cylinder liner standout (above block) rg7445a –un–03nov97 measure cylinder liner standout (above block) a—liner height b—gauge c—dial indicator 1   secure liners using cap screws&flat washers   flat washers should be at least 3  18 mm (1/8 in  ) thick   tighten cap screws to 68 n?m (50 lb-ft)   2   using jdg451/kjd10123 gauge (b)&d17526ci or d17527ci dial indicator (c), measure liner height (a) at 1, 5, 7,&11 o’clock positions as viewed from flywheel end of engine   record all measurements by cylinder number   specification cylinder liner—height above block 0  030—0  100 mm (0  001—0  004 in  )          maximum permissible height difference at nearest point of two adjacent liners,/within a single liner       0  05 mm (0  002 in  ) important: one liner shim only may be installed under each liner flange   3   remove&shim,/replace, any liner that does not meet height specifications   (see remove cylinder liners in group 030  ) note: two sizes of shims are available: 0  05 mm (0  002 in  )&0  10 mm (0  004 in  )   ctm104 (11jul02) 02-021-46 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=174 cylinder head&valves (four-valve head engines) 02 021 47 ouo1089,0000228 –19–06jun02–1/4 install cylinder head rg7447 –un–04nov97 fuel supply pump push rod a—fuel supply pump push rod 1   dip fuel supply pump push rod (a) in clean engine oil and carefully install in cylinder block before installing cylinder head   ouo1089,0000228 –19–06jun02–2/4 rg12389a –un–03jul02 cylinder head guide studs b—guide studs important: the o-ring seal in the head gasket can be damaged if head is repositioned while resting on engine block   use guide studs to position cylinder head on block   2   install two guide studs (b) in cylinder block at locating holes   important: always thoroughly inspect cylinder head gasket for possible manufacturing imperfections   return any gasket that does not pass inspection   3   place new head gasket on cylinder block   do not use sealant; install dry   continued on next page ctm104 (11jul02) 02-021-47 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=175 cylinder head&valves (four-valve head engines) 02 021 48 ouo1089,0000228 –19–06jun02–3/4 rg7415 –un–23nov97 cylinder head to block installation 4   position cylinder head over guide studs&lower onto cylinder block   ouo1089,0000228 –19–06jun02–4/4 rg12401 –un–12jun02 cylinder head bolt tightening sequence a—4-cylinder engine b—6-cylinder engine c—arrow toward front of engine 5   dip entire cap screw in clean engine oil   remove excess oil from screw   6   install flanged-head cylinder head cap screws   7   tighten all cap screws to specified torques (in sequence shown, beginning with no   1), following steps 1—4 below   then, torque-turn cap screws following procedure on next page   cylinder head cap screws—specification step 1—initial—torque        100 n?m (75 lb-ft) step 2—second—torque        150 n?m (110 lb-ft) step 3—verify (after 5 minutes)—torque         150 n?m (110 lb-ft) step 4—final—torque-turn tighten each screw an additional 60° ± 10°   (see torque-turn method for proper torque in this group  )    retorque of cylinder head cap screws after engine break-in is not required when using the recommended torque procedure along with flanged-head cap screws   ctm104 (11jul02) 02-021-48 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=176 cylinder head&valves (four-valve head engines) 02 021 49 ouo1089,0000229 –19–06jun02–1/1 torque-turn method for proper torque rg5698 –un–05dec97 torque angle gauge 60? a b a a b c c 60? 1 2 3 rg11798 –un–25oct01 torque-turn tightening procedure a—first mark on socket b—second mark on socket c—mark on cylinder head surface after tightening cap screws to 150 n?m (110 lb-ft), use jt05993 torque angle gauge/the line scribe method below to tighten each cap screw an additional 60°   line scribe method: 1   make two marks (a&b) on socket 1/6 turn (60° ± 10°) apart   2   place socket on cap screw&make a mark on cylinder head (c) in line with first mark (a) on cap screw   3   tighten all cap screws (in sequence shown on previous page) until second mark (b) on socket aligns with mark (c) on cylinder head   retorque of cylinder head cap screws after engine break-in is not required when using the