John Deere Manual Tecnico PDF

3029
4039, 4045
6059, 6068
Engines (Saran)
( -499999CD)
r
COMPONENT
TECHNICAL
MANUAL
John Deere Usine de Saran

CTM3274 (01JUL99)
European Version
Printed in Germany
ANGLAIS
3029, 4039, 4045, 6059, 6068
Engines (Saran) CTM3274 (01JUL99)
( -499999CD)
Introduction
FOREWORD
This manual is written for an experienced technician. necessary instructions to repair the component.
Essential tools required in performing certain service Operation and tests sections help you identify the
work are identified in this manual and are majority of routine failures quickly.
recommended for use.
Information is organized in groups for the various
Live with safety: Read the safety messages in the components requiring service instruction. At the
introduction of this manual and the cautions beginning of each group are summary listings of all
presented throughout the text of the manual. applicable essential tools, service equipment and
N
tools, other materials needed to do the job, service
This is the safety-alert symbol. When you see parts kits, specifications, wear tolerances, and torque
this symbol on the machine or in this manual, values.
be alert to the potential for personal injury.
Component Technical Manuals are concise service
Use this component technical manual in conjunction guides for specific components. Component technical
with the machine technical manual. An application manuals are written as stand-alone manuals covering
listing in the introduction identifies multiple machine applications.
product-model/component type-model relationship.
See the machine technical manual for information on Fundamental service information is available from
component removal and installation, and gaining other sources covering basic theory of operation,
access to the components. fundamentals of troubleshooting, general
maintenance, and basic type of failures and their
This manual is divided in two parts: repair and causes.
operation and tests. Repair sections contain
DX,CTMIFC -19-22MAY92
CTM3274 (01JUL99) Saran Liter Engines

060799
PN=3
Introduction
ENGINE IDENTIFICATION VIEWS
-UN-19MAY98
-UN-23FEB99
CD30699
CD30518
3029D 3029T
-UN-23FEB99
-UN-23FEB99
CD30701
CD30702
4039D 4039T
CD,3274,G00,27 -19-04JAN99

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Introduction
ENGINE IDENTIFICATION VIEWS (CONTD)
-UN-23FEB99
-UN-23FEB99
CD30703
CD30704
6068D 6068H
CD,3274,G00,28 -19-04JAN99

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Engine application chart
This Component Technical Manual contains service NOTE: Information on how to remove and reinstall
information on the 3029, 4039, 4045, 6059 and 6068 the engine in the vehicle is contained in the
engines produced by JOHN DEERE Saran (FRANCE) relevant Technical Manual.
for the applications listed in the application chart.
3000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER
3100 . . . . . . . . . . . . . . . . . . . . . . . . CD3029DRT65 (189846 - )

3110 . . . . . . . . . . . . . . . . . . . . . . . . CD3029DRT65
3200/3200X . . . . . . . . . . . . . . . . . . . . CD4039DRT35 (181345 - )
3210/3210X . . . . . . . . . . . . . . . . . . . . CD4039DRT35
3300/3300X . . . . . . . . . . . . . . . . . . . . CD4045DRT35 (182145 - )
3310/3310X . . . . . . . . . . . . . . . . . . . . CD4045DRT35
3400/3400X . . . . . . . . . . . . . . . . . . . . CD4039TRT35 (181775 - )
3410/3410X . . . . . . . . . . . . . . . . . . . . CD4039TRT35
4000-SERIES TELESCOPIC ENGINE MODEL SERIAL NUMBER

HANDLERS
4400 . . . . . . . . . . . . . . . . . . . . . . . . CD4039TF005 (237697 - )

4500 . . . . . . . . . . . . . . . . . . . . . . . . CD4039TF005

(Agritalia-built)
5300/5300N . . . . . . . . . . . . . . . . . . . . CD3029DAT01 (315424 - )

5400/5400N . . . . . . . . . . . . . . . . . . . . CD3029TAT02 (289398 - )
5500/5500N . . . . . . . . . . . . . . . . . . . . CD4039TAT01 (346168 - )

(Augusta-built)
5400N . . . . . . . . . . . . . . . . . . . . . . . CD3029TLV01
5500N . . . . . . . . . . . . . . . . . . . . . . . CD4039TLV01 (201353 - )

(For India)
5300 . . . . . . . . . . . . . . . . . . . . . . . . CD3029DPY01 (383283 - )
(Continued on next page) CD,3274,G00,24 -19-04JAN99

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ENGINE APPLICATION CHART (CONT)

6100 (Direct fan drive) . . . . . . . . . . . . CD4045DL001 (101582 - )

6100 (Viscous fan drive) . . . . . . . . . . . CD4045DL002 (101582 - )
6200 (Direct fan drive) . . . . . . . . . . . . CD4039TL001 (101625 - )

6200 (Viscous fan drive) . . . . . . . . . . . CD4039TL004 (101625 - )


6506 (Viscous fan drive) . . . . . . . . . . . CD6068DL001 (214852 - )
WATERLOO TRACTORS ENGINE MODEL SERIAL NUMBER
7600 . . . . . . . . . . . . . . . . . . . . . . . . T06068TRW01
ZWEIBRCKEN COMBINES ENGINE MODEL SERIAL NUMBER
2054 . . . . . . . . . . . . . . . . . . . . . . . . 6068HZ001 (116452 - )

2254 . . . . . . . . . . . . . . . . . . . . . . . . 6068HZ001
ENGINES FOR CHINESE COMBINES SERIAL NUMBER
CD6059TYC01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (367019 - )
CD6059TYC02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (363170 - )
ENGINES FOR GOLDONI TRACTORS SERIAL NUMBER
CD3029DFG21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (287123 - )
CD3029DFG22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (287325 - )
CD3029TFG21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . (287526 - )

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SARAN OEM ENGINES SERIAL NUMBER SARAN OEM ENGINES SERIAL NUMBER
CD3029DF CD3029TF
CD3029DF001 CD3029TF001
CD3029DF005 (162670 - ) CD3029TF002 (170797 - )
CD3029DF031 CD3029TF031
CD3029DF032 CD3029TF032 (176015 - )
CD3029DF033 (177875 - ) CD3029TF033 (177880 - )
CD3029DF034 CD3029TF120
CD3029DF120 CD3029TF121
CD3029DF121 CD3029TF123 (354029 - )
CD3029DF122 (263024 - ) CD3029TF160
CD3029DF123 (312932 - ) CD3029TF161 (288419 - )
CD3029DF124 (340207 - ) CD3029TF162
CD3029DF128 CD3029TF163 (342829 - )
CD3029DF160
CD3029DF161 (288417 - )
CD3029DF162
CD3029DF163
CD3029DF164
CD3029DF165
CD4039DF CD4039TF
CD4039DF001 CD4039TF001
CD4039DF002 CD4039TF002
CD4039DF004 (152613 - ) CD4039TF003 (169516 - )
CD4039DF005 (165009 - ) CD4039TF004 (152616 - )
CD4039DF006 (340212 - ) CD4039TF005
CD4039DF007 (378895 - ) CD4039TF006 (339780 - )
CD4039DF008 CD4039TF007 (379066 - )
CD4039DF031 CD4039TF008
CD4039DF032 CD4039TF031
CD4039TF032 (166826 - )
CD4045DF001 CD4045TF001
CD4045DF031 CD4045TF002 (170081 - )
CD4045TF003 (342250 - )
CD4045TF008
CD4045TF031

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SARAN OEM ENGINES SERIAL NUMBER SARAN OEM ENGINES SERIAL NUMBER
CD6059DF CD6059TF
CD6059DF001 CD6059TF001
CD6059DF002 CD6059TF002 (158390 - )
CD6059DF003 CD6059TF003 (158394 - )
CD6059TF004
CD6059TF005 (166159 - )
CD6059TF006 (166960 - )
CD6059TF008 (341217 - )
CD6068DF001 CD6068TF001
CD6068TF002 (187378 - )
CD6068TF003
CD6068TF004 (344260 - )
CD6068TF008
CD6068TF009
CD,3274,G00,30 -19-04JAN99

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Group 00
Safety
HANDLE FLUIDS SAFELYAVOID FIRES
When you work around fuel, do not smoke or work near 00

heaters or other fire hazards.
1
-UN-23AUG88
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
TS227
spontaneously.
DX,FLAME -19-29SEP98
PREVENT BATTERY EXPLOSIONS
Keep sparks, lighted matches, and open flame away

from the top of battery. Battery gas can explode.
-UN-23AUG88
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm

battery to 16C (60F).
TS204
DX,SPARKS -19-03MAR93
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.

-UN-23AUG88
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
TS291
DX,FIRE2 -19-03MAR93
CTM3274 (01JUL99) 00-1 Saran Liter Engines

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PN=10
Safety
PREVENT ACID BURNS

00 Sulfuric acid in battery electrolyte is poisonous. It is
2 strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.
Avoid the hazard by:

1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:

1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 1530 minutes. Get
medical attention immediately.
If acid is swallowed:
-UN-23AUG88
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not
exceed 2 L (2 quarts).
3. Get medical attention immediately.
TS203
DX,POISON -19-21APR93

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PN=11
Safety
AVOID HIGH-PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the skin 00

causing serious injury.
3
-UN-23AUG88
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect
X9811
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any

fluid injected into the skin must be surgically removed
within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is
available from Deere & Company Medical Department in
Moline, Illinois, U.S.A.
DX,FLUID -19-03MAR93
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment

appropriate to the job.
-UN-23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR -19-10SEP90

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PN=12
Safety
SERVICE MACHINES SAFELY

00 Tie long hair behind your head. Do not wear a necktie,
4 scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
-UN-23AUG88
caught, severe injury could result.
Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.
TS228
DX,LOOSE -19-04JUN90
WORK IN VENTILATED AREA
Engine exhaust fumes can cause sickness or death. If it

is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an
-UN-23AUG88
exhaust pipe extension.
If you do not have an exhaust pipe extension, open the

doors and get outside air into the area.
TS220
DX,AIR -19-04JUN90
WORK IN CLEAN AREA
Before starting a job:

Clean work area and machine.
Make sure you have all necessary tools to do your job.
-UN-18OCT88
Have the right parts on hand.
Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN -19-04JUN90

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PN=13
Safety
REMOVE PAINT BEFORE WELDING OR

HEATING
00
Avoid potentially toxic fumes and dust.
5
-UN-23AUG88
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area. Dispose

of paint and solvent properly.
TS220
Remove paint before welding or heating:
If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.
If you use solvent or paint stripper, remove stripper

with soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
DX,PAINT -19-03MAR93
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
-UN-15MAY90
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH -19-03MAR93
ILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
-UN-23AUG88
cage. The hot filament of an accidentally broken bulb

can ignite spilled fuel or oil.
TS223
DX,LIGHT -19-04JUN90

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PN=14
Safety
USE PROPER LIFTING EQUIPMENT

00 Lifting heavy components incorrectly can cause severe
6 injury or machine damage.
-UN-23AUG88
Follow recommended procedure for removal and
installation of components in the manual.
TS226
DX,LIFT -19-04JUN90
PRACTICE SAFE MAINTENANCE
Understand service procedure before doing work. Keep

area clean and dry.
Never lubricate, service, or adjust machine while it is

moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow
machine to cool.
Securely support any machine elements that must be

raised for service work.
Keep all parts in good condition and properly installed.

Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground
-UN-23AUG88
cable (-) before making adjustments on electrical
systems or welding on machine.
On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or
TS218
welding on machine.
DX,SERV -19-04FEB99

060799
PN=15
Safety
USE PROPER TOOLS
Use tools appropriate to the work. Makeshift tools and 00

procedures can create safety hazards.
7
-UN-08NOV89
Use power tools only to loosen threaded parts and
fasteners.
For loosening and tightening hardware, use the correct

size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
Use only service parts meeting John Deere

specifications.
DX,REPAIR -19-04JUN90
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil,
-UN-26NOV90
fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or
into any water source.
Air conditioning refrigerants escaping into the air can

damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN -19-03MAR93

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PN=16
Safety
LIVE WITH SAFETY

00 Before returning machine to customer, make sure
8 machine is functioning properly, especially the safety
systems. Install all guards and shields.
-19-07OCT88
TS231
DX,LIVE -19-15APR98

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PN=17
Group 01
General information
ENGINE IDENTIFICATION
The engine can be identified from the serial plate (A)

located on the right-hand side of the engine.
Some applications also have an additional serial plate
-UN-07MAR95
located on top of the flywheel housing. Refer to the 01
engine type to identify repair information in the 1
Component Technical Manual.
CD30223
CD,3274,G01,1 -19-24FEB92
ENGINE PLATE INFORMATION (EARLIER

DESIGN)
Three types of plates are used on engines and give the

following information:
-UN-07MAR95
First line (all plates)
CD . . . . . . . . . . . . . Manufacturing factory
(CD = Saran, T0 = Dubuque)
4045 . . . . . . . . . . Engine model designation
CD30230
4 = Number of cylinders
045 = Total displacement
(045 = 4.5 liters)
D . . . . . . . . . Aspiration code
D = Naturally Aspirated
H = air-to-air aftercooled
T = Turbocharged
000000 . . . . Sequential serial number
-UN-07MAR95
Second line (all plates)
4045D . . . . . . . . . . . See above

L . . . . . . . . . . User code
F = OEM application
L = Mannheim
CD30224
RW = Waterloo Tractor
Z = Zweibrcken
001 . . . . . . . . Application number
Third line (OEM plates only)
First field . . . . . . . . . Not used

Second field . . . . . . . Absorption coefficient of smoke
emissions (shown on certain OEM
-UN-07MAR95
engines)
APlate used on John Deere equipment

BPlate used on OEM engines
CD30225
CGeneric plate used on certain OEM engines
CD,3274,G01,2 -19-04JAN99

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PN=18
General information/Repower engine plate
ENGINE PLATE INFORMATION (LATER

DESIGN)
A new engine plate design as shown, is now affixed to

the engine.
-UN-22FEB99
01
2 Information on this new plate is the same as previously.
CD30705
CD,3274,G01,10 -19-04JAN99
REPOWER ENGINE PLATE
A specific plate is fixed on repower engines for proper

identification. This plate gives the following information:
First line
First field . . . . . . . . . . . Engine type
Second field . . . . . . . . . Sequential serial number
Second line
DD . . . . . . . Repower engine part number
-UN-22FEB99
The third line contains a bar code information for factory
use.
CD30706
NOTE: The serial number plate from original engine
must be fixed on the repower plate as shown.
CD,3274,G01,6 -19-04JAN99

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PN=19
General information/Engine references
OEM ENGINE OPTION CODE LABEL
An option code label is secured to the top of the valve

cover and identifies the factory installed options on each
OEM engine to ensure correct parts acquisition.
-UN-10MAY95
01
Always provide option code information and engine base 3
code when ordering repair parts. A listing of option
codes is given in Parts Catalogs and Operators Manual.
CD30433
NOTE: Before hot tank cleaning, ensure that option
codes are recorded elsewhere.
CD,3274,G01,3 -19-01FEB94
ENGINE REFERENCES
Direction of engine rotation:

Clockwise rotation when viewed from water pump end.
Engine front reference:

The water pump end is the front of the engine. Cylinder
number 1 is at the front of engine.
Engine side references:

Right-hand and left-hand sides are determined by
facing the flywheel end (rear) of the engine. Right-hand
side is the camshaft side while left-hand side is the fuel
-UN-04MAY98
injection pump side.
CD30525
CD,CTM125,005 -19-01DEC97

060799
PN=20
General information/Basic engine specifications (3029 - 4039 & 6059)
BASIC ENGINE SPECIFICATIONS (3029 - 4039 & 6059)
UNIT of
Measure 3029D 3029T 4039D 4039T 6059D 6059T
01 GENERAL
4
Number of Cylinders --- 3 3 4 4 6 6
Bore mm 106.5 106.5 106.5 106.5 106.5 106.5

(in.) (4.19) (4.19) (4.19) (4.19) (4.19) (4.19)
Stroke mm 110 110 110 110 110 110

(in.) (4.33) (4.33) (4.33) (4.33) (4.33) (4.33)
Displacement L 2.9 2.9 3.9 3.9 5.9 5.9

(in.3) (179) (179) (239) (239) (359) (359)
Compression Ratio --- 17.8:1 17.8:1 17.8:1 17.8:1 17.8:1 17.8:1
Firing Order --- 1-2-3 1-2-3 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4
Injection System --- Direct Direct Direct Direct Direct Direct
Aspiration --- Natural Turbocharged Natural Turbocharged Natural Turbocharged
Rated Speed* rpm 2500 2500 2500 2500 2500 2500
Power** kW 43 59 60 82 89 123
@ Rated Speed (hp) (58) (79) (80) (110) (120) (165)
Power** kW 35 49 76 123
@ 1800 rpm (hp) (47) (66) (102) (165)
Power** kW 31 40 63 104
@ 1500 rpm (hp) (42) (54) (85) (140)
Weight (dry) kg 323 330 422 458 518 525

(lbs) (712) (728) (931) (1010) (1143) (1158)
*Vary by application; refer to the machine technical or operators

manual for specific engine speeds and powers.
**Without fan. CD,3274,G01,8 -19-01FEB94

060799
PN=21
General information/Basic engine specifications (4045 & 6068)
BASIC ENGINE SPECIFICATIONS (4045 & 6068)
UNIT of
Measure 4045D 4045T 6068D 6068T 6068H
GENERAL 01
5
Number of Cylinders --- 4 4 6 6 6
Bore mm 106.5 106.5 106.5 106.5 106.5

(in.) (4.19) (4.19) (4.19) (4.19) (4.19)
Stroke mm 127 127 127 127 127

(in.) (5.00) (5.00) (5.00) (5.00) (5.00)
Displacement L 4.5 4.5 6.8 6.8 6.8

(cu.in.) (276) (276) (414) (414) (414)
Compression Ratio --- 17.8:1 17.2:1 17.8:1 17.2:1 17.2:1
Firing Order --- 1-3-4-2 1-3-4-2 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Injection System --- Direct Direct Direct Direct Direct
Aspiration --- Natural Turbo- Natural Turbo- Air-to-air

charged charged aftercooler
Rated Speed* rpm 2400 2400 2400 2400 2200
Power** kW 63 86 97 130 140

at Rated Speed (hp) (85) (115) (130) (175) (190)
Power** kW 84
at 1800 rpm (hp) (113)
Power** kW 70 116
at 1500 rpm (hp) (95) (155)
Weight (dry) kg 474 487 588 602

(lbs) (1046) (1074) (1297) (1328)
*Vary by application; refer to the machine technical or operators

manual for specific engine speeds and powers.
**Without fan. CD,3274,G01,9 -19-04JAN99

060799
PN=22
General information/Fuel specifications
DIESEL FUEL
Consult your local fuel distributor for properties of the Fuel lubricity should pass a minimum of 3100
diesel fuel available in your area. gram load level as measured by the BOCLE scuffing
test.
01 In general, diesel fuels are blended to satisfy the low
6 temperature requirements of the geographical area in Sulfur content:
which they are marketed. Sulfur content should not exceed 0.5% Sulfur
content less than 0.05% is preferred.
Diesel fuels specified to EN 590 or ASTM D975 are If diesel fuel with sulfur content greater than 0.5%
recommended. sulfur content is used, reduce the service interval for
engine oil and filter by 50%
In all cases, the fuel shall meet the following DO NOT use diesel fuel with sulfur content greater
properties: than 1.0%
Cetane number of 40 minimum. Bio-diesel fuels may be used ONLY if the fuel
Cetane number greater than 50 is preferred, properties meet DIN 51606 or equivalent specification.
especially for temperatures below -20C (-4F) or
elevations above 1500 m (5,000 ft). DO NOT mix used engine oil or any other type of
lubricant with diesel fuel.
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature.
DX,FUEL1 -19-12FEB99

060799
PN=23
General information/Oil specifications
DIESEL ENGINE OIL
Use oil viscosity based on the expected air temperature

range during the period between oil changes.
The following oil is preferred. 01

7
John Deere PLUS-50
The following oil is also recommended:
John Deere TORQ-GARD SUPREME
-UN-10OCT97
Other oils may be used if they meet one or more of the
following:
API Service Classification CG-4

API Service Classification CF-4
TS1661
ACEA Specification E3
Multi-viscosity diesel engine oils are preferred.
If diesel fuel with sulfur content greater than 0.5% is

used, reduce the service interval by 50%.
Extended service intervals may apply when John Deere

preferred engine oils are used. Consult your John Deere
dealer for more information.
DX,ENOIL -19-10OCT97