recommended torque procedure along with flanged-head cap screws   ctm104 (11jul02) 02-021-49 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=177 cylinder head&valves (four-valve head engines) 02 021 50 ouo1089,000022e –19–06jun02–1/1 install fuel injectors rg12391a –un–10jun02 fuel injector inlet port rg12390a –un–10jun02 fuel supply tube installation rg12392a –un–10jun02 hold-down clamp&fitting a—injector fuel inlet port b—copper washer c—fuel injector d—injector hold-down clamp e—fuel supply tube f—screw g—fitting h—glow plug 1   install copper washer (b) on end of fuel injector (c) tip   2   install fuel injector with injector hold-down clamp (d) into cylinder head   make sure injector fuel inlet port (a) is facing fuel supply tube (e) once installed   3   install fuel supply tube (e) with smaller end in toward fuel injector   important: use proper torque procedure for tightening fitting (g)&screw (f)   4   using proper torque procedure, install fitting (g) and screw (f)   (see install electronic injectors in section 02, group 090 of ctm220—level 11 electronic fuel systems with denso high pressure common rail  ) note: when replacing glow plugs, make sure glow plugs are replaced with new ones of the same voltage rating   24-volt glow plugs have a blue tint while 12-volt glow plugs have a yellow tint   5   install glow plug (h)&torque to specification   specification glow plug—torque        15 n?m (11 lb-ft) 6   repeat procedure for each cylinder   ctm104 (11jul02) 02-021-50 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=178 cylinder head&valves (four-valve head engines) 02 021 51 ouo1089,0000230 –19–07jun02–1/2 install carrier assemly rg12395a –un–03jul02 rocker carrier sealing rings a—rocker arm shaft oil supply o-ring b—carrier sealing ring important: replace sealing ring (b)&rocker arm shaft oil supply o-ring (a) every time the rocker carrier is removed during engine/cylinder head overhaul   1   the following procedure should be used to install a new sealing ring (b): ? carefully remove old sealing ring from rocker carrier   do not use any cutting tool that could damage the carrier   ? clean the groove with acetone   dry with compressed air   ? when installing new sealing ring in groove, start at ends&work toward the center of the cover   do not use sealant on sealing ring   ouo1089,0000230 –19–07jun02–2/2 rg12362 –un–03jul02 rocker arm carrier a—rocker arm carrier b—screw (2 used) 2   install rocker arm carrier (a)&tighten screws (b) to specification   specification rocker arm carrier screws— torque        60 n?m (44 lb-ft) ctm104 (11jul02) 02-021-51 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=179 cylinder head&valves (four-valve head engines) 02 021 52 ouo1089,000022a –19–06jun02–1/2 install rocker arm assembly rg12361 –un–31may02 push rods&bridges a—push rod b—bridge 1   install push rods (a) in same location from which removed   2   install bridges (b) in same location from which removed   continued on next page ctm104 (11jul02) 02-021-52 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=180 cylinder head&valves (four-valve head engines) 02 021 53 ouo1089,000022a –19–06jun02–2/2 rg12360 –un–03jul02 rocker arm shaft installation rg12178 –un–03jul02 fuel injection nozzle harness installation a—nut b—cap screw (2 used) c—clamp d—end clamp important: relieve tension on rocker arm adjusting screws to avoid damaging rocker arm shaft during installation   3   position rocker arm assembly on engine   4   lubricate all rocker arms&push rod sockets with engine oil&make sure they move freely   tighten both rocker arm shaft end clamps (d) to specification   specification rocker arm shaft end clamps— torque        36 n?m (27 lb-ft) 5   tighten rocker arm shaft clamps (c) to specification   specification rocker arm shaft clamps— torque        60 n?m (44 lb-ft) 6   install fuel injection nozzle harness securing wires on injection nozzles with nuts (a),&connector body in rocker arm carrier with cap screws (b)   (see install electronic injectors in section 02, group 090 in ctm220—level 11 electronic fuel systems with denso high pressure common rail  ) 7   adjust valve clearance   (see check&adjust valve clearance earlier in this group  ) ctm104 (11jul02) 02-021-53 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=181 cylinder head&valves (four-valve head engines) 02 021 54 ouo1089,000022b –19–06jun02–1/1 inspect&clean ventilator outlet hose rg12393a –un–10jun02 ventilator outlet hose inspection a—ventilator outlet hose note: if ventilator hose/tube is crimped/restricted in any way, high oil pressure/possible loss of oil could result in engine damage   1   check ventilator outlet hose (a) on rocker arm cover for bent/damaged condition   replace if necessary   2   clean ventilator hose&tube if they are restricted   ouo1089,000022c –19–06jun02–1/2 install rocker arm cover rg12394a –un–10jun02 rocker arm cover sealing ring a—sealing ring important: replace sealing ring (a) every time the rocker arm cover is removed during engine/cylinder head overhaul   the following procedure should be used to install a new sealing ring (a): ? carefully remove the old sealing ring from rocker arm cover   do not use any cutting tool that could damage the cover   ? clean the groove with acetone   dry with compressed air   ? when installing new sealing ring in groove, start at ends and work toward the center of the cover   do not use sealant on sealing ring   important: make sure fuel injection harness wires are properly secured   wires not properly secured will be pinched by valve springs with engine operating   1   install rocker arm cover with sealing ring   ctm104 (11jul02) 02-021-54 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=182 continued on next page cylinder head&valves (four-valve head engines) 02 021 55 ouo1089,000022c –19–06jun02–2/2 rg12177 –un–03jul02 rocker arm cover a—cap screw&o-ring b—button plug 2   install cap screws&o-rings (a)   tighten all cap screws to specifications, starting at the center and alternating sides until reaching the ends   do not overtighten   specification rocker arm cover nuts (four-valve head)—torque       7 n?m (62 lb-in  ) 3   install button plugs (b)   ctm104 (11jul02) 02-021-55 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=183 cylinder head&valves (four-valve head engines) 02 021 56 ouo1089,000022d –19–06jun02–1/4 complete final assembly rg12176 –un–03jul02 fuel return line rg12175 –un–03jul02 fuel lines rg12174 –un–03jul02 fuel filters a—final fuel filter b—primary fuel filter/water separator c—fuel supply pump d—fuel delivery line e—fuel leak-off line assembly f—tee fitting nut g—fuel leak-off line nut h—glow plug harness rail 1   install fuel leak-off line assembly (e) to engine   2   connect fuel leak-off line nut (g)&tee fitting nut nut (f) at each tee fitting   (see remove&install leak off lines in section 02, group 090 in ctm220—level 11 electronic fuel systems with denso high pressure common rail  ) 3   install glow plug harness with rail (h) on engine   torque glow plug harness rail screws to specification   specification glow plug harness rail screws—torque         11 n?m (8 lb-ft) 4   install fuel delivery lines (d)   (see remove and install leak off lines in section 02, group 090 in ctm220—level 11 electronic fuel systems with denso high pressure common rail  ) 5   install fuel supply pump (c)   (see install mechanical fuel transfer pump in section 02, group 090 in ctm220—level 11 electronic fuel systems with denso high pressure common rail  ) 6   install fuel filters (a)&(b)&connect fuel lines   7   install alternator, if previously removed   (see remove and install alternator in group 100  ) ctm104 (11jul02) 02-021-56 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=184 continued on next page cylinder head&valves (four-valve head engines) 02 021 57 ouo1089,000022d –19–06jun02–2/4 rg12173 –un–03jul02 fan pulley mounting plate removal rg12172 –un–03jul02 fan belt&pulley removal a—bracket b—fan belt c—cap screws (4 used) d—plate 8   install plate (d) to engine   9   install bracket (a)   10   install pulley with cap screws (c)   11   install fan belt (b)   continued on next page ctm104 (11jul02) 02-021-57 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=185 cylinder head&valves (four-valve head engines) 02 021 58 ouo1089,000022d –19–06jun02–3/4 rg12171 –un–03jul02 exhaust port sleeve, coolant tube&thermostat housing rg12167 –un–03jul02 exhaust manifold, turbocharger return oil line&heat