060799
PN=24
General information/Coolant specifications
DIESEL ENGINE COOLANT
The engine cooling system is filled to provide water is recommended for mixing with ethylene glycol
year-round protection against corrosion and cylinder base engine coolant concentrate.
liner pitting, and winter freeze protection to -37C
01 (-34F). IMPORTANT: Do not use cooling system sealing
8 additives or antifreeze that contains
John Deere COOL-GARD is preferred for service. sealing additives.
If John Deere COOL-GARD is not available, use a Coolant drain intervals

low silicate ethylene glycol base coolant concentrate
in a 50% mixture of concentrate with quality water. Drain the factory fill engine coolant, flush the cooling
system, and refill with new coolant after the first 3
The coolant concentrate shall be of a quality that years or 3000 hours of operation. Subsequent drain
provides cavitation protection to cast iron and intervals are determined by the coolant used for
aluminum parts in the cooling system. John Deere service. At each interval, drain the coolant, flush the
COOL-GARD meets this requirement. cooling system, and refill with new coolant.
A 50% mixture of ethylene glycol engine coolant in When John Deere COOL-GARD is used, the coolant
water provides freeze protection to -37C (-34F). If drain interval is 3 years or 3000 hours operation.
protection at lower temperatures is required, consult
your John Deere dealer for recommendations. If COOL-GARD is not used, the drain interval is
reduced to 2 years or 2000 hours of operation.
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
DX,COOL8 -19-12FEB99

060799
PN=25
General information/Metric cap screw torque values
METRIC BOLT AND CAP SCREW TORQUE VALUES
01
9
-19-04MAR91
TS1163
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Size Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya
Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5

M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190
M16 100 73 125 92 190 140 240 175 275 200 350 255 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
DO NOT use these values if a different torque value Make sure fasteners threads are clean and that you
or tightening procedure is given for a specific properly start thread engagement. This will prevent
application. Torque values listed are for general use them from failing when tightening.
only. Check tightness of fasteners periodically.
Tighten plastic insert or crimped steel-type lock nuts
Shear bolts are designed to fail under predetermined to approximately 50 percent of the dry torque shown
loads. Always replace shear bolts with identical in the chart, applied to the nut, not to the bolt head.
property class. Tighten toothed or serrated-type lock nuts to the full
torque value.
Fasteners should be replaced with the same or
higher property class. If higher property class
fasteners are used, these should only be tightened to
the strength of the original.
a Lubricated means coated with a lubricant such as engine oil, or
fasteners with phosphate and oil coatings. Dry means plain or zinc
plated without any lubrication. DX,TORQ2 -19-20JUL94

060799
PN=26
General information/Inch cap screw torque values
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES
01
10
-19-04MAR91
TS1162
Grade 1 Grade 2b Grade 5, 5.1, or 5.2 Grade 8 or 8.2
Size Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya
Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 240 175 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 400 300 510 375 400 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
DO NOT use these values if a different torque value Fasteners should be replaced with the same or
or tightening procedure is given for a specific higher grade. If higher grade fasteners are used,
application. Torque values listed are for general use these should only be tightened to the strength of the
only. Check tightness of fasteners periodically. original.
Shear bolts are designed to fail under predetermined Make sure fasteners threads are clean and that you
loads. Always replace shear bolts with identical grade. properly start thread engagement. This will prevent
them from failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts

to approximately 50 percent of the dry torque shown
in the chart, applied to the nut, not to the bolt head.
a Lubricated means coated with a lubricant such as engine oil, or Tighten toothed or serrated-type lock nuts to the full
fasteners with phosphate and oil coatings. Dry means plain or zinc torque value.
plated without any lubrication.
b Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm
(6-in.) long. Grade 1 applies for hex cap screws over 152 mm (6-in.)
long, and for all other types of bolts and screws of any length. DX,TORQ1 -19-20JUL94

060799
PN=27
Group 02
Engine mounting
ENGINE REPAIR STAND
To facilitate engine repair, the D01003AA repair stand

can be used in conjunction with D05225ST adapter for
300 series engines.
-UN-22MAY95
02
1
R26420N
D01003AA repair stand
-UN-22MAY95
D05225ST
D05225ST adapter
CD,3274,G02,1 -19-24FEB92

060799
PN=28
Engine mounting/Engine lifting procedure
SAFETY PRECAUTIONS
This repair stand should be used only by qualified To avoid structural damage or personal injury, do not
service technicians familiar with this equipment. exceed the maximum weight capacity. When engine
weight is more than 450 kg (992 lb), it is
To maintain shear strength specifications, alloy steel recommended to use additional support. Approximate
SAE Grade 8 or higher cap screws must be used to engine weights are listed below:
mount adapters or engine.
3 cyl. engines = 330 kg (728 lb)
02 For full thread engagement, be certain that tapped 4 cyl. engines = 450 kg (992 lb)
2 holes in adapters and engine blocks are clean and 6 cyl. engines = 580 kg (1279 lb)
not damaged. A thread length engagement equal to
1-1/2 screw diameters minimum is required to To prevent possible personal injury due to engine
maintain strength requirements. slippage, recheck to make sure engine is solidly
mounted before releasing support from engine lifting
device.
Never permit any part of the body to be positioned

under a load being lifted or suspended. Accidental
slippage may result in personal injury.
CD,3274,G02,2 -19-24FEB92
ENGINE LIFTING PROCEDURE
Attach JDG23 engine lifting sling (A), or other suitable

sling, to JD-244 engine lifting eyes (B) and hoist the
engine using a lifting device.
-UN-18MAY90
NOTE: Use of an engine lifting sling (as shown) is the
preferred method for lifting engines. However, if a
sling is not on hand, engine can be lifted by
chain(s) attached to lifting eyes and lifting device.
RG4738
IMPORTANT: If a turbocharged engine with
low-profile design is to be lifted,
remove the turbocharger before
attaching engine to repair stand.
CD,3274,G02,3 -19-01FEB94

060799
PN=29
Engine mounting/Disconnect turbocharger oil line
CLEAN ENGINE
1. Cap or plug all openings on engine. If electrical
components (starting motor, alternator, etc...) are not
removed prior to cleaning, cover with plastic and tape
securely to prevent moisture from entering.
2. Steam-clean engine thoroughly.
IMPORTANT: Never steam-clean or pour cold water
on an injection pump while it is still 02
warm. To do so may cause seizure of 3
pump parts.
CD,3274,G02,4 -19-24FEB92
DISCONNECT TURBOCHARGER OIL INLET

LINE
Drain all engine oil and coolant, if not previously done.
-UN-02APR90
IMPORTANT: When servicing turbocharged engines
on a rollover stand, disconnect turbo
oil inlet line from turbocharger (A) or
oil filter housing before rolling engine
over. Failure to do so may cause a
RG5642
hydraulic lock upon starting engine.
Hydraulic lock may cause severe
engine damage.
Hydraulic lock occurs when trapped oil

in the oil filter housing drains through
the turbocharger, the exhaust and
intake manifolds, and then into the
cylinder head. After starting the engine,
the trapped oil in the manifold and
head is released into the cylinders
filling them with oil causing hydraulic
lock and severe engine damage.
CD,3274,G02,5 -19-24FEB92

060799
PN=30
Engine mounting/Disconnect turbocharger oil line
02
4

060799
PN=31
Group 03
Engine rebuild guide
ENGINE DISASSEMBLY SEQUENCE
The following sequence is suggested when complete 7. Remove dipstick, oil filter, and engine oil cooler.
disassembly for overhaul is required. Refer to the Discard standard-flow oil cooler if oil contained metal
appropriate repair group when removing individual particles (see Group 25).
engine components.
8. Remove oil pressure regulating valve assembly
1. Drain all coolant and engine oil. Check engine oil (see Group 25).
for metal contaminates (see Groups 25 and 30).
9. Remove fuel filter, fuel transfer pump, and fuel
2. Remove fan belts, fan, and alternator (see lines (see Group 40).
Group 30).
10. Remove injection lines, injection pump, and
3. Remove turbocharger (if equipped) and exhaust injection nozzles (see Group 40). 03
manifold (see Group 35).
1
11. Remove starting motor.
4. Remove rocker arm cover with vent tube. On
engines having an Option Code label on rocker arm 12. Remove rocker arm assembly and push rods.
cover, be careful not to damage label (see Keep rods in sequence (see Group 05). Check for
Group 05). bent push rods and condition of wear pad contact
surfaces on rockers.
5. Remove water manifold with thermostats (see
Group 30). 13. Remove cylinder head. Check piston protrusion.
Verify piston height selection (see Groups 05 and
6. Remove oil cooler piping and water pump (see 10).
Groups 25 and 30).
14. Remove cam followers. Keep in same sequence
as removed (see Group 20).
(Continued on next page)
CD,3274,G03,1 -19-24FEB92

060799
PN=32
Engine rebuild guide/Engine disassembly sequence
ENGINE DISASSEMBLY SEQUENCE - CONTINUED
15. Remove oil pan (see Group 25). 25. Remove main bearings and crankshaft. Perform
wear checks with PLASTIGAGE (see Group 15).
16. Remove flywheel and flywheel housing (see
Group 15). 26. Remove cylinder liners and mark each one with
cylinder number from which removed (see Group 10).
17. Remove crankshaft pulley (see Group 15).
27. Remove piston cooling orifices (see Groups 10
18. Remove timing gear cover (see Group 20). and 15).
19. Remove oil pump drive gear, outlet tube (and its 28. Remove balancer shaft and camshaft bushings (if
O-ring in block) and pump body (see Group 25). equipped), see Group 20.
03
2 20. Remove oil slinger, timing gears and camshaft. 29. Remove cylinder block plugs and serial number
Perform wear checks (see Group 20). plate (as required) when block is to be put in a hot
tank (see Group 10).
21. Remove balancer shafts (4-cylinder only, if
equipped), see Group 20. 30. Clean out liner bores (upper and lower areas)
with nylon brush (see Group 10).
22. Remove engine front plate (see Group 20).
31. Measure cylinder block (see Groups 10, 15, and
23. Remove lube oil system by-pass valve (see 20).
Group 25).
24. Stamp cylinder number on rod (if required).

Remove pistons and rods. Perform wear checks with
PLASTIGAGE. On 4 and 6-cylinder engines, remove
two at a time (see Group 10).
CD,3274,G03,1A -19-01FEB94

060799
PN=33
Engine rebuild guide/Sealant application guidelines
SEALANT APPLICATION GUIDELINES
Listed below are sealants which have been tested your John Deere engine to assure quality
and are used by the John Deere factory to control performance.
leakage and assure hardware retention. Use the
following recommended sealants when re-assembling
JOHN DEERE CONTENT PRODUCT EXAMPLE OF USE

Part Number
TY9370 6 ml tube LOCTITE 242 Cap screws:

Thread Lock & Sealer Crankshaft pulley
Medium Strengh (blue) Flywheel
03
TY9371 6 ml tube LOCTITE 271 Studs: 3
Thread Lock & Sealer Water pump-to-cylinder block
High Strenght (clear) Injection pump-to-front plate
Exhaust manifold-to-turbocharger
Oil filter nipple
T43514 50 ml tube LOCTITE 277 Steel cap plugs:

Plastic Gasket Cylinder block, cylinder head
High Strength (red) Water pump
DD15664 or 25 ml tube LOCTITE 515 Flywheel housing-to-cylinder block

TY6304 50 ml bottle Flexible Sealant Front plate/Timing gear-to-oil pan
Gen. purpose (purple)
TY9374 or 6 ml tube LOCTITE 592 Pipe plugs:

TY9375 50 ml bottle Pipe Sealant Cylinder block, water pump
with Teflon (white) Dipstick tube threads
Temperature sending unit
TY15969 50 ml bottle LOCTITE 609 Wear ring sleeve-to-crankshaft

Retaining Compound
(green)
CD,CTM125,011 -19-01DEC97

060799
PN=34
Engine rebuild guide/Engine assembly sequence
ENGINE ASSEMBLY SEQUENCE
The following assembly sequence is suggested when 6. Install pistons and rods. Check for piston protusion
engine has been completely disassembled. Be sure to (see Group 10).
check run-out specifications, clearance tolerances,
torques, etc. as engine is assembled. Refer to the 7. Install lube oil system by-pass valve.
appropriate repair group when assembling engine
components. 8. Install front plate (see Group 20).
1. Install all plugs (and serial number plates) in 9. Install balancer shafts. Check end play (see
cylinder block that were removed to service block Group 20).
(see Groups 10 and 15).
10. Install oil outlet tube, O-ring in block, and oil
03 2. Install clean piston cooling orifices and new pump (see Group 25).
4 balancer shaft and camshaft bushings (see
Groups 10 and 20). 11. Install injection pump on front plate (see
Group 40).
3. Install cylinder liners without O-rings and measure
protrusion. Install liners with O-rings (see Group 10). 12. Install camshaft, timing gears, and oil slinger (see
Group 20).
4. Install crankshaft and main bearings. Determine
bearing clearance using PLASTIGAGE (see 13. Time all gears to TDC, No. 1 cylinder on
Group 15). compression stroke (see Group 20).
5. Install flywheel housing, rear oil seal and flywheel 14. Install timing gear cover (with new front seal), see
(see Group 15). Group 20.
CD,3274,G03,2 -19-24FEB92

060799
PN=35
ENGINE ASSEMBLY SEQUENCE - CONTINUED
15. Install oil pan (see Group 25). 23. Install water manifold/thermostat housing with
thermostats (see Group 35).
16. Install oil pressure regulating valve (if equipped),
see Group 25. 24. Install exhaust manifold and turbocharger. Prelube
the turbocharger (see Group 35).
17. Install cam follower in the same sequence as
removed (see Group 20). 25. Install water pump and hoses (see Group 35).
18. Install cylinder head gasket, cylinder head, push 26. Install crankshaft pulley or vibration damper/pulley
rods, and rocker arm assembly (see Group 05). (see Group 15).
19. Install starting motor. 27. Install alternator, fan, and fan belts (see 03
Group 30).
5
20. Install injection nozzles (with new seals) and
injection lines (see Group 40). 28. Adjust valves and install rocker arm cover (see
Group 05).
21. Install fuel filter, fuel transfer pump, and fuel lines
(see Group 40). 29. Install vent tube.
22. Install engine oil cooler, new oil filter, and 30. Fill engine with clean oil and proper coolant.
dipstick. Never clean or reuse a contaminated
standard-flow oil cooler. Install a new one (see 31. Perform engine break-in and perform normal
Group 25). standard performance checks (see Group 210).
CD,3274,G03,2A -19-24FEB92

060799
PN=36
03
6

060799
PN=37
Group 05
Cylinder head and Valves
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or in the
European Microfiche Tool Catalog (MTC).
DX,TOOLS -19-20JUL95
RG5063 -UN-23AUG88
End Brush . . . . . . . . . . . . . . . . . . . . . D17024BR
Clean valve seat and bores.
S53,D17024,BR -19-26JAN87
Lifting eyes . . . . . . . . . . . . . . . . . . . . . . . . . JD-244
Use to lift engine or to remove cylinder head from 05

engine. 1
-UN-22MAY95
JDD244
CD,JD244 -19-01FEB94
RG5085 -UN-23AUG88
Torque wrench adapter . . . . . . . . . . . . . . . . . JD-307
Use with standard torque wrench to tighten head bolts

under rocker arm assembly.
CD,JD307 -19-04AUG92
RG5084 -UN-23AUG88
Nozzle Bore Cleaning Tool . . . . . . . . . . . . . . . JDE39
Clean injection nozzle bores in cylinder head.
RG,JDE39 -19-14FEB92
RG5068 -UN-23AUG88
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Lock engine at TDC when timing valve train. Use with

JDE81-1 or JDE83 Flywheel Turning Tool.
RG,JDE814L -19-02APR90

060799
PN=38
Cylinder head and Valves/Special tools
RG4950 -UN-23AUG88
Flywheel Turning Tool . . . . . . . . . . . . . . . . . . JDE83

or JDG820 (formerly JDE81-1)
Rotate engine flywheel. Use with JDE81-4 Timing Pin.
NOTE: Use JDE83 on engines with a 142 tooth flywheel

ring gear and a flywheel housing tool guide bore
of 26.5 mm (1.04 in.) diameter.
Use JDG820 on engines with a 129 tooth

flywheel ring gear and a flywheel housing tool
guide bore of 29.9 mm (1.18 in.) diameter.
05
2
CD,JDE83 -19-01FEB94
RG5070 -UN-23AUG88
Valve Spring Compressor . . . . . . . . . . . . . . . JDE138
Use to compress valve springs when removing and

installing valves.
RG,JDE138 -19-02APR90
Valve Seat Insert Installing Adapter . . . . . . . . JDG675
Use with JDG676 Pilot Driver to install intake and

exhaust valve seat inserts.
-UN-23AUG88
RG5240
RG,JDG675 -19-02APR90
RG5065 -UN-23AUG88
Valve Seat Driver . . . . . . . . . . . . . . . . . . . . JDG676
Use with JDG675 Adapter to install intake and exhaust

valve seat inserts in cylinder head.
RG,JDG676 -19-20JUL92
RG5612 -UN-12APR90
Valve Stem Seal Installer . . . . . . . . . . . . . . . JDG678
Use to install valve stem seals.
CD,JDG678 -19-24FEB92

060799
PN=39
Cylinder head and Valves/Special tools
RG5100 -UN-23AUG88
Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG680
Used to restore threaded holes in cylinder block for

cylinder head cap screws.
RG,JDG680 -19-02APR90
Nozzle Puller Adapter . . . . . . . . . . . . . . . . . JDG716
Use with JDE38-2 and JDE38-3 to pull Stanadyne

9.5 mm injection nozzles.
-UN-07MAR95
05
CD30338
3
CD,JDG716 -19-12NOV92

060799
PN=40
Cylinder head and Valves/Specifications
SPECIFICATIONS
DIMENSIONS OF NEW PARTS WEAR TOLERANCE
Thickness of new cylinder head . . . . . . . . . . . . . . . . . . . 104.87105.13 mm

(4.1294.139 in.)
Maximum permissible amount to be machined

from cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.03 in.)
Minimum thickness of cylinder head . . . . . . . . . . . . . . . . 104.11 mm (4.099 in.)
Maximum permissible out-of-flat of cylinder

head sealing surface . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Combustion face surface finish . . . . . . . . . . . . . . . . . . . approx. 0.0025 mm C.L.A.*

(0.0001 in. C.L.A.)
05
4
Valve stem diameter (standard)
Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8647.884 mm
(0.30960.3104 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8487.874 mm
(0.30900.3100 in.)
Bore for valve stem . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9127.938 mm

(0.31150.3125 in.)
Clearance between bore and valve stem . . . . . . . . . . . . . 0.05 to 0.10 mm 0.15 mm

(0.002 to 0.004 in.) (0.006 in.)
Valve stem oversize, stem diameter larger

than standard by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.38 mm (0.015 in.)
0.76 mm (0.030 in.)
Valve seat angle (intake and exhaust) . . . . . . . . . . . . . . 30
Valve face angle (intake and exhaust) . . . . . . . . . . . . . . 29.25
Maximum valve seat runout . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Maximum valve face runout . . . . . . . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.)
Valve recess (below cylinder head surface):

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.611.11 mm 1.63 mm
(0.0240.044 in.) (0.064 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.221.72 mm 2.26 mm
(0.0480.068 in.) (0.089 in.)
Valve seat width (intake and exhaust) . . . . . . . . . . . . . . 1.502.00 mm

(0.0590.079 in.)
* C.L.A. (Center Line Average) corresponds to a measure of surface

texture. CD,3274,G05,49 -19-04JAN99

060799
PN=41
Cylinder head and Valves/Specifications
SPECIFICATIONS - CONTINUED
Valve seat insert outside diameter:

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.20547.231 mm
(1.8581.859 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.08743.113 mm
(1.6961.697 in.)
Valve head diameter:

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.4746.73 mm
(1.8301.840 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.3742.63 mm
(1.6681.678 in.)
Firing order: 05
3-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 - 3 5
4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 - 4 - 2
6-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 - 3 - 6 - 2 - 4
Valve clearance (engine cold):

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)
Valve lift (zero valve clearance):

Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5612.37 mm 11.13 mm
(0.4550.487 in) (0.438 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2812.12 mm 10.85 mm
(0.4440.477 in.) (0.427 in.)
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . 19.9920.02 mm 19.94 mm

(0.7870.788 in.) (0.785 in.)
Rocker arm bore diameter . . . . . . . . . . . . . . . . . . . . . . 20.0720.12 mm 20.17 mm