shield a—exhaust manifold b—turbocharger oil drain line c—heat shield d—sleeve e—thermostat housing 12   install thermostat housing (e), coolant manifold and side port   see remove&install coolant manifold, thermostats&side port (four-valve head) in group 070   13   install sleeve (d) in each exhaust port   14   install heat shield (c)&torque to specification   specification heat shield-to-cylinder head screws—torque         60 n?m (44 lb-ft) heat shield-to-rocker arm cover screws—torque         10 n?m (7 lb-ft) 15   install turbocharger oil drain line (b) to engine   16   install exhaust manifold (a) with gaskets   (see remove, inspect&install exhaust manifold in group 080  ) continued on next page ctm104 (11jul02) 02-021-58 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=186 cylinder head&valves (four-valve head engines) 02 021 59 ouo1089,000022d –19–06jun02–4/4 rg12166 –un–03jul02 turbocharger a—oil inlet line b—oil drain line 17   if turbocharger was previously removed from exhaust manifold, install turbocharger to exhaust manifold   (see install turbocharger in group 080  ) 18   connect turbocharger oil inlet line (a)&oil drain line (b)   (see install turbocharger in group 080  ) 19   if engine oil was drained from crankcase, install new oil filter&fill engine with clean oil of correct grade and viscosity   (see section 01, group 002  ) 20   fill cooling system with clean coolant   (see section 01, group 002  ) 21   perform engine break-in   (see perform engine break-in in group 010  ) ctm104 (11jul02) 02-021-59 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=187 cylinder head&valves (four-valve head engines) 02 021 60 ctm104 (11jul02) 02-021-60 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=188 group 030 cylinder block, liners, pistons&rods 02 030 1 dpsg,ouo1004,165 –19–28sep99–1/1 connecting rods—general information rg9447 –un–27jul98 connecting rods rg9556 –un–02jul98 precision joint? connecting rod a—tongue-and-groove rod (early engines) b—precision joint? rod (later engines) c—precision joint? details earlier engines have the traditional tongue-and-groove between the connecting rod&cap (a)   later engines have the precision joint? rod&cap (b)   precision joint? rods&caps were introduced as follows: dubuque built 4  5 l engines (s  n   793938— ) 6  8 l engines (s  n   794055— ) saran built re500002 rod (s  n   554036— ) re500608 rod (s  n   553937— ) torreon built re500002 rod (s  n   039708— ) re500608 rod (s  n   036628— ) to create the precision joint?, the connecting rod is notched with a laser beam   then a precision mandrel in the rod bore is powered to separate the cap from the rod at the joints (c)   both types of rods provide a strong joint,&torque on cap screws is the same   removal&installation is similar, with differences noted   see inspect rod and cap&install piston&connecting rod assembly later in this group   precision joint is a trademark of deere & company ctm104 (11jul02) 02-030-1 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=189 cylinder block, liners, pistons&rods 02 030 2 rg,10,dt7421 –19–06jun02–1/5 remove pistons&connecting rods if engine is to be removed from the machine, see your machine technical manual   caution: do not drain engine coolant until it cools below operating temperature   then slowly loosen block drain valve to relieve any pressure   1   drain coolant&engine oil   note: if engine is to be completely disassembled, see engine disassembly sequence in group 010   2   remove cylinder head   (see remove cylinder head in group 020 for two valve head/remove cylinder head in group 21 for four valve head  ) 3   remove camshaft followers&keep in order for reassembly in same position   4   clean all foreign material from cylinder block top deck   rg,10,dt7421 –19–06jun02–2/5 rg3819 –un–07dec88 cylinder liner hold-down a—cap screws b—washers c—liners important: cap screws&washers must be tightened to the correct specification to achieve an accurate reading when checking liner standout (height above block), as detailed later in this group   5   use short cap screws (a)&3 mm (1/8 in  ) thick washers (b) to bolt down cylinder liners (c)   fasten each liner in two locations   tighten cap screws to 68 n?m (50 lb-ft)   note: do not rotate crankshaft with cylinder head removed unless liners are fastened down   ctm104 (11jul02) 02-030-2 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=190 continued on next page cylinder block, liners, pistons&rods 02 030 3 rg,10,dt7421 –19–06jun02–3/5 rg7455 –un–04nov97 using ridge reamer in cylinder bore a—ridge reamer note: always follow manufacturer’s directions provided with ridge reamer   6   remove carbon from liner bore with a scraper/ridge reamer (a)   use compressed air to remove loose material from cylinders   rg,10,dt7421 –19–06jun02–4/5 rg7457 –un–04nov97 bearing&rod cap removal rg7459 –un–23nov97 measure bearing clearance a—rod caps 7   remove oil pan, oil pump,&pick-up tube   (see remove, inspect&install oil pump pick-up tube assembly in group 060  ) (see remove engine oil pump in group 060  ) 8   mark rods, pistons,&caps to ensure correct assembly in same location   important: keep inserts with their respective caps for rod&main bearings   9   remove all rod caps (a) with bearings   10   measure rod bearing-to-journal oil clearance with plastigage? before removing piston&rod assembly   record measurements   (see inspect and measure connecting rod bearings, later in this group  ) note: use plastigage? as directed by the manufacturer   plastigage? will determine bearing-to-journal oil clearance, but will not indicate the condition of either surface   plastigage is a registered trademark of the dana corp   ctm104 (11jul02) 02-030-3 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=191 continued on next page cylinder block, liners, pistons&rods 02 030 4 rg,10,dt7421 –19–06jun02–5/5 rg7460 –un–23nov97 piston removal rg7934 –un–05jan98 piston removal important: hold onto piston to prevent piston from dropping   piston will drop once piston rings have cleared cylinder liner   if liners are to be reused, be extremely careful not to let connecting rod hit liner bore when removing piston and rod assembly   11   gently tap piston through top of cylinder block from the bottom   12   remove pistons&rods from engine   13   if piston rings are to be reused, measure piston ring end gap&compare to the following specifications: piston rings—4045df, tf150&6068df, tf150 engines — specification no   1 compression—end gap    0  33—0  58 mm (0  013—0  023 in  ) no   2 compression—end gap    1  24—1  49 mm (0  049—0  059 in  ) no   3 oil control—end gap    0  30—0  56 mm (0  011—0  022 in  ) piston rings—4045tf250&6068tf250 engines—specification no   1 compression—end gap    0  33—0  64 mm (0  013—0  025 in  ) no   2 compression—end gap    0  75—1  00 mm (0  030—0  039 in  ) no   3 oil control—end gap    0  33—0  64 mm (0  013—0  025 in  ) heavy duty piston rings—specification no   1 compression—end gap    0  33—0  59 mm (0  013—0  023 in  ) no   2 compression—end gap    0  89—1  14 mm (0  035—0  049 in  ) no   3 oil control—end gap    0  33—0  59 mm (0  013—0  023 in  ) 14   remove all main bearing caps with bearings   remove crankshaft from engine   ctm104 (11jul02) 02-030-4 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=192 cylinder block, liners, pistons&rods 02 030 5 rg,10,dt7420 –19–12nov97–1/3 remove cylinder liners rg6439 –un–03nov97 liner standout rg7461 –un–23nov97 marking cylinder liner location/position a—liner height important: cap screws&washers must be tight to achieve an accurate liner height reading   1   using d17526ci (or d17527ci) dial indicator and jdg451 (or kjd10123) height gauge, measure height (a) of each liner at 1, 5, 7,&11 o’clock positions as viewed from rear of engine   record all measurements   specification cylinder liner—height above block 0  030—0  100 mm (0  001—0  004 in  )          maximum permissible difference between readings within one cylinder/between adjacent cylinders       0  05 mm (0  002 in  ) 2   remove cap screws&washers securing liners to cylinder block   important: do not stamp top of piston   piston may be damaged   3   number cylinder liners&pistons   stamp front of liner to ensure correct assembly   do not stamp liner flange; stamp on fire dam only   continued on next page ctm104 (11jul02) 02-030-5 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=193 cylinder block, liners, pistons&rods 02 030 6 rg,10,dt7420 –19–12nov97–2/3 