(0.7900.792 in.) (0.794 in.)
Rocker arm shaft spring tension

at a length of 46 mm (1.81 in.) . . . . . . . . . . . . . . . . . . . 1827 N (46 lb)
Valve springs free height . . . . . . . . . . . . . . . . . . . . . . . approx. 54 mm (2.125 in.)
Valve spring tension:

at a length of 46 mm (1.81 in.) 240180 N (5462 lb)
at a length of 34.5 mm (1.36 in.) 590680 N (133153 lb)
CD,3274,G05,50 -19-04JAN99

060799
PN=42
Cylinder head and Valves/Cylinder head exploded view
TORQUES FOR HARDWARE
Rocker arm shaft clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)

Cylinder head cap screws:
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . 100 Nm (75 lb-ft)
Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . 150 Nm (110 lb-ft)
Step 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wait 5 minutes and verify 150 Nm (110 lb-ft)
Step 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... . Tighten additional 60 10
Fuel injection nozzles to cylinder head . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . 40 Nm (30 lb-ft)
Intake manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . 50 Nm (37 lb-ft)
Exhaust manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . 50 Nm (37 lb-ft)
Rocker arm cover to cylinder head . . . . . . . . . . . . . . . . . . . . . ........... . . . . . . . . . 10 Nm (7 lb-ft)
CD,3274,G05,52 -19-01FEB94
CYLINDER HEAD - EXPLODED VIEW

05
6
-UN-10MAY95
CD30378
1Cylinder head 3Cylinder head gasket 5Rocker arm cover 6Vent tube
2Valve seat 4Cylinder head bolt
(1/2-13UNC X 112 mm;
4.41 in.)
CD,3274,G05,53 -19-01FEB94

060799
PN=43
Cylinder head and Valves/Check valve lift
CHECK VALVE LIFT
NOTE: Measuring valve lift can give an indication of

wear on cam lobes.
-UN-18JAN95
1. Rotate engine and determine valve locations as
indicated under Valve Clearance in this group.
2. Adjust valve to zero clerance.
L103621
3. Position dial indicator on valve spring cap or rotator
and adjust indicator to 0.
4. Rotate engine and observe indicator reading as valve

moves to the fully open position. Compare readings with
specifications given below:
05
VALVE LIFT at 0.00 mm (in.) clearance 7
Intake valves . . . . . . . . . . . . . . . . . . . . . . .
11.5612.37 mm
(0.4550.487 in.)
Wear tolerance . . . . . . . . . . . . . . . . . . 11.13 mm (0.438 in.)
Exhaust valves . . . . . . . . . . . . . . . . . . . . . .11.2812.12 mm

(0.4440.477 in.)
5. Repeat above procedure for all valves and readjust

valves to specified clearance after this operation.
6. If valve lift is not within specification, remove and

inspect camshaft.
CD,3274,G05,2 -19-24FEB92

060799
PN=44
Cylinder head and Valves/Cleaning injection nozzle bores
REMOVING CYLINDER HEAD
Remove intake and exhaust manifolds.
Using special puller JDG716, remove the fuel injection
-UN-17FEB95
nozzles.
NOTE: Removal of fuel injection nozzles is necessary to

prevent them being damaged when cylinder head
is removed.
CD30324
NOTE: Before removal, mark all parts so that they can
be reinstalled in their original positions.
Remove rocker arm shaft.
05 Remove cylinder head cap screws and lift off cylinder

8 head assembly.
-UN-07MAR95
NOTE: Do not turn crankshaft after removal of cylinder
head until each liner has been secured with a
washer and cap screw.
L103623
CD,3274,G05,4 -19-24FEB92
CLEANING INJECTION NOZZLE BORES
Using special tool JDE39, remove carbon deposits from

bores of fuel injection nozzles.
-UN-18JAN95
IMPORTANT: Always turn the tool clockwise through
the bore, even when pulling back.
Otherwise tool will get dull.
Check cooling passages for lime deposits. Clean when
L103626
necessary, using a suitable cooling system cleaning
solution.
CD,3274,G05,5 -19-24FEB92

060799
PN=45
Cylinder head and Valves/Valve actuating exploded view
VALVE ACTUATING PARTS
05
9
-UN-10MAY95
CD30379
1Cam follower 4Support 7Keepers 10Metering seal
2Push rod 5Shaft 8Rotator 11Valve seat insert
3Rocker arm 6Plug 9Spring 12Valve
CD,3274,G05,54 -19-01FEB94

060799
PN=46
Cylinder head and Valves/Checking cylinder head flatness
REMOVE VALVES AND VALVE SPRINGS
1. Using JDE138 Valve Spring Compressor, compress

the valve springs far enough to remove keepers.
-UN-07MAR95
2. Release spring tension and remove valve rotator and
valve spring. Mark each part so that it can be
reassembled in the same position it was removed from.
3. Remove valves, marking them for reassembly.
L103629
4. Remove valve stem seals from valve guide tower.
05
10
CD,3274,G05,8 -19-24FEB92
CHECKING CYLINDER HEAD FLATNESS
Maximum permissible flatness is 0.08 mm (0.003 in.).
Machined surface of cylinder head must be refaced if

flatness is more than specified maximum.
NOTE: Maximum permissible amount to be machined
-UN-08AUG89
from cylinder head is 0.76 mm (0.03 in.).
After any head remachining, always recheck
valve recesses.
L30699
CD,3274,G05,6 -19-24FEB92

060799
PN=47
Cylinder head and Valves/Cleaning valve guides
CLEANING VALVE SEATS
Use an electric hand drill with D17024BR End Brush to

remove all carbon deposits.
-UN-25MAY89
Z20754
05
11
CD,3274,G05,9 -19-24FEB92
CLEANING VALVE GUIDES
Using a plastic brush, clean valve guides.
NOTE: A few drops of light oil or kerosene will make
-UN-07MAR95
cleaning of valve guides easier.
CD7254
CD,3274,G05,10 -19-24FEB92

060799
PN=48
Cylinder head and Valves/Valve seats
MEASURE VALVE GUIDES
Using a micrometer, measure valve guides then compare

with specifications.
-UN-04MAY98
VALVE GUIDE SPECIFICATIONS
Valve guide bore diameter

in a new cylinder head . . . . . . . . . . . . . . . . . 7.9127.938 mm
(0.3120.313in.)
New guide-to-valve
CD30550
stem clearance . . . . . . . . . . . . . . . . . . . . . . . . 0.050.10 mm
(0.0020.004 in.)
Maximum permissible
clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
If valve guide-to-stem oil clearance exceeds the wear

limit, 0.38 mm (0.015 in.) and 0.76 mm (0.030 in.)
05 oversize valve stems are available. Have valve guides
12 reamed by a qualified workshop to assure a proper
guide-to-stem clearance.
NOTE: Production valve guides have a very shallow

spiral cut (arrow), similar to a thread, to lubricate
the valve stem with a metered supply of oil. Be
sure, when valve guides are reamed that this
groove is restored.
-UN-19MAY98
CD30548
CD,CTM125,027 -19-01DEC97
LAPPING VALVE SEATS
Check seat width and contact pattern between seat and

valve with blueing. If necessary lap the valve onto its
seat using a lapping tool and lapping compound.
-UN-10MAY95
IMPORTANT: Always check valve recess in cylinder

head after lapping, as described in this
group.
CD30380
CD,3274,G05,55 -19-01FEB94

060799
PN=49
CHECK VALVE RECESS
After lapping valve seat or remachining combustion face,

install refaced or new valves in cylinder head and check
valve recess (A).
-UN-06DEC88
VALVE RECESS SPECIFICATIONS
Intake . . . . . . . . . . . . . . . . . 0.611.11 mm (0.0240.044 in.)

Wear tolerance . . . . . . . . . . . . . . . . . . . 1.63 mm (0.064 in.)
RG4756
Exhaust . . . . . . . . . . . . . . . . 1.221.72 mm (0.0480.068 in.)
Wear tolerance . . . . . . . . . . . . . . . . . . . 2.26 mm (0.089 in.)
When maximum valve recess is reached, replace valve

seat inserts.
05
13
-UN-07NOV88
T81869
CD,3274,G05,13 -19-01FEB94

060799
PN=50
REMOVE VALVE SEAT INSERTS
Valve seat inserts are made of sintered metal. Following

method, performed by experienced personnel or
specialized workshop, can be used to remove inserts.
-UN-10NOV97
Using an arc welder
1. Protect the valve guide by installing a cap screw or
RG7761
dowel in guide to protect from weld spatter.
2. Protect the cylinder head surface with a

non-flammable welders cloth (A). Apply a thin bead of
weld (B) around internal diameter of valve seat insert.
Allow insert to cool and use a screwdriver (C) or similar
05 tool and carefully pry insert from bore.
14
-UN-13NOV97
3. After removal of inserts, thoroughly clean area around
valve seat bore and inspect for damage or cracks.
Replace cylinder head as necessary.
RG7813
-UN-10NOV97
RG7763
CD,CTM125,030 -19-01DEC97

060799
PN=51
Machining valve seat insert
1. Machine insert according to valve seat bore

specifications as shown, until a thin layer of material
stays in cylinder head.
-UN-10MAR90
2. Remove rest of material and clean valve seat bore.
AExhaust: 42.98743.013 mm (1.6924

1.6934 in.)
Intake: 47.10447.130 mm (1.85451.8555 in.)
BExhaust: 3.82 mm (0.150 in.) Reference
RG5606
Intake: 3.45 mm (0.136 in.) Reference
C9.93610.064 mm (0.39120.3962 in.)
D3842
EMaximum radius 0.5 mm (0.019 in.)
05
15
CD,CTM125,031 -19-29JUN99
VALVE SEAT INSERT INSTALLATION
1. Freeze the valve seat inserts to -30C (-22F).
2. Using JDG676 Pilot Driver (A) and JDG675 Valve

Seat Insert Installing Adapter (B), install valve seat
inserts.
3. Lap valve seats to maintain correct valve recess and

valve to valve seat sealing. (See Lapping valve seats,
-UN-12APR90
in this group)
RG5653
CD,3274,G05,16 -19-01FEB94

060799
PN=52
Cylinder head and Valves/Valves
CHECK VALVES
Thoroughly clean and inspect valves to help determine if

they can be reused. Replace valves that are burned,
cracked, eroded, or chipped.
-UN-07NOV88
1. Measure valve stem diameter and compare with
corresponding valve guide diameter to check clearance
(See Measure valve guides, in this group).
T82053
VALVE STEM DIAMETER SPECIFICATIONS
Intake valve . . . . . . . . . . . . . . . . . . . . . . . . 7.8647.884 mm

(0.30960.3104 in.)
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . 7.8487.874 mm

(0.30900.3100 in.)
05
16
-UN-05DEC97
2. Check for valve face runout and bent valves.
Maximum permissible
runout of valve face . . . . . . . . . . . . . . . . 0.038 mm (0.0015 in.)
RG4234
CD,CTM125,032 -19-01DEC97
GRIND VALVES
Serviceable valves should be refaced to specified angle

(A). Face angle on intake and exhaust valves is 29.25
0.25.
-UN-19NOV89
RG4755
CD,3274,G05,3 -19-24FEB92
CHECK VALVE SPRING TENSION

VALVE SPRING COMPRESSION
Free length . . . . . . . . . . . . . . . . . . . . approx. 54 mm (2.125 in.)

-UN-08NOV88
Load with spring compressed

to 46 mm (1.81 in.) . . . . . . . . . . . . . . . 240280 N (5462 lb)
Load with spring compressed

to 34.5 mm (1.36 in.) . . . . . . . . . . . . . 590680 N (133153 lb)
T82054
CD,3274,G05,19 -19-01FEB94

060799
PN=53
Cylinder head and Valves/Valves
INSPECT VALVE ROTATORS
Insure that valve rotators turn freely in both directions.

Replace if defective.
-UN-28OCT88
T91224
CD,3274,G05,20 -19-24FEB92
INSTALL VALVES
1. Apply engine oil to valve stems and guides. 05

17
2. Insert valves in head (in same location as found
-UN-12APR90
during removal).
NOTE: Valves must move freely and seat properly.
3. Using JDG678 Valve Stem Seal Installer (A), slide
RG5654
seal (B) over valve stem and onto valve guide tower (C).
4. Install valve springs and rotators.
5. Compress valve springs using JDE138 Valve Spring

Compressor and install new keepers on valves.
NOTE: After having installed the valves, strike end of
-UN-12APR90
each valve three times with a soft mallet to
ensure proper positioning of the keepers.
RG5655
-UN-07MAR95
CD30233
CD,3274,G05,21 -19-01FEB94

060799
PN=54
Cylinder head and Valves/Install cylinder head
INSTALL CYLINDER HEAD
1. Clean tapped holes in cylinder block using JDG680

Tap (or any 1/2-13 UNC-2A tap). Use compressed air to
remove debris or any fluids from cap screw holes.
-UN-13DEC88
2. Install new cylinder head gasket dry (without sealant)
IMPORTANT: Insure that cam followers are present

before cylinder head installation.
RG4718
3. Install two guide studs in cylinder block at locating
holes (D).
IMPORTANT: Without guide studs, the Viton O-ring

attached to cylinder head gasket (at
05 rocker arm lube oil passage) could be
18 damaged when repositioning cylinder
head on engine block to align cap
screw holes.
4. Position cylinder head over guide studs and lower into

place on cylinder block.
5. Dip cap screws entirely in clean engine oil.
6. Remove guide studs and install cap screws in all

open bores.
7. Tighten cap screws in sequence to the torque

specified, beginning with No. 1. Use JD-307 Torque
Wrench Adapter if necessary.
Step 1 - Tighten all cap screws to 100 Nm (75 lb-ft)

Step 2 - Tighten all cap screws to 150 Nm (110 lb-ft)
Step 3 - Wait 5 minutes and recheck to insure
150 Nm (110 lb-ft) on all cap screws
Step 4 - Tighten each cap screw an additional
60 10
A3 cylinder engine
B4 cylinder engine
C6 cylinder engine
DGuide stud locations
EFront of engine
-UN-06DEC88
RG4773
CD,3274,G05,23 -19-01FEB94

060799
PN=55
Cylinder head and Valves/Torque turn tightening method
TORQUE TURN TIGHTENING METHOD
To ensure that the full 60 angle is reached (4th step),

the following procedure can be used:
Step A - Make a mark on socket and make a second
-UN-31OCT97
mark 60 counterclockwise from the first
Step B - Make a mark on cylinder head next to each
cap screw
Step C - Place socket on cap screw so that first mark
aligns with mark on cylinder head
RG5587
Step D - Tighten (in sequence) all cap screws until
second mark on socket aligns with mark on cylinder
head
NOTE: The torque turn method eliminates the need to AReference mark
retorque the cylinder head bolts after the first B60 mark
05
hours of engine operation. However, valve 19
clearance adjustment is still required.
CD,CTM125,035 -19-01DEC97

060799
PN=56
Cylinder head and Valves/Rocker arm shaft
CHECKING ROCKER ARM SHAFT
Disassembling and checking
1. Remove plugs (A) and bowed washers (B) from
-UN-10MAY95
rocker arm shaft.
2. Slide springs, rocker arms and supports off rocker arm
shaft, identifying their sequence for reassembly in the
same order.
3. Clean all parts with solvent and dry with compressed
CD30381
air.
4. Check all parts for good condition (See
Specifications for part dimensions).
5. Replace parts as necessary.
NOTE: If the rocker arm has been damaged by a valve

05 failure, replace it together with the corresponding
20 push rod, valve rotator and keepers.
-UN-18MAY95
Reassembling
1. Lubricate shaft, bores of rocker arms and supports.

2. Slide springs, rocker arms and supports onto shaft.
CD30382
Assemble in the same order in which they were removed
during disassembly.
IMPORTANT: The hole (C) in the shaft must be in

line with the oil supply hole (D) of APlug
cylinder head. BBowed washer
COil supply hole in rocker arm shaft
3. Install bowed washers (B) and new plugs (A) on shaft. DOil supply hole in cylinder head
CD,3274,G05,56 -19-01FEB94

060799
PN=57
Cylinder head and Valves/Valve clearance
INSTALL ROCKER ARM ASSEMBLY
1. Install push rods in same location from which they

were removed.
-UN-07MAR95
NOTE: Valve stem tips are specially hardened, wear
caps are not required.
2. Position rocker arm assembly on engine.
L103631
3. Lubricate the rocker arms with engine oil.
4. Tighten attaching cap screws to 50 Nm (35 lb-ft).
05
21
CD,3274,G05,29 -19-01FEB94
VALVE CLEARANCE
The valve clearance must be adjusted when engine is

cold.
-UN-19MAY98
Using JDE83 or JDG820 Flywheel Turning Tool (A),
rotate engine flywheel in running direction (clockwise
viewed from water pump) until No.1 piston (front) has
reached top dead center (TDC) on compression stroke.
Insert timing pin JDE81-4 (B) into flywheel bore.
CD30544
NOTE: When No. 1 piston is at TDC on compression
stroke, valve springs of No. 1 cylinder are not
under tension.
VALVE CLEARANCE SPECIFICATIONS
Intake valve . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
-UN-19MAY98
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)
Adjust valve clearance as directed in the following

CD30545
module.
CD,CTM125,036 -19-01DEC97

060799
PN=58
Cylinder head and Valves/Valve adjustment sequence
VALVE ADJUSTMENT SEQUENCE
3- Cylinder engine:
Adjust valve clearance on No.1 and 2 exhaust valves
and No.1 and 3 intake valves.
-UN-08MAR95
Turn crankshaft 360 and reinsert timing pin.
Adjust valve clearance on No.3 exhaust valve and No.2

intake valve.
CD30000
4- Cylinder engine:
Turn crankshaft 360 so that No.4 piston is at TDC

05 (compression stroke) and reinsert timing pin.
22
-UN-08MAR95
6- Cylinder engine:
Adjust valve clearance on No.1, 3 and 5 exhaust valves
CD7103
and No.1, 2 and 4 intake valves.
Turn crankshaft 360 so that No.6 piston is at TDC

(compression stroke) and reinsert timing pin.
Adjust valve clearance on No.2, 4 and 6 exhaust valves

and No.3, 5 and 6 intake valves.
-UN-08MAR95
AFront of engine
BExhaust valve
CIntake valve
DNo. 1 piston at TDC compression stroke
ENo. 6 piston at TDC compression stroke
(6-cylinder engine)
CD30237
FNo. 4 piston at TDC compression stroke
(4-cylinder engine)
GNo. 1 piston at TDC exhaust stroke
(3-cylinder engine)
CD,3274,G05,7 -19-24FEB92

060799
PN=59
Cylinder head and Valves/Final work
INSTALL ROCKER ARM COVER
Two types of rocker arm cover are used:
Sheet metal cover (A)
-UN-07MAR95
Install rocker arm cover with gasket (without sealant)
and tighten cap screws to 10 Nm (7 lb-ft).
Gasket can continue to be used until it starts to leak.
Composite material cover (B)
CD30152
Install rocker arm cover with built-in sealing ring
(without sealant).
Install the cap screws by hand and tighten to 10 Nm
(7 lb-ft), starting from center and moving towards both
front and rear ends of the cover.
The sealing ring is reusable. In case of leak, proceed
as follows: 05
1. Remove sealing ring. 23
-UN-07MAR95
2. Clean cover sealing ring groove with acetone and dry
with compressed air.
3. Install new sealing ring with grease in cover groove.
4. Cut the sealing ring slightly longer than necessary.
5. Put the sealing ring ends edge to edge then press the
CD30153
sealing ring all along the groove to ensure proper
installation.
CD,3274,G05,31 -19-24FEB92
FINAL WORK
1. Re-install parts previously removed.

2. Check crankcase vent tube hose (A) for proper
condition. Replace if necessary. When re-installing, be
sure that the hose is not pinched.
3. Start engine and check for oil or coolant leaks.
4. Run engine for 30 minutes at 1500 rpm or perform
break-in in case of engine overhaul.
5. Recheck valve clearances and readjust when
necessary.
NOTE: Retorque of cylinder head bolts is not required.

-UN-17JUN98
CD30547
CD,CTM125,039 -19-01DEC97

060799
PN=60
Cylinder head and Valves/Final work
05
24

060799
PN=61
Group 10
Cyl. Block, Liners, Pistons & Rods

RG5074 -UN-23AUG88
Flexible Cylinder Hone . . . . . . . . . . . . . . . D17004BR
Hone cylinder liners.
S53,D17004,BR -19-03APR90
O-Ring Groove Cleaning Brush . . . . . . . D17015BR
Clean cylinder liner O-ring groove in block.
-UN-23AUG88
10
1
RG5075
S53,D17015,BR -19-25MAR91
RG5120 -UN-23AUG88
Balancer shaft bushing driver . . . . . . . . . . . . . JD-249
Replace balancer shaft bushings.
CD,JD249 -19-04AUG92
RG5076 -UN-23AUG88
Ring groove wear gauge . . . . . . . . . . . . . . . . JDE62
Used to check top groove of pistons on engine with

15 angle ring.
CD,JDE62 -19-04JAN99
RG5031 -UN-23AUG88
Piston Ring Compressor . . . . . . . . . . . . . . . . JDE84
Compress rings while installing pistons.
S53,JDE84 -19-03APR90

060799
PN=62
Cyl. Block, Liners, Pistons & Rods/Special tools
RG5107 -UN-23AUG88
Piston pin bushing remover and

installer . . . . . . JDE88 (35 mm [1.377 in.] medium pin)
JD-286 (41 mm [1.614 in.] large pin)
Replace piston pin bushing in connecting rods with

straight pin-end.
CD,JDE88 -19-04JAN99
Connecting Rod Bushing Remover and

Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG738
Replace pin bushing in connecting rods with tapered

pin-end.
10 Set consists of:
2
ARemover/Replacer Driver .. . . . . . . . . . JDG738-1
-UN-26OCT94
BInstaller Pilot . . . . . . . . ... . . . . . . . . . JDG738-2
CReceiver Cup . . . . . . . ... . . . . . . . . . JDG738-3
DRemover/Replacer Driver .. . . . . . . . . . JDG738-4
EInstaller Pilot . . . . . . . . ... . . . . . . . . . JDG738-5
FReceiver Cup . . . . . . . ... . . . . . . . . . JDG738-6
RG7028
RG,JDG738 -19-27DEC94
Camshaft bushing service set . . . . . . . . . . . JDG739B

(formerly JDG739 or JDG739A)
Used to replace camshaft bushing.
Set consists of: -UN-07NOV97
ABushing remover. . . . . . . . . . . . . . . . . . JDG739-1

BFlat bottom legs (3/8-16) (3) . . . . . . . . . . JDG739-2
CRemoving/installing plate . . . . . . . . . . . . JDG739-3
RG7651
DBushing installer screw . . . . . . . . . . . . . JDG739-4

EBushing installer . . . . . . . . . . . . . . . . . JDB739-5B
FTapered bottom leg (3/8-16) . . . . . . . . . . JDG739-6
GTapered bottom leg (M8 x 1.25) . . . . . . JDG739-7*
HFlat bottom leg (M8 x 1.25) (3) . . . . . . . JDG739-8*
*Metric part, not for this application. CD,JDG739B,1 -19-04JAN99

060799
PN=63
Cyl. Block, Liners, Pistons & Rods/Special tools
RG5076 -UN-23AUG88
Ring groove wear gauge . . . . . . . . . . . . . . . JDG957
Used to check top groove of pistons on engine with 6 an
CD,JDG957,1 -19-04JAN99
CD30234 -UN-08MAR95
Cylinder liner puller . . . . . . . . . . . . . . . . . KCD10001
Used to remove and install cylinder liners.
CD,KCD10001 -19-20FEB92
CD30235 -UN-08MAR95
Piston/Liner height gauge . . . . . . . . . . . . . . KJD10123
Used to measure piston/liner heights.
CD,KJD10123 -19-20FEB92
10
CD30236 -UN-08MAR95
3
Piston ring expander . . . . . . . . . . . . . . . . . KJD10140
Used to replace piston rings.
CD,KJD10140 -19-20FEB92

060799
PN=64
Cyl. Block, Liners, Pistons & Rods/Specifications
SPECIFICATIONS
Centerline of main bearing bore-

to-top deck of cyl. block:
3029, 4039, 6059 Engines . . . . . . . . . . . 301.98302.11 mm (11.88911.894 in.)
4045, 6068 Engines . . . . . . . . . . . . . . . 337.87338.00 mm (13.30213.307 in.)
Maximum acceptable block out-of-flat:

For entire length or width . . . . . . . . . . . 0.13 mm (0.005 in.)
For every 150 mm (5.90 in.) length
or width . . . . . . . . . . . . . . . . . . . . . . 0.025 mm (0.001 in.)
Cam follower bore ID . . . . . . . . . . . . . . . . 31.7031.75 mm (1.2481.250 in.)
Cam followers OD . . . . . . . . . . . . . . . . . . 31.6231.64 mm (1.2451.246 in)
Cam follower clearance . . . . . . . . . . . . . . 0.060.13 mm (0.0020.005 in.)
10 Camshaft bore without bushing . . . . . . . . . 55.9856.01 mm (2.2042.205 in.)

4
Camshaft bore with bushing (No. 1 only)
cyl. block bore for bushing
installation . . . . . . . . . . . . . . . . . . . . 59.9659.99 mm (2.3612.362 in.)
bushing ID (installed) . . . . . . . . . . . . . 55.9655.99 mm (2.2032.204 in.)
Balancer shaft bushing bore in cyl. block*

Standard Bushings . ........ . . . . . . . 41.2641.29 mm (1.6251.626 in.)
Oversize Bushings** ........ . . . . . . . 43.2443.26 mm (1.7021.703 in.)
Chamfer . . . . . . . . ........ . . . . . . . 2025 x 1.50 mm (0.060 in.)
Crankshaft main bearing bores . . . . . . . . . 84.4684.48 mm (3.3253.326 in.)
Upper block bore for seating liner . . . . . . . 120.70120.75 mm (4.7524.754 in.)
OD of liner at upper bore . . . . . . . . . . . . . 120.61120.69 mm (4.7484.751 in.)
Clearance between liner and cylinder

block at upper bore . . . . . . . . . . . . . . . . . 0.100.14 mm (0.0040.005 in.)
*4039 and 4045 Engines only.
**4039 engines with one-piece balancer shafts only. CD,3274,G10,31 -19-04JAN99

060799
PN=65
Lower block bore for seating liner . . . . . . . 115.75115.80 mm (4.5574.559 in.)
Outside diameter of liner at lower bore

level (measured 10 mm (0.39 in.) below
lower shoulder)
Engine ( - 317306CD)
Production liner (first class) . . . . . . . . . 115.724115.748 mm (4.5564.557 in.)
Production liner (second class) . . . . . . . 115.698115.723 mm (4.5554.556 in.)
Service liner . . . . . . . . . . . . . . . . . . . 115.724115.748 mm (4.5564.557 in.)
Clearance between block and liner:
Production liner (first class) . . . . . . . . . 0.0250.075 mm (0.0010.003 in.)
Production liner (second class) . . . . . . 0.0250.075 mm (0.0010.003 in.)
Service liner . . . . . . . . . . . . . . . . . . . 00.075 mm (00.003 in.)
Engine (317307CD - ) ......... . . . 115.695115.735 mm (4.5554.556 in.)
Clearance between block and liner . . . . 0.0150.105 mm (0.00060.0041 in.)
Cylinder liner internal diameter . . . . . . . . . 106.49106.52 mm (4.19254.1937 in.) 10

Maximum permissible wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.) 5
Maximum permissible taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Maximum permissible out-of-round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Liner counterbore depth in block . . . . . . . . . 5.955.99 mm (0.2340.236 in.)
Liner height above block . . . . . . . . . . . . . 0.010.10 mm (0.00040.004 in.)
Maximum permissible height difference at

nearest point of two adjacent liners . . . . . . 0.03 mm (0.001 in.)
Thickness of liner shim CD15466 . . . . . . . . 0.05 mm (0.002 in.)
Thickness of liner shim R65833 . . . . . . . . . 0.10 mm (0.004 in.)
Minimum dimension for proper

compression of liner packing . . . . . . . . . . . 0.13 mm (0.005 in.)
Desired cylinder liner wall finish

(cross-hatch pattern) . . . . . . . . . . . . . . . . 0.00060.0011 mm (2545 micro-in.)
CD,3274,G10,32 -19-04JAN99

060799
PN=66
Piston OD at 19 mm (0.74 in.) from
bottom of skirt and measured 90
to piston pin . . . . . . . . . . . . . . . . . . . . . . 106.381106.399 mm (4.18824.1890 in.)
Piston-to-cylinder liner clearance,

measured at bottom of skirt . . . . . . . . . . . 0.090.14 mm (0.00350.0055 in.)
Piston ring end gap:

3029DF120/DF160 (263024CD- )
3029DAT01
3029TAT02
3029TF120/TF160 (287526CD- )
3029TF001/TF031 (264813CD- )
3029TLV01 (261581CD- )
3029DPY01 . . . . . . . . . . . . . . . . . . . . No.1: 0.330.58 mm (0.0130.023 in.)
No.2: 1.231.49 mm (0.0490.059 in.)
10 No.3: 0.300.56 mm (0.0120.022 in.)
6 All other engines . . . . . . . . . . . . . . . . . No.1: 0.350.60 mm (0.0140.024 in.)
No.2 (earlier): 0.330.58 mm (0.0130.023 in.)
No.2 (later): 0.711.00 mm (0.0280.039 in.)
No.3: 0.300.60 mm (0.0120.024 in.)
Piston height:
Measured from center of piston
pin bore to top of piston
3029, 4039, 6059 Engines . . . . . . . . . . 66.2766.33 mm (2.6092.611 in.)
4045 and 6068 Engines . . . . . . . . . . . 71.6471.70 mm (2.8202.823 in.)
Piston protrusion above block . . . . . . . . . . 0.080.35 mm (0.0030.014 in.)
Piston pin bore*:

For small pin (32 mm [1.26 in]) . . . . . . 32.00332.013 mm (1.26001.2603 in.)
For medium pin (35 mm [1.377 in.]) . . . 34.93334.943 mm (1.37531.3757 in.)
For large pin (41 mm [1.614 in.]) . . . . . 41.28541.295 mm (1.62541.6258 in.)
Piston pin Outside Diameter:

Small pin . . . . . . . . . . . . . . . . . . . . . 31.99432.000 mm (1.25961.2598 in.)
Medium pin . . . . . . . . . . . . . . . . . . . . 34.9234.93 mm (1.37481.3752 in.) 0.013 mm (0.0005 in.)
Large pin . . . . . . . . . . . . . . . . . . . . . 41.2741.28 mm (1.62481.6252 in.) 0.013 mm (0.0005 in.)
Rod pin bushing Internal Diameter:

Small pin . . . . . . . . . . . . . . . . . . . . . 32.01032.036 mm (1.26021.2612 in.)
Medium pin . . . . . . . . . . . . . . . . . . . . 34.95034.976 mm (1.3761.377 in.) 0.05 mm (0.002 in.)
Large pin . . . . . . . . . . . . . . . . . . . . . 41.30041.326 mm (1.6261.627 in.) 0.05 mm (0.002 in.)
*Some piston pin bores are elliptical, the width being 0.038_mm
(0.0015_in.) wider than specification given. CD,3274,G10,33 -19-04JAN99

060799
PN=67
Pin-to-bushing oil clearance:
Small pin . . . . . . . . . . . . . . . . . . . . . 0.0100.042 mm (0.00040.0016 in.)
Medium pin . . . . . . . . . . . . . . . . . . . . 0.0200.056 mm (0.00080.0022 in.)
Large pin . . . . . . . . . . . . . . . . . . . . . 0.0070.043 mm (0.00030.0017 in.)
Connecting rod bearing (assembled)

Internal Diameter:
3029, 4039, 6059 Engines . . . . . . . . . . . 69.84869.898 mm (2.74992.7519 in.)
4045, 6068 Engines . . . . . . . . . . . . . . . 77.84777.897 mm (3.06483.0668 in.)
Bearing-to-journal clearance . . . . . . . . . . . 0.0230.099 mm (0.00090.0039 in.) 0.16 mm (0.006 in.)
Connecting rod bore for bearing

3029, 4039, 6059 Engines . . . . . . . . . . . 73.66073.686 mm (2.9002.901 in.)
4045, 6068 Engines . . . . . . . . . . . . . . . 82.67782.703 mm (3.2553.256 in.)
Undersize connecting rod bearings

available . . . . . . . . . . . . . . . . . . . . . . . . 0.25; 0.51 and 0.76 mm 10
(0.01; 0.02 and 0.03 in.) 7
Piston cooling orifice flow (each) . . . . . . . . 1.5 L/min (1.4 qt/min)
CD,3274,G10,45 -19-04JAN99

060799
PN=68
Cyl. Block, Liners, Pistons & Rods/Torques for hardware
Piston cooling orifices into cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (7.5 lb-ft)
Connecting rod cap screws

3029, 4039, 6059 Engines:
Initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Nm (40 lb-ft)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plus 90100 degrees
4045, 6068 Engines:
Initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Nm (50 lb-ft)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plus 90100 degrees
Cylinder block plug or fitting:

Coolant drain (1/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Nm (13 lb-ft)
Turbocharger oil return (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (33 lb-ft)
Dipstick tube (1/2 cylindrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Nm (50 lb-ft)
Oil pressure galleries (1/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Nm (13 lb-ft)
Oil gallery (3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (33 lb-ft)
Rear coolant gallery (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (33 lb-ft)
10 Side coolant gallery (1/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Nm (13 lb-ft)
8 Side coolant gallery (15/8):
Sheet metal plug ( -379251CD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (44 lb-ft)
Composite material plug (379252CD- ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
CD,3274,G10,34 -19-04JAN99

060799
PN=69
Cyl. Block, Liners, Pistons & Rods/Exploded view
EXPLODED VIEW
10
9
-UN-10MAY95
CD30383
1Cylinder block 4Piston rings 7Liner seals 10Oil by-pass valve
2Cylinder liner 5Piston pin 8Balancer shaft bushing 11Connecting rod
3Piston 6Snap ring 9Oil pressure regulating
valve seat
CD,3274,G10,46 -19-01FEB94

060799
PN=70
Cyl. Block, Liners, Pistons & Rods/Pistons & connecting rods removal
PISTON AND CONNECTING ROD REMOVAL
Remove cylinder head and oil pan.
-UN-07DEC88
Install large flat washers (B) with cap screws (A) to hold
cylinder liners (C) down.
IMPORTANT: After any cylinder head removal, never
RG3819
turn crankshaft until all liners have
been secured with screws and washers.
Remove ridge and carbon from cylinder liner with a ridge

reamer.
IMPORTANT: Keep bearing inserts with their

respective rods and caps.
-UN-07NOV88
During removal, mark and identify the
pistons, connecting rods and caps, as
they must be reinstalled in the same
10 cylinder from which they were
T81615
10 removed.
Remove rod cap screws and caps.
Remove connecting rod and piston assembly from the

cylinder liner.
Remove piston pin snap rings.
-UN-28MAR90
Press piston pin out of bore and lift connecting rod out
of piston.
RG5623
CD,3274,G10,2 -19-01FEB94

060799
PN=71
Cyl. Block, Liners, Pistons & Rods/Cylinder liner
CYLINDER LINER BORE MEASURE
Measure liner bore at four points of ring travel.
CYLINDER LINER BORE SPECIFICATIONS
-UN-07MAR95
Cylinder liner ID . . . . . . . . . . . . . . . . . . . . 106.49106.52 mm
(4.19254.1937 in.)
Maximum wear . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)
Maximum taper . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Maximum out-of-round . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
CD7132
Compare liner measurements with piston skirt diameter.
For clearance between piston skirt and liner, see
Specifications.
NOTE: Oversize liners do not exist. Install a complete

set including standard liner and piston.
CD,3274,G10,18 -19-01FEB94
10
11
CYLINDER LINER REMOVAL
Pull liners out of cylinder block using KCD10001 puller.
-UN-10MAY95
CD30384
CD,3274,G10,19 -19-01FEB94

060799
PN=72
Cyl. Block, Liners, Pistons & Rods/Cylinder block
CYLINDER LINER DEGLAZING
Place cylinder liners in a suitable clamping device.
Use D17004BR Flex-Hone to deglaze liner. Follow

instructions supplied with tool to obtain 45 degree
crosshatch pattern.
NOTE: After deglazing, clean cylinder liner bore with a

mixture of warm water and soap. Rinse with clear
water until rinse water is clear. Dry with clean
-UN-13DEC88
towels and coat bore with clean engine oil.
IMPORTANT: Do NOT use gasoline, kerosene or

commercial solvents to clean liners.
R26164
10
12
CD,3274,G10,20 -19-18FEB92
CYLINDER BLOCK CLEANING
Remove liner O-rings from cylinder block. Clean block

with cleaning solvent or pressure steam.
Make sure all passages and openings are free from

sludge, rust and grease.
Use D17015BR cleaning brush to clean liner O-ring

grooves.
-UN-13DEC88
R26166
CD,3274,G10,21 -19-18FEB92

060799
PN=73
CHECKING PISTON COOLING JETS
Check each piston cooling jet (1) for plugging or

damage.
-UN-23FEB89
NOTE: A cooling jet failure could cause damage to
pistons, piston pins, rod pin bushings and liners.
Reinstall jets and tighten to 10 Nm (7.5 lb-ft).
CD5782
CD,3274,G10,24 -19-18FEB92
CAM FOLLOWER BORE MEASURE

CAM FOLLOWER BORE SPECIFICATIONS
Cam follower bore ID . . . . . . . . . . . . . . . . . .

31.7031.75 mm
(1.2481.250 in.)
-UN-01NOV88
Maximum clearance . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.) 10
13
If diameter is more than specified, install a new cylinder
block. Service bushings are not available through service
T81656
parts.
CD,3274,G10,35 -19-18FEB92
CAMSHAFT BORE MEASURE

CAMSHAFT BORE SPECIFICATIONS
Camshaft bore without bushing . . . . . . . . . . . 55.9856.01 mm

(2.2042.205 in.)
-UN-07MAR95
Camshaft bore with bushing (No. 1 only)
cyl. block bore for
bushing installation . . . . . . . . . . . . . . . . 59.9659.99 mm
(2.3612.362 in.)
bushing ID (installed) . . . . . . . . . . . . . . . 55.9655.99 mm
(2.2032.204 in.)
CD7107
If only diameter of No.1 camshaft bore with bushing is
more than specified, replace the bushing. In other cases,
install a new cylinder block.
CD,3274,G10,36 -19-18FEB92

060799
PN=74
CAMSHAFT BUSHING REPLACEMENT TOOL
From engine serial number 138541CD on, the camshaft

bushing can be replaced either with front plate removed
or with front plate in place on engine. In this case,
-UN-10MAY95
JDG739 Tool must be modified, if not yet done, as
follows:
1. Machine an angle of 82 on one threaded spacer (A).
CD30385
2. Remove material from bushing driver (B) as shown.
NOTE: With this modification, JDG739 became

JDG739A. Then, with the adoption of metric
threaded spacers, JDG739A has become
JDG739B. Metric threaded spacers are not used
on this application.
-UN-10MAY95
AThreaded spacer
BBushing driver
10 CMaterial to be removed
14
CD30386
-UN-10MAY95
CD30387
CD,3274,G10,47 -19-04JAN99

060799
PN=75
REMOVE CAMSHAFT BUSHING
-UN-10MAY95
-UN-17FEB95
CD30340
CD30388
Extract camshaft bushing using JDG739B tool as 2. Insert bushing puller (D) into camshaft bushing
follows: bore.
1. Assemble threaded spacers (A) and forcing plate 3. Tighten hex. nut until bushing is free of block bore.
(B) to cylinder block (C). 10
15
CD,CTM125,051 -19-01DEC97
INSTALLING CAMSHAFT BUSHING
IMPORTANT: Bushing must be installed so oil supply

hole (arrow) aligns with oil drilling in
block bore.
-UN-10MAY95
1. Apply TY6333 grease* to internal diameter and
outside diameter of bushing.
2. Slide bushing onto driver so notched end (A) of
CD30389
bushing will be toward front end of engine when
installed.
3. Tighten forcing screw until flange of driver bottoms

against face of block.
*Available as service part. CD,3274,G10,49 -19-01FEB94

060799
PN=76
CRANKSHAFT BORE MEASURE

CRANKSHAFT BORE SPECIFICATIONS
Crankshaft bore ID . . . . . . . . . . . . . . . . . . . 84.4684.48 mm

(3.3253.326 in.)
-UN-07MAR95
NOTE: Before measuring, the cap screws must be
tightened to 120 Nm (85 lb-ft) for engines prior
to serial number 135641CD and to 135 Nm
(100 lb-ft) for other engines.
CD7271
If diameter is more than specified or bearing cap is
damaged, replace cap and line bore to specifications.
CD,3274,G10,38 -19-01FEB94
10
16
CRANKSHAFT BEARING CAP
REPLACEMENT
Replacement bearing caps are supplied with unfinished

bore (undersize radius 41.4 mm / 1.63 in.).
-UN-14DEC88
Install replacement cap in block and tighten cap screws
to 120 Nm (85 lb-ft) for engines prior to serial number
135641CD and to 135 Nm (100 lb-ft) for other engines.
RG4788
After having positioned block on a boring machine, bore
new bearing caps to 84.4584.48 mm (3.3253.326 in.)
diameter. Take care to remain within the specified
dimension (A) (crankshaft bore center line to block top
face).
DISTANCE (A)
3029, 4039, 6059 engines . . . . . . . . . . . . . 301.98302.11 mm