rg7462 –un–23nov97 pulling cylinder liners out of block rg1179 –un–05dec97 cylinder liner puller a—liners b—cylinder liner puller c—jaw important: keep matched pistons&liners together   liners must be reinstalled in same cylinder bore   4   pull liners out of cylinder block with d01062aa, d01073aa, kcd10001/jdg1145 cylinder liner puller   note: if the kcd10001 puller is used, secure puller with two cylinder head cap screws   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   continued on next page ctm104 (11jul02) 02-030-6 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=194 cylinder block, liners, pistons&rods 02 030 7 rg,10,dt7420 –19–12nov97–3/3 rg4745 –un–31oct97 cylinder liner in block cutaway a—o-rings b—cylinder block c—packing d—cylinder liner 5   remove cylinder liner o-rings (a) from grooves in cylinder block (b)   also remove packing (c) from cylinder liner (d)   rg,10,dt7419 –19–29nov99–1/1 complete disassembly of cylinder block (if required) if not previously removed, also remove: 1   crankshaft pulley   (see remove pulley or vibration damper&pulley in group 040  ) 2   if equipped with spring, plunger&seat type oil pressure regulating valve, remove valve assembly   (see remove&install oil pressure regulating valve in group 060  ) 3   timing gear cover, timing gears,&camshaft   (see remove camshaft in group 050  ) 4   camshaft bushing   (see remove&install camshaft bushing in group 050  ) 5   balancer shafts&balancer shaft bushings (if equipped)   (see remove&install balancer shaft bushings in group 050  ) 6   if equipped with cartridge type oil pressure regulating valve, remove valve   (see remove and install oil pressure regulating valve in group 060  ) 7   front plate   (see remove cylinder block front plate in group 050  ) 8   oil bypass valve   (see remove, inspect and install oil bypass valve in group 060  ) 9   main bearings   (see remove crankshaft main bearings in group 040  ) 10   crankshaft   (see remove crankshaft in group 040  ) 11   piston cooling orifices   (see remove, inspect and install piston cooling orifices in this group  ) 12   remove water gallery plugs   13   if necessary to “hot tank” the block, also remove screw-in type oil gallery plugs&the engine serial number plate   ctm104 (11jul02) 02-030-7 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=195 cylinder block, liners, pistons&rods 02 030 8 rg,10,dt7418 –19–12nov97–1/1 preliminary liner, piston&rod checks scuffed/scored pistons: ? insufficient lubrication   ? insufficient cooling   ? improper piston-to-liner clearance   ? coolant leakage in crankcase   ? misaligned/bent connecting rod   ? improperly installed piston   ? low oil level   ? improper operation   ? incorrect connecting rod bearing clearance   ? carbon build-up in ring groove   ? improper break-in   ? worn piston   ? contaminated oil   ? distorted cylinder liner   worn/broken compression rings: ? insufficient lubrication   ? insufficient cooling   ? improper ring installation   ? improper combustion   ? improper timing   ? abrasives in combustion chamber   clogged oil control ring: ? improper oil   ? excessive blow-by   ? contaminated oil   ? improper periodic service   ? low operating temperature   dull satin finish&fine vertical scratches on rings: dirt&abrasive in air intake system   stuck rings: ? improper oil classification   ? improper periodic service   ? poor operating conditions   ? coolant leakage in crankcase   ? excessive cylinder liner taper   cylinder liner wear&distortion: ? incorrectly installed compression rings   ? insufficient lubrication   ? uneven cooling around liner   ? improper piston-to-liner clearance   ? liner bore damage   warped cylinder block: insufficient cooling   broken connecting rod: ? inadequate piston-to-liner clearance   ? worn connecting rod bearing   ? distorted cylinder liner   ? piston pin failure   piston pin&snap ring failure: ? misaligned connecting rod   ? excessive crankshaft end play   ? incorrect snap rings   mottled, grayish/pitted compression rings: internal coolant leaks   ctm104 (11jul02) 02-030-8 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=196 cylinder block, liners, pistons&rods 02 030 9 rg,10,dt7417 –19–12nov97–1/2 disassemble piston&rod assembly rg7463 –un–23nov97 piston ring removal from piston important: do not reuse piston rings   1   remove piston rings using the jde135 (shown), jde85,/kjd10140 piston ring expander   rg,10,dt7417 –19–12nov97–2/2 rg7464 –un–23nov97 piston pin snap ring removal 2   remove&discard piston pin snap rings   3   separate piston&rod   keep these parts in place with their respective cylinder liner   ctm104 (11jul02) 02-030-9 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=197 cylinder block, liners, pistons&rods 02 030 10 rg,10,dt7424 –19–12nov97–1/1 clean pistons rg7465 –un–23nov97 cleaning piston ring grooves caution: always follow manufacturer’s instructions&safety steps exactly   1   clean piston ring grooves using a piston ring groove cleaning tool   important: when washing pistons, always use a stiff bristle brush—not a wire brush—to loosen carbon residue   do not bead blast ring groove areas   2   clean pistons by any of the following methods: ? immersion-solvent “d-part”   ? hydra-jet rinse gun   ? hot water with liquid detergent soap   if cleaning with hot water&liquid detergent, soak pistons in a 50 percent solution of liquid household detergent&hot water for 30 to 60 minutes   use a stiff bristle brush—not a wire brush—to loosen carbon residue   dry with compressed air   ctm104 (11jul02) 02-030-10 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=198 cylinder block, liners, pistons&rods 02 030 11 rg,10,dt7416 –19–12nov97–1/1 visually inspect pistons rg3326 –un–04dec97 piston (defects exaggerated) a—piston head b—ring lands c—piston pin bore carefully inspect pistons under magnification   check for: ? signs of fatigue ? fine cracks in the piston head (a) ? bent/broken ring lands (b) ? cracks in the skirt (c) at inner&outer ends of piston pin bore ? excessive piston skirt wear (original machining marks must be visible) if any imperfections are found, replace the piston&liner as a set   ctm104 (11jul02) 02-030-11 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=199 cylinder block, liners, pistons&rods 02 030 12 rg,10,dt7425 –19–12nov97–1/1 clean cylinder liners 1   use a stiff bristle brush to remove all debris, rust, and scale from od of liners, under liner flange,&in o-ring packing areas   make certain there are no nicks or burrs in areas where packings will seat   important: do not use gasoline, kerosene or commercial solvents to clean liners   solvents will not remove all abrasives from liner walls   2   thoroughly clean liner id with a 50 percent solution of hot water&liquid detergent   3   rinse thoroughly&wipe dry with a clean rag   4   swab out liner as often as necessary with clean sae 10w oil   clean liner until a clean, white rag shows no discoloration   ctm104 (11jul02) 02-030-12 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=200 cylinder block, liners, pistons&rods 02 030 13 rg,10,dt7415 –19–03jun02–1/2 visually inspect cylinder liners rg4643 –un–05dec97 cylinder liner inspection a—liner pitting b—liner erosion c—liner thickness d—packing step important: if liner pitting has occurred, check condition of coolant   note: when installing reusable liners, rotate 90° from original position   the liners should be deglazed and ring sets installed in pistons   1   inspect exterior length of liner for pitting (a)   check packing step for erosion (b)   if pitting/erosion is observed, measure depth of pits with a fine wire or needle   replace piston&liner if: ? depth of any pit is one-half/more of liner thickness (c)   ? depth of erosion is one-half/more of the packing step (d)   specification cylinder liner—thickness 6  23—6  89 mm (0  25—0  27 in  )        cylinder liner packing step— dimension 2  02—2  29 mm (0  08—0  09 in  )          continued on next page ctm104 (11jul02) 02-030-13 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=201 cylinder block, liners, pistons&rods 02 030 14 rg,10,dt7415 –19–03jun02–2/2 rg1188 –un–04dec97 a—flange area cylinder liner b—ring travel area 2   visually inspect liner id   replace piston&liner if: ? the crosshatch honing pattern is not visible immediately below the top ring turn-around area for turbocharged engines   ? the hone pattern is not visible all the way around the liner in over 75 percent of the ring travel area for