(11.88911.894 in.)
4045, 6068 engines . . . . . . . . . . . . . . . . . . 337.87338.00 mm
(13.30213.307 in.)
IMPORTANT: Make sure all crankshaft bearing bores

are in alignment.
CD,3274,G10,39 -19-01FEB94

060799
PN=77
CYLINDER BLOCK TOP DESK FLATNESS
Measure cylinder block top desk flatness using a

precision straightedge.
-UN-07NOV88
TOP DESK OUT-OF-FLAT
for entire length . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)

for every 150 mm (5.90 in.) length
or width . . . . . . . . . . . . . . . . . . . . . . . 0.025 mm (0.001 in.)
T81658
If flatness is not as specified, resurface cylinder block.
IMPORTANT: Make sure that the distance between

crankshaft centerline and cylinder block
top desk is within specifications (see
CRANKSHAFT BEARING CAP
REPLACEMENT in this group).
Also measure depth of liner
counterbores. Bore depth must be
within 5.955.99 mm (0.2340.236 in.). 10
17
CD,3274,G10,40 -19-18FEB92
BALANCER SHAFT BORE MEASURE

BALANCER SHAFT BORE SPECIFICATIONS
Bore diameter without

standard bushing . . . . . . . . . . . . . . . . . . . . 41.26241.288 mm
-UN-07MAR95
(1.62451.6255 in.)
Standard or oversize
bushing ID . . . . . . . . . . . . . . . . . . . . . . . . 38.17738.237 mm
(1.50301.5054 in.)
CD30157
If diameter with standard bushings is more than
specified, replace bushings. If cylinder block bore
(without bushing) is damaged or more than specified,
install oversize bushings.
CD,3274,G10,22 -19-18FEB92

060799
PN=78
BALANCER SHAFT BUSHING

REPLACEMENT
1. Drive unserviceable bushings out of cylinder block

using JD-249 bushing driver.
-UN-18JAN95
2. Drive new bushings into cylinder block using JD-249
bushing driver.
IMPORTANT: Make sure oil holes in bushing and
CD7114
cylinder block are aligned except for
engines without balancer shafts where
the bushings must be oriented (B) to
block the oil galleries (A).
NOTE: Bushing-to-balancer shaft clearance is correct if

shaft can be rotated by hand with a slight to
moderate drag.
-UN-10MAY95
AOil gallery
10 BBushing oriented to block oil gallery
18
CD30390
CD,3274,G10,43 -19-01FEB94

060799
PN=79
OVERSIZE BALANCER SHAFT BUSHING

INSTALLATION
IMPORTANT: The use of oversize balancer shaft

bushings on 4045 and 4039 engines
with bolt-on weights is not
recommended due to the rotating mass
of bolt-on weights compared to
thickness of balancer shaft web.
1. Check for cracked or broken cylinder block bosses.
2. Rebore cylinder block to dimensions given.
3. Chamfer front and middle bearing bores by 20-25

towards front of engine and rear bearing bore by 20-25
-UN-08MAR95
towards rear of engine to facilitate installation of the
bushings.
4. Check bores for smoothness or material defects after

10
CD30158
machining.
19
5. Install new oversize bushings.
A41.98542.035 mm (1.6531.655 in.)

B257.985258.035 mm (10.15710.159 in.)
C64.98665.036 mm (2.5582.560 in.)
D43.23743.263 mm (1.70151.7025 in.)
EReference dowel pin
CD,3274,G10,23 -19-20FEB92

060799
PN=80
CYLINDER LINER PROTRUSION MEASURE
IMPORTANT: First insert liners into bore without

seals to check the liner protrusion.
When correctly installed, liners can be
-UN-09DEC88
smoothly rotated by hand.
If, when inserted, the liners cannot be
rotated, remove liners and lap the liner
bottom pilot diameter until specified
free rotation is obtained.
L103013
1. Install liners without packing or O-rings and secure at
four points. Tighten screws to 100 Nm (74 lb-ft).
2. Measure liner protrusion at four points.
LINER PROTRUSION SPECIFICATIONS
Liner protrusion . . . . . . . . . . . . . . . . . . . . . . . . 0.010.10 mm
-UN-07MAR95
(0.00040.004 in.)
Maximum permissible difference between
adjacent cylinders . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
10
20 3. If the liner protrusion or permissible difference is
outside the specifications, apply lapping compound to
CD30199
liner flange shoulder in the block, then install liner and
turn to left and right using KCD10001 special tool to rub
off enough material to seat liner as necessary.
4. If protrusion is below specification, install one liner
shim under liner flange. Two sizes of shims are
available: 0.05 mm (0.002 in.) and 0.10 mm (0.004 in.).
IMPORTANT: ONLY ONE SHIM IS ALLOWED PER

CYLINDER. If liner requires more than
one shim, install either a new liner or
cylinder block.
CD,3274,G10,26 -19-01FEB94
LINER PACKING INSTALLATION
Apply lubricating soap to new packing and install over

liner until it contacts liner shoulder. Liner packing must
be compressed to a minimum of 0.13 mm (0.005 in.).
-UN-07MAR95
1Cylinder liner
2Packing
AImproper installation
BProper installation
CD7134
CD,3274,G10,27 -19-18FEB92

060799
PN=81
LINER O-RING INSTALLATION
Apply lubricating soap to new O-rings. Install O-rings in

respective grooves.
-UN-07MAR95
ARectangular section packing
BRed or white O-ring
CBlack O-ring
DCylinder liner
ECylinder block
CD7135
CD,3274,G10,28 -19-18FEB92
CYLINDER LINER INSTALLATION
NOTE: Recent cylinder liners are machined with a

shoulder on the lower guiding diameter (A).
Liners, up to machining code 848M stamped on
the outside have a shoulder radius of 0.8 mm
(0.03 in.) which may cause damage to liner seals 10
during installation. The 0.8 mm (0.03 in.) radius
21
has been changed then to 3 mm (0.13 in.)
allowing proper installation when using
KCD10001 tool.
1. On liners with 0.8 mm (0.03 in.) radius blunt the sharp

edge with a honing stone or emery cloth.
2. Slide liner together with shim (when needed) and

packing into its bore in cylinder block.
3. Seat liners using KCD10001 special tool.
-UN-22FEB99
4. Secure liners by means of large washers and cap
screws.
CD30707
-UN-04MAY98
CD30565
Installation with KCD10001
CD,3274,G10,29 -19-04JAN99

060799
PN=82
Cyl. Block, Liners, Pistons & Rods/Connecting rod
CONNECTING ROD BEARING MEASURE
NOTE: Before measuring, the cap screws of connecting

rod must be tightened according to specifications.
-UN-07MAR95
SPECIFICATIONS
Connecting rod bearing (assembled) ID:

3029, 4039, 6059 engines . . . . . . . . . . . . . 69.84869.898 mm
(2.74992.7519 in.)
4045, 6068 engines . . . . . . . . . . . . . . . . . 77.84777.897 mm
CD7120
(3.06483.0668 in.)
Crankshaft journal OD:
3029, 4039, 6059 engines . . . . . . . . . . . . . 69.79969.825 mm
(2.7482.749 in.)
4045, 6068 engines . . . . . . . . . . . . . . . . . 77.79877.824 mm
(3.0633.064 in.)
Maximum permissible
clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
-UN-07MAR95
If clearance is not within specifications, grind crankshaft
10 journals and select correct undersize bearings. Bearings
22 are available in 0.25, 0.50 and 0.76 mm (0.01, 0.02 and
0.03 in.) undersizes.
CD7121
NOTE: Crankshafts with rolled grooves (steel and cast
iron crankshafts) do not allow any more
regrinding operations. Undersized crankshafts will
be furnished by factory if available.
CD,3274,G10,3 -19-01FEB94
ROD BEARING CLEARANCE
Remove connecting rod cap. Place a piece of

Plastigage in the center of the bearing. Install cap and
tighten cap screws according to specifications.
-UN-21AUG92
Remove cap and compare the width of Plastigage with
scale provided on the side of package to determine
clearance.
RG6405
Max. permissible clearance: 0.16 mm (0.006 in.).
CD,3274,G10,1 -19-01FEB94

060799
PN=83
CONNECTING ROD BUSHING
NOTE: Depending on applications, engines may be

equipped with straight or tapered pin-end
connecting rods.
-UN-04MAY98
If diameter or clearance are more than specified below,
replace connecting rod/piston pin assembly for engines
with 32 mm (1.26 in.) piston pin diameter and replace
bushing on all other engines.
CD30566
SPECIFICATIONS
Straight pin-end
Rod pin bushing Internal Diameter:
Small pin . . . . . . . . . . . . . . . . . . . . . . 32.01032.036 mm
(1.26021.2612 in.)
Medium pin . . . . . . . . . . . . . . . . . . . . . 34.95034.976 mm
(1.3761.377 in.)
Large pin . . . . . . . . . . . . . . . . . . . . . . 41.30041.326 mm
(1.6261.627 in.)
-UN-04MAY98
Small pin . . . . . . . . . . . . . . . . . . . . . . . 0.0100.042 mm
10
(0.00040.0016 in.) 23
Medium pin . . . . . . . . . . . . . . . . . . . . . . 0.0200.056 mm
(0.00080.0022 in.)
CD30567
Large pin . . . . . . . . . . . . . . . . . . . . . . . 0.0070.043 mm
(0.00030.0017 in.)
Maximum . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) Tapered pin-end
CD,3274,G10,44 -19-04JAN99

060799
PN=84

REPLACEMENT (STRAIGHT PIN-END
CONROD EXCEPT SMALL PIN)
1. Push bushing out of connecting rod using following
-UN-18JAN95
tools:
JD-286 Driver for large pin on engines with straight
pin-end
JDE88 Driver for medium pin on engines with
straight pin-end
CD7122
2. Install new bushing using same tool as for removal.
Straight pin-end
IMPORTANT: Oil holes (A) MUST be aligned. If holes
are not aligned, remove and discard
bushing then re-install a NEW bushing.
DO NOT attempt to reuse a bushing.
3. Have the new bushing reamed by a specialized

workshop to obtain specified oil clearance with piston
10 pin.
24
CD,3274,G10,4 -19-04JAN99

060799
PN=85

REPLACEMENT (TAPERED PIN-END
CONROD)
Using JDG738 Connecting Rod Bushing Service Set,
-UN-10OCT94
proceed as follows.
1. Slide driver JDG738-1 (A) into one side of rod

bushing (C). Turn driver until taper on driver flange
matches up with taper on bushing.
RG7130
2. Install receiver cup JDG738-3 onto opposite side of
rod bushing.
NOTE: Stud in cup keeps rod properly located on the

cup. Use JDG738-2 pilot ring (B) as a hollow
spacer when pressing bushing out of rod.
3. Using hydraulic press, push bushing out of rod until

driver and bushing fall into receiver cup.
10
25
-UN-10OCT94
RG7131
CD,3274,G10,52 -19-04JAN99

060799
PN=86
-UN-10OCT94
RG7132
10
26 4. Slide bushing (A) onto JDG738-1 driver (B) and 5. Apply TY6333 grease* to:
install JDG738-2 pilot ring (C) onto O-ring end of Outside diameter of bushing
driver. Outside diameter of pilot ring
Inside diameter of rod pin bore
*Available as service part. CD,CTM125,079 -19-01DEC97
6. Insert driver into rod pin bore so pilot ring pilots in rod
bore and bushing taper aligns with taper on driver
flange. Align oil hole in bushing (D) with oil hole in end
of rod (E).
7. Install JDG738-3 receiver cup (F) onto opposite side

of rod so taper on rod aligns with taper on receiver cup.
8. Press bushing into rod until edge of bushing is flush

machined surface on connecting rod face.
-UN-10OCT94
IMPORTANT: Oil holes MUST be aligned. If holes are
not aligned, remove and discard
bushing then re-install a NEW bushing.
DO NOT attempt to reuse a bushing.
RG7236
9. Have the new bushing reamed by a specialized

workshop to obtain an oil clearance of 0.020 to 0.056
mm (0.0008 to 0.002 in.) with piston pin.
CD,CTM125,063 -19-01DEC97

060799
PN=87
Cyl. Block, Liners, Pistons & Rods/Piston
MEASURE PISTON PIN

SPECIFICATIONS
Piston pin outside diameter:

Small pin . . . . . . . . . . . . . . . . . . . . . . . 31.99432.000 mm
-UN-07NOV88
(1.25961.2598 in.)
Medium pin . . . . . . . . . . . . . . . . . . . . . . . 34.9234.93 mm
(1.37481.3752 in.)
Large pin . . . . . . . . . . . . . . . . . . . . . . . . 41.2741.28 mm
(1.62481.6252 in.)
T81604
Small pin . . . . . . . . . . . . . . . . . . . . . . . . 0.0100.042 mm
(0.00040.0016 in.)
Medium pin . . . . . . . . . . . . . . . . . . . . . . . 0.0200.056 mm
(0.00080.0022 in.)
Large pin . . . . . . . . . . . . . . . . . . . . . . . . 0.0070.043 mm
(0.00030.0017 in.)
Maximum . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
If diameter is less or clearance is more than specified,

replace connecting rod/piston pin assembly for emgines 10
with small piston pin and replace pin or pin/bushing 27
assembly for all other engines.
CD,3274,G10,11 -19-04JAN99
PISTON CLEANING
Clean pistons, using a commercial cleaner and a jet

rinse gun or glass bead blasting machine.
N CAUTION: Follow manufacturers instruction

exactly. DO NOT ALLOW CHEMICAL TO COME
INTO CONTACT WITH SKIN OR EYES ;
chemical contains creosols which can be very
harmful.
CD,3274,G10,5 -19-18FEB92

060799
PN=88
MEASURE PISTON PIN BORE

SPECIFICATIONS
Bore for small pin . . . . . . . . . . . . . . . . . . . 32.00332.013 mm

(1.26001.2603 in.)
-UN-03AUG92
Bore for medium pin . . . . . . . . . . . . . . . . . 34.93334.943 mm
(1.37531.3757 in.)
Bore for large pin . . . . . . . . . . . . . . . . . . . 41.28541.295 mm
(1.62541.6258 in.)
RG6283
NOTE: Some piston pin bores are elliptical, the width
being 0.038 mm (0.0015 in.) larger than the bore
specifications.
If bore is not within specifications, replace piston/liner

set.
CD,3274,G10,50 -19-04JAN99
10
28
PISTON TOP RING GROOVE
Depending on engine configuration, two wear gauges

can be used to check wear of top compression ring
groove.
-UN-31OCT97
Use JDE62 wear gauge (for 15 angle):
on engines for following applications
3029DF001, DF031
3029TF001, TF031 ( -264812CD)
RG4746
3029DF120, DF160 ( -263023CD)
3029TF120, TF160 ( -287525CD)
3029TLV01 ( -261580CD)
3029DRT65
APiston can be used again
Use JDG957 wear gauge (for 6 angle): BDiscard piston and replace
on all other engines CJDG957 or JDE62 Gauge
DTool shoulder-to-ring land clearance
CD,3274,G10,6 -19-04JAN99

060799
PN=89
SECOND AND THIRD PISTON RING

GROOVES
Use a new piston ring and feeler gauge. Ring groove

clearance must not exceed 0.20 mm (0.008 in.).
-UN-28MAR90
If clearance exceeds specification, install a new piston.
RG5625
CD,3274,G10,7 -19-18FEB92
PISTON HEAD AND SKIRT CHECKING
Check piston for scuffing, scoring, or signs of

overheating.
-UN-10MAY95
Measure piston diameter 19 mm (0.74 in.) from bottom
of skirt and 90 from piston pin. 10
29
Compare measurement with Specifications.
CD30391
CD,3274,G10,8 -19-01FEB94
PISTON RING IDENTIFICATION
Depending on engine configuration, piston rings no.1 and

2 are different.
-UN-21AUG92
On following engines, compression rings (no.1 and 2)
may have either one or two depression marks (A) or a
TOP mark stamped on the top side of rings.
- 3029DF001..., DF031...
- 3029TF001..., TF031... ( -264812CD)
RG6400
- 3029DF120..., DF160... ( -263023CD)
- 3029TF120..., TF160... ( -287525CD)
- 3029TLV01 ( -261580CD)
- 3029DRT65
ADepression marks
On all other engines, no.1 compression ring has a blue BTOP mark
CYellow or blue dye mark
dye mark (C) and no.2 ring a yellow dye mark on the
face of the ring. Dye marks must be on the left side of
ring gap as shown.
CD,3274,G10,53 -19-04JAN99

060799
PN=90
INSTALL PISTON RINGS
-UN-04MAY98
-UN-16JUN98
CD30568
CD30569
Use KJD10140 or any other suitable piston ring
expander for a proper installation and to prevent any
damage to the piston.
10 1. Install oil control ring (C) in bottom ring groove over

30
-UN-04MAY98
ring expander. Be sure that the ring expander and the
wire are correctly fitted.
2. Install second ring (B) in center ring groove according

to identification mark. For ring with dye mark, proper
CD30570
installation is obtained when the yellow dye mark (F) is
at 7 oclock when end gap is at 6 oclock.
3. Install top ring (A) in top ring groove according to

identification mark. For ring with dye mark, proper ATop ring
installation is obtained when the blue dye mark (E) is at BSecond ring
COil control ring
7 oclock when end gap is at 6 oclock.
DKJD10140 Piston Ring Expander
EBlue mark
FYellow mark
CD,3274,G10,54 -19-04JAN99
PISTON RINGS STAGGERING
Stagger piston rings as shown opposite.
APiston head
-UN-23FEB89
BTop compression ring gap

COil control ring gap
DExpander ring gap
EBottom compression ring gap
FFront of engine
CD5781
CD,3274,G10,15 -19-18FEB92

060799
PN=91
Cyl. Block, Liners, Pistons & Rods/Piston & connecting rod assembly
PISTON/LINER SET INFORMATION
Service piston is available only as an assembly

including:
Liner (A)
Piston (B)
Piston ring set (C)
Liner seal set (D)
NOTE: Liner, piston ring set and liner seal set are
-UN-16JUN98
available separately.
Piston/Liner sets may be packaged in an anti-corrosion

bag and therefore are not coated with oil or grease.
Before to open the bag, be sure that the parts will be
CD30579
installed immediately to prevent any risk of getting
corroded parts.
CD,CTM125,080 -19-01DEC97
10
31
PISTON AND CONNECTING ROD
ASSEMBLY
NOTE: Pistons must be installed on connecting rods

from which they were removed.
-UN-28MAR90
1. Assemble pistons and connecting rods, making sure
the word FRONT (A) on the side or top of the piston
and on the side of the connecting rod are on the same
side.
RG5627
IMPORTANT: If FRONT is not visible on side or top
of piston, install piston on rod so that
offset in combustion bowl of piston is
opposite camshaft side of engine. The
long side of the connecting rod should
face camshaft side of block.
-UN-18JAN95
2. Coat piston pin (B) with engine oil and insert it
through piston and connecting rod bores. Install NEW
piston pin retaining rings (C) with sharp edge of ring
facing away from piston pin. Make sure retaining rings
are seated correctly in their grooves.
CD30006
1Camshaft side
2Centerline of liner bore
3Combustion chamber offset
CD,3274,G10,12 -19-18FEB92

060799
PN=92
Cyl. Block, Liners, Pistons & Rods/Piston & connect. rod installation
PISTON AND CONNECTING ROD

INSTALLATION
NOTE: Pistons must be installed in the cylinder liner

from which they were removed.
-UN-18JAN95
1. Coat pistons and rings with clean engine oil. Install
pistons in liners, using JDE84 piston ring compressor.
NOTE: Make sure that FRONT mark (A) on the top of
CD7129
each piston faces toward front end of cylinder
block.
2. Push piston down until top ring is in liner.
3. Install bearing inserts, making sure small tangs (B) on

each half of the inserts fit in recess of rod and cap.
-UN-18JAN95
4. Install cap so that large slot in cap (C) fits large tang
(D) on connecting rod.
10
32 5. Dip NEW connecting rod cap screws in clean oil and
tighten them alternately to following torques:
CD7130
IMPORTANT: NEVER use connecting rod cap screws
more than once.
3029, 4039 and 6059 engines:

Initially tighten cap screws to 56 Nm (40 lb-ft)
4045 and 6068 engines:

Initially tighten cap screws to 66 Nm (50 lb-ft)
6. Torque-turn all cap screws 90100 degrees. (See

next module).
CD,3274,G10,16 -19-20FEB92

060799
PN=93
Cyl. Block, Liners, Pistons & Rods/Torque-turn method
TORQUE-TURN METHOD
1. Position the wrench parallel to engine axis (A).
2. Tighten until the wrench is perpendicular to engine
-UN-08MAR95
axis (B).
3. Check for proper side clearance in all rods. Each rod

SHOULD HAVE slight side-to-side movement.
CD30239
-UN-08MAR95
10
33
CD30240
CD,3274,G10,41 -19-01FEB94

060799
PN=94
Cyl. Block, Liners, Pistons & Rods/Final verifications
PISTON PROTRUSION MEASURE
NOTE: Press down on top of piston to remove

clearances before measuring piston protrusion.
-UN-15NOV88
1. Place KJD10123 Gauge (with flat side up) on cylinder
block so that indicator point rests on block surface.
2. Set dial indicator at zero.
L103012
3. While pressing gauge downward, turn crankshaft until
piston is at TDC position.
4. Piston protrusion should not exceed 0.25 mm

(0.010 in.) when KJD10123 is used.
NOTE: If KJD10123 Gauge is not available, use a dial

indicator. In this case, the piston protrusion
-UN-07FEB95
should not exceed 0.35 mm (0.014 in.).
10 5. If protrusion is out of specifications, check all

34 concerned parts to determine the cause.
CD30005
1Centerline of cylinder liner bore
2Piston at TDC
CD,3274,G10,10 -19-01FEB94
FINAL VERIFICATIONS
1. Rotate crankshaft several revolutions to be sure

engine rotates without excessive tightness.
2. Check liners for deep scratches which would indicate

an improperly installed or broken piston ring.
3. Check for proper side clearance in all rods. Each rod

SHOULD HAVE slight side-to-side movement.
CD,3274,G10,30 -19-18FEB92

060799
PN=95
Cyl. Block, Liners, Pistons & Rods/Complete final assembly
COMPLETE FINAL ASSEMBLY
1. Re-install all components previously removed. Apply

following recommendations then perform engine test as
described in Final Work in Group 05.
2. Cylinder block has some orifices which are in relation

either with the lubrication or cooling system. When
re-assembling an engine, be sure that coolant lines are
connected to corresponding coolant ports and oil lines to
oil ports. Apply torques as indicated.
NOTE: From engine serial number (121942CD- ), the
-UN-16JUN98
plugs for oil holes (D) are coated with sealant
and can be reused several times without addition
of sealing compound.
CD30576
Plug or fitting torques
ACoolant drain (1/4) . . . . . . . . . . . ...... . . . . 17 Nm (13 lb-ft)
BTurbocharger oil return (1/2) . . . . ...... . . . . 45 Nm (33 lb-ft)
C1/2 cyl. for dipstick tube . . . . . . . ...... . . . . 67 Nm (50 lb-ft) Front right view (3 cyl. shown)
DOil galleries (1/8) . . . . . . . . . . . . ...... . . . . 17 Nm (13 lb-ft) 10
E1/4 Coolant gallery (side) . . . . . . ...... . . . . 17 Nm (13 lb-ft) 35
FRear Coolant gallery (1) . . . . . . . ...... . . . . 45 Nm (33 lb-ft)
GOil gallery (3/8) . . . . . . . . . . . . . ...... . . . . 45 Nm (33 lb-ft)
K1-5/8 coolant gallery (side):
Steel plug ( -379251CD) . . . . . . . . . . . . . . 60 Nm (44 lb-ft)
Composite material plug
(379252CD- ) . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
NOTE: If during the tightening phase the composite

material plug (K) is broken, it can be removed
using lock-pliers after having applied two flat
faces on opposite sides of it.
3. Be sure that piston cooling jets (H) and, when
-UN-16JUN98
needed, oil gallery steel caps (J) are installed.
CD30577
Rear left view (3 cyl. shown)
-UN-22FEB99
CD30708
CD,3274,G10,51 -19-04JAN99

060799
PN=96
Cyl. Block, Liners, Pistons & Rods/Complete final assembly
4. Service cylinder block may have additional side

mounting bosses (A). In case where these bosses
interfere with the chassis or other machine components,
grind concerned area.
IMPORTANT: Be sure, when grinding, that particles
-UN-10DEC96
do not enter dipstick hole (B).
CD551P1
CD,CTM125,076 -19-01DEC97
10
36
5. Oil gallery ball (A) is provided with service cylinder
block, but may not be installed. In this case, proceed as
follows:
Put ball (A) in oil passage (B).
Drive in ball using an appropriate driver (C) until ball
bottoms.
Check for proper installation. The distance between
pan rail and top of ball should be approximatively 54 mm
(2.16 in.).
-UN-07NOV96
CD551P5
CD,CTM125,077 -19-01DEC97

060799
PN=97
Group 15
Crankshaft, Main Bearings and Flywheel

ES107506 -UN-07MAR95
Dial indicator . . . . . . . . . . . . . . . . . . . . . FKM10103

(Part of KJD10123 Piston/Liner height gauge)
To be used with a magnetic base.
CD,FKM10103 -19-01FEB94
RG5109 -UN-23AUG88
Slide hammer seal puller . . . . . . . . . . . . . . . . JDG22
Used to remove seal.
CD,JDG22 -19-01MAR92
RG5112 -UN-06APR89
Vibration Damper Puller Set . . . . . . . . . . . . . JDG410
Remove vibration damper and pulley. 15

1
JDG410 -19-09APR92
CD30241 -UN-08MAR95
Rear crankshaft wear sleeve puller . . . . . . . JDG645E
Remove wear sleeve from rear crankshaft flange.
CD,JDG645E -19-01MAR92
JDG794 -UN-10MAY95
Crankshaft gear driver . . . . . . . . . . . . . . . . JDG794A

(Formerly JDH7 or JDG794)
Install gear on crankshaft.
NOTE: JDG794A consists of JDG794 and JDG794A-1

longer screw.
CD,JDG794A -19-04JAN99

060799
PN=98
Crankshaft, Main Bearings and Flywheel/Special tools
CD30709 -UN-22FEB99
Oil seal/Wear sleeve installer set . . . . . . . KCD10002A

(Formerly KCD10002)
Install rear crankshaft oil seal/wear sleeve assembly.
CD,KCD10002A -19-04JAN99
KJD10206 -UN-19JUN95
Crankshaft pulley puller . . . . . . . . . . . . . . . KJD10206
Remove crankshaft pulley without threaded holes on

6000-Series tractors.
NOTE: This tool can be also self-manufactured (see

drawing in this group).
15
2
CD,KJD10206 -19-01FEB94

060799
PN=99
Crankshaft, Main Bearings and Flywheel/Self-Manufactured Tools
SELF-MANUFACTURED TOOL
PULLER FOR CRANKSHAFT PULLEY W/O THREADED HOLES
-UN-10MAY95
15
3
CD30434
ASteel plate dia. 110 mm CM20 Threaded rod, EWeld H8 mm (0.31 in.)
(4.33 in.), 15 mm (0.59 200 mm (7.87 in.) length F38 mm (1.50 in.) I30 mm (1.18 in.)
in.) thick DM20 Nut G8 mm (0.31 in.) J15 mm (0.59 in.)
BSteel hook (4 used)
CD,3274,G15,40 -19-01FEB94

060799
PN=100
Crankshaft, Main Bearings and Flywheel/Specifications
SPECIFICATIONS
Max. vibration damper radial run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.06 in.)
Max. vibration damper wobble (outer ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.06 in.)
Max. vibration damper wobble (inner ring)

(engine with front PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.02 in.)
Max. pulley wobble (engine with front PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.02 in.)
Crankshaft end play:

Engine with 2-piece thrust bearing . . . . . . 0.130.40 mm (0.0050.016 in.) 0.50 mm (0.02 in.)
Engine with 5/6-piece thrust bearing* . . . . 0.030.35 mm (0.0010.014 in.) 0.50 mm (0.02 in.)
Oversize thrust washers available . . . . . 0.18 mm (0.007 in.)
Crankshaft main journals OD (Std.) . . . . . . 79.32479.350 mm (3.1233.124 in.)
Taper . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.) 0.03 mm (0.0012 in.)

15
4 Out-of-roundness . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.) 0.075 mm (0.003 in.)
Main bearings assembled ID (Std.) . . . . . . 79.39679.440 mm (3.1263.127 in.)
Crankshaft to main bearing clearance . . . . . 0.0460.116 mm (0.00180.0046 in.) 0.15 mm (0.006 in.)
Undersize bearing available . . . . . . . . . . . 0.25, 0.50 and 0.76 mm

(0.01, 0.02 and 0.03 in.)
*Standard thrust washer sets for service contain now 4 thrust washers
instead of 3 currently installed by the factory and previously included in
service sets. CD,3274,G15,29 -19-01FEB94

060799
PN=101
Crankshaft, Main Bearings and Flywheel/Specifications
Crankshaft conrod OD (Std.)

3029, 4039, 6059 engines . . . . . . . . . . 69.79969.825 mm (2.7482.749 in.)
4045, 6068 engines . . . . . . . . . . . . . . . 77.79877.824 mm (3.0633.064 in.)
Taper . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.) 0.03 mm (0.0012 in.)
Out-of-roundness . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.) 0.075 mm (0.003 in.)
Crankshaft OD for front pulley . . . . . . . . . . 37.98838.014 mm (1.49561.4966 in.)
Specifications for grinding purposes:

Crankshaft fillet radii
on main journals (all engines) . . . . . . 3.74.0 mm (0.1460.156 in.)
on rod journals (3029,4039,6059) . . . 4.24.4 mm (0.1650.175 in.)
(4045, 6068 engines) . . . . . . . . . . . 3.74.0 mm (0.1460.156 in.)
Grinding surface finish (C.L.A.*)

Main and connecting rod journals . . . 0.2 micron (8 micro-in.)
Thrust faces . . . . . . . . . . . . . . . . . 0.4 micron (16 micro-in.)
15
5
* C.L.A. (Center Line Average) corresponds to a measure of surface

texture. CD,3274,G15,30 -19-01MAR92

060799
PN=102
Crankshaft, Main Bearings and Flywheel/Torques for hardware
Main bearing caps

( 135640) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm (85 lb-ft)
(135641 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Nm (100 lb-ft)
Damper/pulley to crankshaft (engine without

crankshaft gear-driven aux. drive):
45 mm (1.77 in.) bolt length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft)
112 mm (4.41 in.) bolt length (lubricated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft)
plus 60 angle
Damper/pulley to crankshaft (engine with

crankshaft gear-driven aux. drive):
plus 60 angle
Collet to crankshaft (engine with front PTO):

plus 60 angle
15 Damper/pulley to collet (engine with front PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm (25 lb-ft)
6
Flywheel to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm (120 lb-ft)
Flywheel housing to block:

3/8 in. cap screws on 3000/3010-Series tractors:
( -244461CD)
1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (23 lb-ft)
2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
(244462CD- ) Cap screws lubricated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm (50 lb-ft)
3/8 in. cap screws on other applications:
1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (23 lb-ft)
2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
5/8 in. cap screws on 3000/3010 Series tractors:
( -244461CD) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Nm (235 lb-ft)
(244462CD- ) Cap screws lubricated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm (150 lb-ft)
Plus 45 angle
5/8 in. cap screws on other applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Nm (170 lb-ft)
CD,3274,G15,31 -19-04JAN99

060799
PN=103
Crankshaft, Main Bearings and Flywheel/Pulley (without front PTO)
VIBRATION DAMPER CHECKING

(ENGINE WITHOUT FRONT PTO)
NOTE: When cleaning torsion damper never soak in a

cleaning solvent. Use a steam cleaner, soap
solution or water only.
1. Measure total run-out (a) and wobble (b) of torsion
-UN-24APR89
damper outer ring. Compare with specifications.
2. Replace torsion damper if total run-out or wobble

exceeds specifications, or if outer ring has slipped
relative to rubber member or drive hub.
L30721
3. Grasp torsion damper and attempt to turn in both
directions (clockwise and counter-clockwise). If rotation is
felt, replace damper.
IMPORTANT: Replace torsion damper after 4500

hours of operation or every five years,
whichever occurs first.
15
7
CD,3274,G15,1 -19-01FEB94
PULLEY OR VIBRATION DAMPER REMOVAL
IMPORTANT: Handle damper with care. Never apply

thrust to outer ring of damper.
Damper is sensitive to such impacts as
-UN-23MAY95
being dropped or struck with a
hammer. Such impact damage can
impair damper function.
1. Remove pulley/vibration damper attaching cap screw.
CD7258
2. Using JDG410 Puller or KJD10206 (A) for pulley
without threaded holes, remove vibration damper or
pulley from crankshaft. -UN-10MAY95
CD30435
Pulling with KJD10206
CD,3274,G15,2 -19-04JAN99

060799
PN=104
Crankshaft, Main Bearings and Flywheel/Pulley (without front PTO)
PULLEY OR VIBRATION DAMPER

INSTALLATION
NOTE: 3 cylinder crankshaft pulleys and flywheels are

unbalanced and therefore are not interchangeable
-UN-16JUN98
with 4 or 6 cyl. engine parts. Several unbalance
values are used, take care not to mix parts.
Refer to relevant Parts Catalogs to order
appropriate parts.
CD30581
1. Install shaft key (A) on crankshaft.
2. Position pulley or vibration damper on crankshaft nose

with washer (B) and cap screw (C).
2. Tighten as follows:
TORQUE SPECIFICATIONS
45 mm (1.77 in.) bolt

length (dry) . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft)
112 mm (4.41 in.) bolt
length (lubricated) . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft)
plus 60 angle
15
8
CD,3274,G15,3 -19-04JAN99

060799
PN=105
Crankshaft, Main Bearings and Flywheel/Pulley (with front PTO)
VIBRATION DAMPER OR PULLEY

CHECKING
(ENGINE WITH FRONT PTO)
NOTE: When cleaning torsion damper, never soak in a
-UN-07MAR95
cleaning solvent. Use a steam cleaner, soap
solution or water only.
1. Prior to disassembly, check the following

specifications:
CD7260
SPECIFICATIONS
Vibration damper only

Max. total run-out (A) . . . . . . . . . . . . . . . 1.50 mm (0.06 in.)
Max. wobble (B) . . . . . . . . . . . . . . . . . . 1.50 mm (0.06 in.)
Vibration damper or pulley

Max. wobble (C) . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.)
-UN-07MAR95
2. Replace torsion damper if total run-out (A) or wobble
(B) exceeds specifications, or if outer ring has slipped
relative to rubber member or drive hub.
CD7261
3. Grasp torsion damper and attempt to turn in both 15
directions (clockwise and counter-clockwise). If rotation is
9
felt, replace damper.
4. If wobble (C) exceeds specifications, it indicates

improper mating of tapered surfaces due to uneven
tightening of collet cap screws or damage to one or both
-UN-07MAR95
the tapered surfaces.
IMPORTANT: Replace torsion damper after 4500

hours or every five years, whichever
occurs fist.
CD7262
CD,3274,G15,4 -19-01MAR92

060799
PN=106
VIBRATION DAMPER OR PULLEY REMOVAL

1. Remove the eight cap screws (A) attaching damper or

pulley to collet.
2. Using a wooden block and a hammer, tap on inner

damper ring or pulley until it loosens from conical seat of
collet.
IMPORTANT: Never tap or apply thrust to outer ring

of torsion damper.
-UN-22FEB99
3. Remove collet attaching cap screw (B).
4. Remove collet and damper or pulley.
ACap screw (Qty: 8)
CD30710
BCap screw
CPulley
DCollet drive
EWear sleeve
FO-ring
GCrankshaft
HGear
15 JOil deflector
10 KFront oil seal
LTiming gear cover
-UN-05OCT94
CD30008
CD,3274,G15,5 -19-04JAN99

060799
PN=107
VIBRATION DAMPER OR PULLEY

INSTALLATION
1. Lightly oil tapered surfaces of collet and damper or
-UN-10MAY95
pulley.
2. Position collet in damper or pulley. Install both cap

screws (A) 180 apart to keep collet with the damper or
pulley.
CD30395
3. Install collet/damper or collet/pulley assembly on the
crankshaft with washer and cap screw (B).
4. For 3-cylinder engines only, put cylinder No._1 at

TDC then turn pulley/collet assembly so that external
groove mark (C) on pulley is aligned with TDC reference
mark on timing cover (D).
-UN-05OCT94
5. Tighten collet retaining cap screw (B) as follows:
45 mm (1.77 in.) bolt

CD30160
112 mm (4.41 in.) bolt
length (lubricated) . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft) 15
plus 60 angle 11
6. Tighten the two collet cap screws (A) alternately and
evenly to a final torque of 35 Nm (25 lb-ft).
7. Install remaining six collet cap screws. Again

alternately and evenly tighten the two cap screws 90
from the first two cap screws to 35 Nm (25 lb-ft).
Tighten the remaining cap screws to 35 Nm (25 lb-ft).
Always tighten collet cap screws in pairs opposite each
other.
8. Repeat the collet cap screw tightening sequence until

all the cap screws have been tightened to the specified
torque of 35 Nm (25 lb-ft).
9. Check damper/pulley wobble to ensure that tapered

surfaces are mated correctly.
CD,3274,G15,6 -19-04JAN99

060799
PN=108
Crankshaft, Main Bearings and Flywheel/Flywheel
INSTALL VIBRATION DAMPER OR PULLEY

(ENGINE WITH CRANKSHAFT-GEAR-DRIVEN
AUX. DRIVE)
1. Install shaft key (F) in crankshaft.
-UN-13MAY98
2. Clean and lubricate crankshaft nose and bore of
pulley/damper.
3. Install pulley/damper on crankshaft. Place washer (B),
CD630P3
with flat side toward engine, and cap screws.
NOTE: Depending on equipment, the special washer (H)

may be used along with O-ring (J). In this case,
O-ring (D) is not needed. ACap screw
BWasher
4. Tighten cap screw as follows: CCollet
DO-Ring
EAuxiliary drive gear
45 mm (1.77 in.) bolt
FShaft key
HSpecial washer
112 mm (4.41 in.) bolt
JO-ring
length (lubricated) . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft)
plus 60 angle
15
12
CD,3274,G15,41 -19-04JAN99
FLYWHEEL REMOVAL
N CAUTION: Flywheel is heavy. Plan a proper

lifting procedure to avoid personal injury.
-UN-02APR90
1. Remove two cap screws and install guide studs in
their place (shown installed) then remove the other cap
screws.
2. Install two 1/2-13UNC or M10 cap screws (length

RG5632
100 mm/4 in.) into the threaded holes (A) to push

flywheel off crankshaft and to facilitate flywheel handling.
NOTE: Flywheel may not have the handling threaded

holes (A). In this case, install two cap screws into
clutch system threaded holes then, using a soft
hammer, gently tap on flywheel to unstick it.
CD,CTM125,088 -19-01DEC97

060799
PN=109
Crankshaft, Main Bearings and Flywheel/Flywheel
FLYWHEEL RING GEAR REPLACEMENT
1. Drive ring gear off with a brass drift and hammer.
2. Heat new ring gear to 150C (300F) using either
-UN-14OCT88
heated oil, oven heat, or flame heat.
N CAUTION: Oil fumes or oil can ignite above

190 C (380F). When heating ring gear, use a
thermometer and do not exceed 180C (360F).
T90596
Heat the oil in a well ventilated area. Plan a
safe handling procedure to avoid burns.
IMPORTANT: If flame is used to heat ring gear, be

sure gear is heated uniformly around
circumference.
-UN-14OCT88
3. Tap heated ring gear into place against flywheel
shoulder. Chamfered edge of teeth (A) must be toward
engine.
NOTE: Be sure complete ring gear circumference is flush
RG3838
against shoulder of flywheel.
15
13
CD,3274,G15,8 -19-01MAR92
BALL BEARING INSTALLATION
Some flywheels may have a ball bearing (A) and

possibly a positioning shim (B) to be installed with
flywheel removed from engine.
-UN-05OCT94
1. Press ball bearing into flywheel until it bottoms.
2. If required, install the positioning shim against ball

bearing.
CD30251
NOTE: The positioning shim must be installed between

ball bearing and crankshaft flange.
CD,3274,G15,35 -19-01MAR92

060799
PN=110
Crankshaft, Main Bearings and Flywheel/Crankshaft wear sleeve
FLYWHEEL INSTALLATION
NOTE: 3 cylinder flywheels and crankshaft pulleys are

unbalanced and therefore are not interchangeable
with 4 or 6 cyl. engine parts. Several unbalance
-UN-07MAR95
values are used, take care not to mix parts.
Refer to relevant Parts Catalogs to order
appropriate parts.
1. Install two guide studs in crankshaft.
CD7140
2. Place flywheel on studs and slide into position against
crankshaft.
IMPORTANT: Always replace flywheel cap screws

when flywheel has been removed.
3. Install cap screws and tighten crosswise to 160 Nm

(120 lb-ft).
15
14
CD,3274,G15,9 -19-04JAN99
CRANKSHAFT WEAR SLEEVE REMOVAL
1. Place and center JDG645E cap screws and driver

plate assembly onto crankshaft rear face. Then, using
snap ring pliers, set the thinner shoulder of ring tool
-UN-06MAR95
between sleeve flange and seal case.
2. Secure the assembly with a clamp then gradually

tighten the screw until wear sleeve is extracted.
CD30243
-UN-06MAR95
CD30244
CD,3274,G15,11 -19-01MAR92

060799
PN=111
Crankshaft, Main Bearings and Flywheel/Crankshaft wear sleeve
CRANKSHAFT WEAR SLEEVE REMOVAL

(CONTD)
3. Cut the rubber lip now accessible and remove it.
-UN-10MAY95
4. Using a punch and a hammer, tap the seal case
toward engine at any location until seal case pivots.
5. Using JDG22 Slide Hammer Puller, extract seal case.
CD30396
-UN-10MAY95
CD30397
15
15
-UN-06MAR95
CD30247
CD,3274,G15,32 -19-01FEB94

060799
PN=112
Crankshaft, Main Bearings and Flywheel/Flywheel housing replacement
FLYWHEEL HOUSING REPLACEMENT
N CAUTION: Flywheel housing weighs 20 to

40 kg (43 to 86 lb).
-UN-23MAY95
1. Remove flywheel and oil pan.
2. Remove the eight 3/8 in. cap screws (A) and the four
5/8 in. cap screws, then remove flywheel housing.
CD7141
3. Clean mating surfaces and install new gasket (C).
4. Install flywheel housing with the eight 3/8 in. cap

screws (A). Tighten as follows:
3000/3010-Series tractors with engines
( -244461CD):
1st stage . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (23 lb-ft)

2nd stage . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
-UN-16JUN98
(244462CD- ):
Cap screws lubricated . . . . . . . . . . . . . . . . . 70 Nm (50 lb-ft)

Other applications:
15
CD30585
16 1st stage . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (23 lb-ft)
2nd stage . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
5. Install the four 5/8 in. cap screws (B) then tighten as
follows:
( -244461CD):
Cap screws dry . . . . . . . . . . . . . . . . . . . . . . 320 Nm (235 lb-ft)

(244462CD- ):
Cap screws lubricated . . . . . . . . . . . . . . . . . 200 Nm (150 lb-ft)

plus 45 angle
Other applications:
Cap screws dry . . . . . . . . . . . . . . . . . . . . . . 230 Nm (170 lb-ft)
NOTE: On certain applications, the open holes need to

be obturated. Apply sealing compound on threads
of cap screws.
CD,3274,G15,12 -19-04JAN99

060799
PN=113
Crankshaft, Main Bearings and Flywheel/Oil seal/wear sleeve installation
OIL SEAL/WEAR SLEEVE INSTALLATION
NOTE: Due to a diameter change of the crankshaft bore,

it may be necessary to suppress the pilot pin (A)
from KCD10002 tool. With this modification
-UN-16JUN98
KCD10002 becomes KCD10002A.
1. Apply a light coating of sealant compound (Loctite 609

or equivalent) on crankshaft end.
CD30586
2. Position the guide plate (A) from KCD10002A tool set
over dowel with two cap screws. Finger tighten both cap
screws until they contact the pilot.
3. Using the oil seal/wear sleeve assembly with open

side toward engine, center the guide plate and tighten
the two cap screws.
-UN-18JAN95
4. Slide driver (B) onto guide and gradually tighten nut
until driver bottoms.
CD7142
15
17
-UN-18JAN95
CD7143
CD,3274,G15,14 -19-04JAN99

060799
PN=114
Crankshaft, Main Bearings and Flywheel/Crankshaft
CRANKSHAFT END PLAY MEASURE
NOTE: It is recommended to measure crankshaft end

play prior to removing crankshaft to determine
condition of thrust bearings.
-UN-07MAR95
Check crankshaft end play using a dial indicator and
compare with specifications.
IMPORTANT: Do not apply too much pressure with
CD7144
bar as this could damage bearing
inserts.
If end play is still not within specification with new

standard 2-piece or 5/6-piece thrust bearings*, install a
5-piece thrust bearing with oversized thrust washers.
NOTE: Oversized thrust bearing set contains three
-UN-07MAR95
0.18 mm (0.007 in.) oversized thrust washers to
be installed as shown.
AOversized thrust washers

BFront of engine
CD30220
CRear bearing cap side
15
18
CRANKSHAFT REMOVAL
1. Identify main bearing caps to assure correct

placement during reassembly.
-UN-01NOV88
2. Attach nylon slings (or other suitable lifting slings) to
journals of crankshaft or to cap screws installed on both
ends of crankshaft.
3. Carefully lift crankshaft out of cylinder block.

T81184
CD,3274,G15,18 -19-01FEB94

060799
PN=115
CRANKSHAFT IDENTIFICATION
Crankshafts can be made of steel (C) or cast iron (D).
Cast iron crankshafts have rolled grooves (B) while steel
-UN-08MAR95
crankshafts may have machined fillet radii (A) or rolled
grooves.
ACrankshaft with fillet radii

BCrankshaft with rolled grooves
CD30248
CSteel crankshaft
DCast iron crankshaft
-UN-17FEB95
CD30337
15
19
CD,3274,G15,36 -19-01FEB94
CRANKSHAFT INSPECTION
1. Clean crankshaft thoroughly, especially oil passages

from crankshaft bearings to connecting rod bearings.
-UN-23FEB89
2. Check crankshaft for cracks or signs of load stress
(see illustration for critical areas of load stress in a
crankshaft).
3. Inspect both shoulders of thrust bearing journal for
CD7147
scores or unevenness.
CD,3274,G15,19 -19-01MAR92

060799
PN=116
JOURNAL OD CHECK
Measure OD of all crankshaft journals at several points

around journal and compare with specifications.
-UN-07MAR95
CRANKSHAFT JOURNAL OD SPECIFICATIONS
Main journal OD (Std.) . . . . . . . . . . . . . . . . 79.32479.350 mm

(3.1233.124 in.)
Rod journal OD (Std.)
CD7148
3029, 4039, 6059 engines . . . . . . . . . . . . 69.79969.825 mm
(2.7482.749 in.)
4045, 6068 engines . . . . . . . . . . . . . . . . 77.79877.824 mm
(3.0633.064 in.)
Maximum wear
Taper . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.0012 in.)
Out-of-roundness . . . . . . . . . . . . . . . . . 0.075 mm (0.003 in.)
If journal OD is not within specifications regrind or

replace crankshaft.
15
20
CD,3274,G15,20 -19-01MAR92

060799
PN=117
MAIN BEARING CLEARANCE
1. Install main bearing inserts and caps then tighten cap

screws to 120 Nm (85 lb-ft) for engines prior to serial
number 135641CD and to 135 Nm (100 lb-ft) for other
-UN-07MAR95
engines.
2. Measure I.D. of main bearing (assembled) and

compare with specification.
CD7149
MAIN BEARINGS (ASSEMBLED) ID SPECIFICATIONS
Main bearings assembled

ID (Standard) . . . . . . . . . . . . . . . . . . . . . . 79.39679.440 mm
(3.1263.127 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.0460.116 mm
(0.00180.0046 in.)
Maximum wear . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
3. If main bearings (assembled) ID or clearance are not

within specifications, regrind or replace crankshaft.
NOTE: This clearance can also be determined using

PLASTIGAGE. 15
If engine had a previous major overhaul and 21
undersized bearing inserts were used, I.D. and
O.D. dimensions listed above may not be the
same as those recorded. However, the bearing
clearance should be within specifications.
CD,3274,G15,23 -19-01FEB94
DETERMINE CRANKSHAFT MAIN BEARING

CLEARANCE USING PLASTIGAGE
1. Place a strip of PLASTIGAGE in the center of the

bearing.
-UN-23MAY95
2. Install cap and tighten cap screws to 120 Nm
(85 lb-ft) for engines prior to serial number 135641CD
and to 135 Nm (100 lb-ft) for other engines.
CD7145
3. Remove cap and compare the width of

PLASTIGAGE with scale provided on side of package
to determine clearance.
4. Maximum permissible clearance is 0.15 mm

(0.006 in.).
CD,3274,G15,17 -19-01FEB94

060799
PN=118
CRANKSHAFT REGRINDING
If journals are worn, tapered, out-of-round, scored or Regrind cast iron crankshafts only once as
damaged, the crankshaft journals should be reground well to 0.25 mm (0.10 in.) under standard
and correct undersize bearing inserts installed. size. These crankshafts must be lapped
afterwards according to the micro-finishing
Undersize bearing inserts available: 0.25, 0.50, specifications given in this group.
0.76 mm (0.01, 0.02, 0.03 in.).
IMPORTANT: Crankshaft grinding should be
NOTE: To avoid damaging steel crankshafts with carried out ONLY by experienced
rolled grooves, only regrind them once to personnel on equipment capable of
0.25 mm (0.01 in.) under standard size maintaining crankshaft size and
specified. finish specifications.
CD,3274,G15,21 -19-01MAR92
15
22

060799
PN=119
CRANKSHAFT REGRINDING GUIDELINES
If the crankshaft is to be reground, use the following NOTE: When thrust surfaces are reground and an
recommended guidelines: oversize washer is used, crankshaft end play
specification must be maintained.
1. Determine the size to which the journals are to be
reground according to the measures taken during 6. If the thrust surfaces of the crankshaft are worn or
inspections. grooved excessively, they must be reground and
polished. Care must be taken to maintain the
2. If one or more main or connecting rod journals specified radius between each thrust surface and the
require grinding, then grind all of the main journals or bearing journal. An oversize thrust washer set is
all of the connecting rod journals to the same available.
required size. Grind clockwise (as viewed from nose
of crankshaft). 7. Stone the edge of all oil holes in the journal
surfaces smooth to provide a radius of approximately
3. All journal fillets radii must be free of any sharp 1.50 mm (0.060 in.).
grind marks or scratches. The fillet must blend
smoothly into the journal and crank cheek. The radius 8. After grinding has been completed, inspect the
may be checked with a fillet gauge. crankshaft by the fluorescent magnetic particle
method, or other similar method to determine if
4. Care must be taken to avoid localized heating cracks have originated due to the grinding operation.
which often produces grinding cracks. Use coolant
generously to cool the crankshaft while grinding. Do 9. De-magnetize the crankshaft.
not crowd the grinding wheel into the work.
10. Thoroughly clean the crankshaft and oil passages 15
5. Polish or lap (clockwise) the ground surfaces to with solvent. Dry with compressed air.
23
the specified finish except for cast iron crankshafts
(see MICRO-FINISHING SPECIFICATIONS in this
group). The reground journals will be subject to
excessive wear unless polished smooth.
CD,3274,G15,33 -19-01MAR92

060799
PN=120
MICRO-FINISHING SPECIFICATIONS
The following specifications are required when cast

iron crankshafts have to be reground:
Center Line Average (C.L.A.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 micron (8 micro-in.) or better

Skewness parameter (Sk) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative
Bearing ratio (Tp) with 1% Tp reference line
0.22 micron (8.8 micro-in.) depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tp more than 20 %
0.38 micron (15.2 micro-in.) depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tp more than 80 %
0.64 micron (25.6 micro-in.) depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tp more than 90 %
Final journal finishing operation must be done in IMPORTANT: DO NOT attempt to regrind cast iron
clockwise direction (as viewed from nose of crankshafts if above specifications
crankshaft). cannot be obtained.
CD,3274,G15,37 -19-01MAR92
CRANKSHAFT GEAR REPLACEMENT
15 1. Pull gear using a suitable commercial puller

24 2. Remove Woodruff key from crankshaft and remove
any burrs from gear journal.
-UN-13JUN95
3. Install a new Woodruff key in crankshaft keyway.
4. Heat new gear to 180C (360F).
N CAUTION: Oil fumes or oil can ignite above

190C (380F). Use a thermometer to ensure
CD30439
that a temperature of 180C (360F) is not
exceeded. Do not allow a flame or heating
element to come into direct contact with the
oil. Heat the oil in a well-ventilated area. Plan a
safe handling procedure to avoid burns.
5. Drive gear onto crankshaft using JDG794A driver

(formerly JDH7 or JDG794).
-UN-10MAY95
NOTE: JDG794A driver must be used to install the gear
while crankshaft is in place in engine block. CD30398
CD,3274,G15,22 -19-04JAN99

060799
PN=121
Crankshaft, Main Bearings and Flywheel/5/6-piece thrust bearing installation
MAIN BEARING INSERTS INSTALLATION
Install main bearing inserts, making sure that tang (A) on

the inserts engages in slot (B) in cylinder block and main
-UN-14OCT88
bearing caps. Also ensure that oil bores of bearing
inserts are aligned with oil passages in cylinder block.
ABearing insert tang

BCylinder block slot
T88555
CD,3274,G15,26 -19-01FEB94
2-PIECE THRUST BEARING INSTALLATION
Install one thrust bearing (A) from 2-piece thrust bearing

set in rear web of cylinder block and the other in rear
-UN-14OCT88
bearing cap.
T88556
15
25
CD,3274,G15,38 -19-01FEB94
5/6-PIECE THRUST BEARING

INSTALLATION*
Install two thrust washers in the block and two on

bearing cap. The oil grooves (A) must face towards
-UN-10MAY95
crankshaft thrust surfaces.
NOTE: If previous 5-piece thrust bearing set* is to be

used, reassemble engine with two thrust washers
on the cap and the third one on the rear face of
CD30399
the block even if the engine was originally built
with two thrust washers in the block and one on
cap.
AOil grooves

060799
PN=122
Crankshaft, Main Bearings and Flywheel/Crankshaft installation
CRANKSHAFT INSTALLATION
1. Apply a liberal coating of clean engine oil to bearing
-UN-14OCT88
surfaces and crankshaft journals and install crankshaft.
2. Dip all main bearing cap screws in clean engine oil

and position them with washers in the bearing caps.
T88557
3. Install all bearing caps (B) according to the
identification marks stamped on them, and so that tangs
(A) of both bearing halves are on the same side. Install
all cap screws finger-tight.
4. Apply a first torque not exceeding 20 Nm (14 lb-ft).
5. Using a soft-face hammer, move crankshaft first
-UN-06MAR95
towards the rear and then towards the front to align the
rear thrust washers.
IMPORTANT: Before tightening rear cap screws,

ensure that rear thrust washer of cap is
CD30250
aligned with rear thrust washer of
block.
15 6. Tighten all cap screws to 120 Nm (85 lb-ft) on
26 engines prior to serial number 135641CD and to
135 Nm (100 lb-ft) on other engines.
7. Check for free rotation and end play of the crankshaft.
CD,3274,G15,34 -19-01FEB94

060799
PN=123
Group 20
Camshaft, Balancer Shafts and Timing Gear Train

Magnetic follower holder kit . . . . . . . . . . . D15001NU
Hold cam followers when removing and installing

camshaft.
-UN-07MAR95
ES114010
CD,D15001NU -19-12NOV92
CD30253 -UN-08MAR95
Balancer shaft holding tool . . . . . . . . . . . . . . . JD-247
Used to hold balancer shaft when installing drive gear.
CD,JD247 -19-04AUG92
RG5111 -UN-23AUG88
20
Front crankshaft oil seal driver . . . . . . . . . . . . JD-250
1
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG537
Install front crankshaft oil seal in aluminium timing gear

cover.
CD,JD250 -19-04AUG92
RG5111 -UN-23AUG88
Idler gear bushing driver . . . . . . . . . . . . . . . . JD-252

Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG537
Install idler gear bushings.
CD,JD252 -19-04AUG92
RG5118 -UN-23AUG88
Gear timing tool . . . . . . . . . . . . . . . . . . . . . JD-254A

(Formerly JD-254)
Time camshaft gear, injection pump gear, and balancer

shafts.
CD,JD254 -19-04JAN99
RG5068 -UN-23AUG88
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Lock engine at TDC when timing valve train. Use with

JDE81-1 or JDE83 Flywheel Turning Tool.
RG,JDE814L -19-02APR90

060799
PN=124
Camshaft, Balancer Shafts and Timing Gear Train/Special tools
RG4950 -UN-23AUG88
Flywheel Turning Tool . . . . . . . . . . . . . . . . . . JDE83

or JDG820 (formerly JDE81-1)
Rotate engine flywheel. Use with JDE81-4 Timing Pin.
NOTE: Use JDE83 on engines with a 142 tooth flywheel

ring gear and a flywheel housing tool guide bore
of 26.5 mm (1.04 in.) diameter.
Use JDG820 on engines with a 129 tooth

flywheel ring gear and a flywheel housing tool
guide bore of 29.9 mm (1.18 in.) diameter.
CD,JDE83 -19-01FEB94
RG7939 -UN-05JAN98
Idler Gear Installer Pilot . . . . . . . . . . . . . . . JDG791A

(Formerly JDG791)
Guide idler gear onto idler shaft, on engines with

camshaft-gear-driven auxiliary drive and 70 mm (2.75 in.)
upper idler gear bushing.
20
2
CD,JDG791A -19-04JAN99
CD30252 -UN-08MAR95
Front crankshaft oil seal driver . . . . . . . . . . KJD10164
Install front crankshaft oil seal on composite material

timing gear cover.
CD,KJD10164 -19-10MAR92

060799
PN=125
Camshaft, Balancer Shafts and Timing Gear Train/Special tools
TEMPLATE FOR FRONT PLATE REPLACEMENT
-UN-08MAR95
CD30185
CD,3274,G40,1 -19-27APR92
20
3

060799
PN=126
Camshaft, Balancer Shafts and Timing Gear Train/Specifications
SPECIFICATIONS
DIMENSIONS OF NEW PARTS WEAR LIMIT
Camshaft journal OD . . . . . . . . . . . . . . . . 55.87255.898 mm (2.19972.2007 in.) 55.85 mm (2.199 in.)
Camshaft bore to journal clearance . . . . . . 0.100.15 mm (0.0040.006 in.) 0.18 mm (0.007 in.)
Camshaft end play . . . . . . . . . . . . . . . . . 0.080.23 mm (0.0030.009 in.) 0.38 mm (0.015 in.)
Camshaft thrust plate thickness . . . . . . . . . 3.9353.985 mm (0.1550.157 in.) 3.8 mm (0.15 in.)
Cam follower OD . . . . . . . . . . . . . . . . . . 31.6231.64 mm (1.2451.246 in.)
Cam follower to bore clearance . . . . . . . . . 0.060.13 mm (0.0020.005 in.)
Camshaft lobe height:

Intake lobe . . . . . . . . . . . . . . . . . . . . . 6.937.42 mm (0.2730.292 in.) 6.68 mm (0.263 in.)
Exhaust lobe . . . . . . . . . . . . . . . . . . . 6.767.26 mm (0.2660.286 in.) 6.50 mm (0.256 in.)
Balancer shaft journal OD . . . . . . . . . . . . 38.13538.161 mm (1.50141.5024 in.)
Balancer shaft bushing ID (installed) . . . . . 38.18538.235 mm (1.50331.5053 in.)
Bushing to journal clearance . . . . . . . . . . 0.0240.100 mm (0.0010.004 in.) 0.15 mm (0.006 in.)
Balancer shaft thrust plate thickness . . . . . 2.9753.025 mm (0.1170.119 in.)