naturally aspirated engines   ? liners are pitted/contain deep vertical scratches that can be detected by the fingernail   3   carefully examine liner for signs of fatigue, such as fine cracks in the flange area (a)&cracks in the ring travel area (b)   note: inspect block for cracks/erosion in the o-ring packing areas   (see inspect&clean cylinder block later in this group  ) ctm104 (11jul02) 02-030-14 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=202 cylinder block, liners, pistons&rods 02 030 15 rg,10,dt7414 –19–12nov97–1/2 check piston ring groove wear rg7467 –un–04nov97 piston ring groove wear gauge rg9059 –un–16mar98 piston ring grooves a—piston with good keystone ring groove b—piston with worn keystone ring groove c—ring groove wear gauge d—clearance (normal) e—no clearance (replace) pistons with tapered rods will use jde62 ring groove wear gauge&pistons with straight rods will use jdg957 ring groove wear gauge   1   use the appropriate ring groove wear gauge (c) to check wear of keystone ring groove (top groove)   check grooves at several locations around the circumference of piston   gauge shoulders should not contact ring land   clearance (d) between shoulders of tool&ring land indicate ring groove is good   if ring groove is worn, replace piston&liner as a matched set   if ring groove is good, proceed to next step   continued on next page ctm104 (11jul02) 02-030-15 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=203 cylinder block, liners, pistons&rods 02 030 16 rg,10,dt7414 –19–12nov97–2/2 rg7468 –un–23nov97 piston ring groove wear 2   check second (compression) ring groove using new piston ring&a feeler gauge   measure clearance at several points   compare measurements with specifications   3   check third (oil control) ring groove using proper new piston ring&a feeler gauge   measure clearance at several points   compare measurements with specifications   specification piston ring-to-groove clearance—new piston ring (second compression ring groove)—maximum clearance     0  20 mm (0  008 in  ) piston ring-to-groove clearance—new piston ring (third oil control ring groove, standard ring)—maximum clearance        0  82 mm (0  032 in  ) piston ring-to-groove clearance—new piston ring (third oil control ring groove, heavy duty ring)—maximum clearance        0  15 mm (0  006 in  ) 4   replace piston&liner (as a set) if clearance exceeds specification   rg,10,dt7413 –19–12nov97–1/1 measure piston pin bore rg7402 –un–23nov97 piston pin bore measure piston pin bore   if bore is not within specification, replace piston&liner set   specification piston pin bore (small pin)—id 34  935—34  945 mm (1  3754—1  3758 in  )        piston pin bore (large pin)—id 41  285—41  295 mm (1  6254—1  6258 in  )        ctm104 (11jul02) 02-030-16 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=204 cylinder block, liners, pistons&rods 02 030 17 rg,10,dt7412 –19–12nov97–1/1 measure piston skirt rg7403 –un–03nov97 piston skirt wear a—piston skirt b—measurement area 1   measure piston skirt (a) 90° to piston pin bore&28 mm (1  1 in  ) from bottom of piston (b)   record measurement   specification piston skirt (measurement taken at bottom of skirt 28 mm [1  1 in  ] from bottom of piston)—diameter 106  38—106  40 mm (4  188—4  189 in  )      2   measure cylinder liner as directed later in this group and compare with piston measurement   dpsg,ouo1004,212 –19–04jun02–1/1 measure piston height measure piston height from center of piston pin bore-to-top of piston   piston (two valve head engines)—specification piston—height (measured from center of pin bore to top of piston) 71  64—71  70 mm (2  820—2  823 in  )          piston (four valve head engines)—specification piston—height (measured from center of pin bore to top of piston) 71  60—71  65 mm (2  819—2  820 in  )          ctm104 (11jul02) 02-030-17 powertech? 4  5 l & 6  8 l diesel engines 071102 pn=205 cylinder block, liners, pistons&rods 02 030 18 dpsg,ouo1004,1169 –19–23nov99–1/2 determine piston-to-liner clearance rg7403 –un–03nov97 measuring piston skirt a—skirt od b—bottom of piston dimension 1   measure skirt od (a) at right angles to piston pin bore, 28 mm (1  1 in  ) from the bottom of the piston (b)   2   record measurement&compare