20
4
Balancer shaft end play . . . . . . . . . . . . . . 0.050.26 mm (0.0020.010 in.) 0.38 mm (0.015 in.)
Helical timing gear backlash between:

Upper idler/crankshaft gear . . . . . . . . . . . 0.070.30 mm (0.0030.012 in.) 0.40 mm (0.016 in.)
Upper idler/camshaft gear . . . . . . . . . . . 0.070.35 mm (0.0030.014 in.) 0.51 mm (0.020 in.)
Upper idler/injection pump gear . . . . . . . . 0.070.35 mm (0.0030.014 in.) 0.51 mm (0.020 in.)
Lower idler/crankshaft gear . . . . . . . . . . . 0.070.35 mm (0.0030.014 in.) 0.51 mm (0.020 in.)
Lower idler/oil pump gear . . . . . . . . . . . . 0.040.38 mm (0.00160.015 in.) 0.40 mm (0.016 in.)
Lower idler/balancer shaft gear . . . . . . . . 0.050.40 mm (0.0020.016 in.) 0.51 mm (0.020 in.)
Oil pump/balancer shaft gear . . . . . . . . . 0.050.36 mm (0.0020.014 in.) 0.51 mm (0.020 in.)
CD,3274,G20,1 -19-01FEB94

060799
PN=127
Spur timing gear backlash: DIMENSIONS OF NEW PARTS WEAR LIMIT
5300/5300N Tractors with engines (-242551CD)
All other 3 cyl. engines ( -270818CD)
4 cyl. engines ( -286631CD)
Upper idler/crankshaft gear . . . . . . . . . . 0.040.35 mm (0.00160.014 in.) 0.60 mm (0.024 in.)
Upper idler/camshaft gear . . . . . . . . . . . 0.080.45 mm (0.0030.018 in.) 0.85 mm (0.033 in.)
Upper idler/injection pump gear . . . . . . . 0.080.45 mm (0.0030.018 in.) 0.85 mm (0.033 in.)
Lower idler/crankshaft gear . . . . . . . . . . 0.040.35 mm (0.00160.014 in.) 0.65 mm (0.025 in.)
Lower idler/oil pump gear . . . . . . . . . . . 0.080.40 mm (0.0030.016 in.) 0.75 mm (0.030 in.)
Camshaft gear/aux. drive gear . . . . . . . . 0.091.24 mm (0.00350.049 in.) 1.34 mm (0.053 in.)
Spur timing gear backlash: DIMENSIONS OF NEW PARTS WEAR LIMIT

5300/5300N Tractors with engines (242552CD-)
All other 3 cyl. engines (270819CD- )
4 cyl. engines (286632CD- )
Upper idler/crankshaft gear . . . . . . . . . . 0.010.49 mm (0.00040.019 in.)
Upper idler/camshaft gear . . . . . . . . . . . 0.010.52 mm (0.00040.020 in.)
Upper idler/injection pump gear . . . . . . . 0.010.52 mm (0.00040.020 in.)

20
Lower idler/crankshaft gear . . . . . . . . . . 0.010.46 mm (0.00040.018 in.)
5
Lower idler/oil pump gear . . . . . . . . . . . 0.010.49 mm (0.00040.019 in.)
Camshaft gear/aux. drive gear . . . . . . . . 0.010.54 mm (0.00040.021 in.) 1.34 mm (0.053 in.)
Balancer shaft/oil pump gear . . . . . . . . . 0.010.47 mm (0.00040.018 in.)
Balancer shaft/lower idler gear . . . . . . . . 0.010.54 mm (0.00040.021 in.)
CD,3274,G20,46 -19-04JAN99

060799
PN=128
Idler gear shaft OD

Upper with helical gear and lower
with helical or spur gear . . . . . . . . . . . . 44.43744.463 mm (1.74951.7505 in.) 44.41 mm (1.748 in.)
Upper with spur gear . . . . . . . . . . . . . . . 69.75969.775 mm (2.74642.747 in.)
Idler gear bushing ID

Upper with spur gear . . . . . . . . . . . . . . . 69.82769.857 mm (2.74912.7503 in.)
Idler gear/bushing clearance

Upper with spur gear . . . . . . . . . . . . . . . 0.0520.098 mm (0.0020.0038) in.)
Hub width of idler gear . . . . . . . . . . . . . . 21.97522.025 mm (0.8650.867 in.) 21.93 mm (0.863 in.)
Width of idler shaft . . . . . . . . . . . . . . . . . 22.1722.27 mm (0.8730.877 in.)
End play of idler gear . . . . . . . . . . . . . . . 0.140.29 mm (0.0060.012 in.) 0.40 mm (0.016 in.)
20
6 Spring pins protrude from shaft:
On lower idler gear by . . . . . . . . . . . . . . 6.57 mm (0.2560.275 in.)
On upper idler gear by

Helical gear . . . . . . . . . . . . . . . . . . . 44.5 mm (0.1570.177 in.)
Spur gear . . . . . . . . . . . . . . . . . . . . 7.58.5 mm (0.2950.335 in.)
CD,3274,G20,02 -19-04JAN99

060799
PN=129
Camshaft, Balancer Shafts and Timing Gear Train/Auxiliary drive specifications (37 kW)
AUXILIARY GEAR DRIVE SPECIFICATIONS

(37 KW)
Drive ratio
(output gear / crankshaft gear) . . . . . . . . . 0.97 : 1
Crankshaft O.D. for collet . . . . . . . . . . . . . 37.98838.014 mm (1.49561.4966 in.)
Collet I.D. . . . . . . . . . . . . . . . . . . . . . . . 38.01338.063 mm (1.4961.498 in.)
Drive gear (crankshaft, 34-tooth):

I.D. at front face . . . . . . . . . . . . . . . . . . 46.192 mm (1.818 in.)
I.D. of idler gear (49-tooth) . . . . . . . . . . . . 39.93639.962 mm (1.5721.573 in.)
O.D. of idler shaft for gear . . . . . . . . . . . . 39.98740.013 mm (1.5741.575 in.)
O.D. of idler shaft for bearings . . . . . . . . . 34.97034.986 mm (1.3761.377 in.)
O.D. of output gear (35-tooth)

for bearings . . . . . . . . . . . . . . . . . . . . . . 34.97034.986 mm (1.3761.377 in.)
Machined bore in gear covers:

For idler shaft bearing . . . . . . . . . . . . . . 79.9279.96 mm (3.1463.148 in.)
20
For output shaft bearing . . . . . . . . . . . . . 71.9371.97 mm (2.8322.833 in.) 7
Idler shaft bearing:
O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . 79.98780.000 mm (3.1493.150 in.)
I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.98735.000 mm (1.3771.378 in.)
Output shaft bearing:

O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . 71.98772.000 mm (2.8342.835 in.)
I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.98735.000 mm (1.3771.378 in.)
Dowel pin protrusion above front face of

timing gear cover . . . . . . . . . . . . . . . . . . 11.012.0 mm (0.4300.470 in.)
Set screws in unused threaded holes . . . . . 01.0 mm (00.004 in.) recess

from flange surface
CD,3274,G20,3 -19-01FEB94

060799
PN=130
Camshaft, Balancer Shafts and Timing Gear Train/Torques for hardware
Front plate to cylinder block, special screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm (25 lb-ft)
Drive gear on oil pump shaft, hex. nut (staked) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm (55 lb-ft)
Upper idler gear, cap screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm (81 lb-ft)
Lower idler gear, nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm (81 lb-ft)
Timing gear cover to cylinder block and front

plate, cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (33 lb-ft)
Fuel injection pump gear:

Stanadyne (model DB2)
with 8 mm (0.315 in.) thick nut (chrome finish) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (45 lb-ft)
with 10 mm (0.394 in.) thick nut (black finish) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm (92 lb-ft)
Stanadyne (model DB4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm (147 lb-ft)
Stanadyne (model DM4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm (147 lb-ft)
Lucas-CAV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (60 lb-ft)
MICO in-line pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm (63 lb-ft)
20 Camshaft thrust plate, cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)

8
Balancer shaft thrust plate, cap screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Oil filler neck, cap screws:

Aluminium neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Composite material neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
Auxiliary gear cover to cylinder block and

front plate, cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Pulley or damper/pulley to crankshaft

(engines with crankshaft-gear-driven aux. drive):
45 mm (1.77 in.) bolt length (dry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm (135 lb-ft)
112 mm (4.41 in.) bolt length (lubricated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lb-ft)
plus 60 angle
CD,3274,G20,4 -19-04JAN99

060799
PN=131
Camshaft, Balancer Shafts and Timing Gear Train/Camshaft
TIMING GEAR BACKLASH MEASURE
Measure backlash between gears using a dial indicator

and compare with specifications.
If backlash is not correct, install new gears.
ACamshaft/upper idler gear

BInjection pump/upper idler gear
CUpper idler/crankshaft gear
DCrankshaft/lower idler gear
EBalancer shaft/oil pump gear
FOil pump/lower idler gear
GLower idler/balancer shaft gear
-UN-28OCT88
T94704
CD,3274,G20,5 -19-10MAR92
20
CAMSHAFT END PLAY MEASURE 9
Using a dial indicator, check camshaft end play.
-UN-07MAR95
Camshaft end play . . . . . . . . . . . . . . . . . . . . . 0.080.23 mm
(0.0030.009 in.)
Thrust plate thickness . . . . . . . . . . . . . . . . . 3.9353.985 mm

(0.1550.157 in.)
CD7104
Maximum wear . . . . . . . . . . . . . . . . . . . . . 3.8 mm (0.15 in.)
NOTE: If end play exceeds specifications then check

thickness of thrust plate as this determines end
play.
CD,3274,G20,6 -19-01FEB94

060799
PN=132
REMOVING CAMSHAFT
NOTE: Mark parts so that they can be reinstalled in their

original positions.
-UN-07MAR95
Remove cylinder head, cam followers and fuel pump.
Remove cap screws (A) and pull camshaft straight out.
IMPORTANT: When removing camshaft, be careful

that lobes do not damage the bearing
CD7105
surfaces in bores.
NOTE: Camshaft can be removed from engine without

removing cylinder head by holding cam followers
away from camshaft lobes with D15001NU
Magnetic Holding Set.
-UN-07NOV88
T90981
CD,3274,G20,7 -19-10MAR92
20
10 CAMSHAFT JOURNAL MEASURE
CAMSHAFT JOURNAL SPECIFICATIONS
Camshaft journal OD . . . . . . . . . . . . . . . . . 55.87255.898 mm

(2.19972.2007 in.)
-UN-07NOV88
Maximum wear . . . . . . . . . . . . . . . . . . 55.85 mm (2.199 in.)
Max. clearance between bore

and camshaft journal . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
T81260
If diameter or clearance are more than specified, replace
camshaft.
IMPORTANT: To keep the initial working condition

between cam lobes and cam followers,
always replace cam followers when
installing a new camshaft.
CD,3274,G20,8 -19-01FEB94

060799
PN=133
MEASURE HEIGHT OF CAM LOBE
Measure longest and shortest diameter of each cam.

Subtract shorter diameter from longer diameter to find
the height of the cam lobe. If any lobe is not of the
-UN-01NOV88
correct height, install a new camshaft.
CAMSHAFT LOBE HEIGHT SPECIFICATIONS
Intake lobe . . . . . . . . . . . . . . 6.937.42 mm (0.2730.292 in.)
T81262
Exhaust lobe . . . . . . . . . . . . 6.767.26 mm (0.2660.286 in.)

IMPORTANT: To keep the initial working condition

between cam lobes and cam followers,
always replace cam followers when
installing a new camshaft.
CD,3274,G20,9 -19-10MAR92
20
CAMSHAFT GEAR REPLACEMENT 11
1. Remove gear from camshaft using a press.
-UN-28OCT88
2. Install gear with timing mark (A) away from camshaft.
3. Press gear on shaft until flush with shoulder on

camshaft.
T88697
CD,3274,G20,10 -19-10MAR92
TACHOMETER PICK-UP PIN REMOVAL
1. Drill and tap an extraction hole of approx. 6 mm

(0.250 in.) diameter and 12 mm (0.500 in.) depth in
center of pin.
-UN-07MAR95
2. Using a self-made puller (spacer, washer, screw), pull

out the tachometer pick-up pin.
CD30200
CD,3274,G20,11 -19-10MAR92

060799
PN=134
FUEL SUPPLY PUMP REAR CAM

INSTALLATION
Some engine models have the fuel supply pump

actuated by a cam (A) fitted at the rear of camshaft.
-UN-10MAY95
When ordering a new camshaft, also order the fuel
supply pump rear cam. Install the cam using a press.
CD30436
CD,3274,G20,45 -19-01FEB94
INSTALL CAMSHAFT
-UN-16JUN98
20
12
CD30596
1. Before installation of the tachometer drive shaft 4. Install cap screws (D) and tighten to 50 Nm (35
(A), check the diameter of the knurled shaft area (B). lb-ft).
If diameter exceeds 12.92 mm (0.5087 in.), rework
shaft to 12.8812.92 mm (0.50710.5087 in.). IMPORTANT: To keep the initial working condition
between cam lobes and cam
2. Coat camshaft with clean engine oil. On engines followers, always replace cam
with camshaft bushing, lubricate the inner followers (E) when installing a new
circumference of bushing with TY6333* grease. camshaft.
3. Install camshaft and thrust plate (C) in cylinder

block.

060799
PN=135
Camshaft, Balancer Shafts and Timing Gear Train/Balancer Shafts
CAM FOLLOWER CHECKING
Measure cam follower OD and compare with

specifications.
-UN-09NOV88
CAM FOLLOWER SPECIFICATIONS
Cam follower OD . . . . . . . . . . . . . . . . . . . . . 31.6231.64 mm

(1.1241.246 in.)
Cam follower to bore
T81239
clearance . . . . . . . . . . . . . . . 0.060.13 mm (0.0020.005 in.)
If diameter or clearance are not within specifications or if

the follower face is flat or concave, replace cam follower.
CD,3274,G20,13 -19-10MAR92
BALANCER SHAFT IDENTIFICATION

(4-CYLINDER ENGINES)
Three types of balancer shafts are used:
-UN-07MAR95
A- Integral shaft in light version for 4039D engines
20
B- Integral shaft in heavy-duty version for 4039T engines 13
C- Shaft with bolt-on weights for 4045D and 4045T
CD30154
engines
IMPORTANT: Make sure that the balancer shafts

used on any engine are of the same
design. Refer to appropriate machine or
engine parts catalog for correct parts
acquisition.
-UN-06MAR95
CD30254
CD,3274,G20,14 -19-10MAR92

060799
PN=136
BALANCER SHAFT END PLAY MEASURE
Using a dial indicator, check balancer shaft end play.
-UN-09DEC88
Balancer shaft end play . . . . . . . . . . . . . . . . . . 0.050.26 mm
(0.0020.010 in.)
Thrust plate thickness . . . . . . . . . . . . . . . . . 2.9753.025 mm

(0.1170.119 in.)
CD7109
NOTE: If end play exceeds specifications, check also
thickness of thrust plate.
CD,3274,G20,15 -19-10MAR92
BALANCER SHAFT REMOVAL
IMPORTANT: During removal, identify left and right

balancer shafts to ensure correct
reassembly.
-UN-02NOV94
Journals are lapped for one direction of
20 rotation. Interchanging shaft locations
14 could therefore cause premature wear
on shafts and bushings.
CD7110
1. Remove lower idler gear and oil pump gear.
2. Remove balancer shaft weights (A), if equipped.
3. Loosen cap screws (B) and pull balancer shafts out of

cylinder block.
NOTE: Take care when removing balancer shafts that
-UN-02NOV94
neither shaft journals nor bushings in cylinder
block are damaged.
CD7111
CD,3274,G20,16 -19-10MAR92

060799
PN=137
BALANCER SHAFT JOURNAL MEASURE

BALANCER SHAFT JOURNAL SPECIFICATIONS
Balancer shaft journal OD . . . . . . . . . . . . . . 38.13538.161 mm

(1.50141.5024 in.)
-UN-09NOV88
Balancer shaft journal to bushing
Clearance . . . . . . . . . . . . 0.0240.100 mm (0.0010.004 in.)
T81899
If diameter or clearance are not within specifications,
replace balancer shaft.
CD,3274,G20,17 -19-10MAR92
20
15

060799
PN=138
BALANCER SHAFT GEAR REPLACEMENT
NOTE: Service balancer shafts can be delivered without

gear. To identify proper shafts a letter is stamped
at the rear as follows:
-UN-25OCT94
R for right-hand side shaft
L for left-hand side shaft
Be sure when installing the gear that the timing
mark (E) corresponds to the proper shaft.
CD30400
1. Remove gear from balancer shaft using a press.
2. Inspect the gear, woodruff key and thrust plate for

cracks or wear. Replace if necessary.
3. Position balancer shaft in JD-247 Holding Tool (A)

then install thrust plate and appropriate gear on the
shaft. Be sure timing mark on the gear faces away from
-UN-07NOV88
the balancer shaft.
4. Using tube driver (B), press gear onto shaft until 0.05
to 0.20 mm (0.002 to 0.008 in.) clearance is obtained
between thrust plate and gear.
T88842
AJD-247 Holding Tool
BTube driver
CEngine front face
DRight-hand side balancer shaft (letter R)
20 ETiming marks
16 FLeft-hand side balancer shaft (letter L)
-UN-07NOV88
T88840
CD,3274,G20,18 -19-01FEB94

060799
PN=139
Camshaft, Balancer Shafts and Timing Gear Train/Idler Gears and front plate
INSTALL BALANCER SHAFTS
1. Apply clean engine oil to bushings in cylinder block

and to balancer shaft journals.
-UN-02NOV94
IMPORTANT: Do not mix up shafts. If the gears are
removed from shafts during
disassembly and possibly mixed up,
install new shaft bushings.
CD7111
2. Install balancer shafts and thrust plates. Tighten cap
screws (B) to 50 Nm (35 lb-ft).
3. On engines equipped with bolt-on shaft weights (A),

install weights on shafts so that they are positioned
opposite the spot facings provided for the attaching nuts.
Tighten nuts to 65 Nm (48 lb-ft).
-UN-02NOV94
CD7110
CD,3274,G20,19 -19-10MAR92
20
IDLER GEAR END PLAY MEASURE 17
Using a dial indicator, check end play of upper and lower

idler gears.
-UN-23MAY95
End play . . . . . . . . . . . . . . . 0.140.29 mm (0.0060.012 in.)
CD7155
CD,3274,G20,20 -19-11MAR92

060799
PN=140
REMOVE FRONT PLATE
1. Proceed as follows in case of front plate replacement:
IMPORTANT: Replacement front plates do not have
-UN-07MAR95
any injection pump timing marks. It is
extremely important that the timing be
accurately transferred from original
front plate to the replacement plate in
the exact location for proper injection
CD30186
pump timing.
Build an aluminum template as shown under

Self-manufactured tool.
Attach template to previous front plate using three 3/8

in. cap screws and transfer timing mark from previous
front plate (A) to template (B) with a pencil.
Attach template to new front plate and transfer timing

mark to the new front plate (C) using a scriber.
CD,CTM125,194 -19-01DEC97
20
18
-UN-19MAY98
-UN-04MAY98
CD30597
CD30598
2. Remove upper and lower idler gears. 4. Remove countersunk screws (A) and lift off front
plate.
3. Remove camshaft, fuel injection pump and oil
pump. 5. Remove oil by-pass valve and spring (B).
CD,CTM125,118 -19-01DEC97

060799
PN=141
IDLER GEAR BUSHING AND SHAFT

MEASURE
IDLER GEAR SPECIFICATIONS
-UN-07MAR95
Idler gear shaft OD
with helical or spur gear . . . . . . . . . . . . . 44.43744.463 mm
(1.74951.7505 in.)
Upper with spur gear . . . . . . . . . . . . . . . . 69.75969.775 mm
CD7159
(2.74642.747 in.)
Idler gear bushing ID

with helical or spur gear . . . . . . . . . . . . . 44.50144.527 mm
(1.7521.753 in.)
Upper with spur gear . . . . . . . . . . . . . . . . 69.82769.857 mm

(2.74912.7503 in.)
-UN-07MAR95
Idler gear/bushing clearance
with helical or spur gear . . . . . . . . . . . . . . . 0.0380.09 mm
(0.00150.0035 in.)
CD7160
Upper with spur gear . . . . . . . . . . . . . . . . . 0.0520.098 mm
(0.0020.0038 in.)
20
If clearance is more than specified, replace worn parts
19
with new ones.
CD,3274,G20,22 -19-01FEB94

060799
PN=142
IDLER GEAR BUSHING REPLACEMENT
NOTE: Bushing for spur upper idler gear is not available

separately. Install a new idler gear/bushing
assembly.
-UN-07MAR95
1. Press worn idler gear bushing out of gear.
IMPORTANT: The upper and lower idler gears require

different bushings.
CD7161
UPPER IDLER GEAR: Being pressure lubricated, this
gear is specified with a smooth-bore bushing.
LOWER IDLER GEAR: Being splash lubricated, this

gear is specified with a lube-groove fitted bushing.
2. Press in new bushing with JD-252 Driver and JDG537

Handle so that it is flush with one side of the gear.
CD,3274,G20,23 -19-01FEB94
20
20 REMOVE IDLER SHAFT
Remove upper or lower idler shaft by driving shaft out of

the front plate. Remove thrust washer.
-UN-04MAY98
CD30599
CD,CTM125,119 -19-01DEC97

060799
PN=143
SPRING PIN INSTALLATION (IF EQUIPPED)
Install spring pin in shaft with end of pin protruding by:
-UN-06DEC88
Lower shaft pin protrusion (A) . . . . . . . . . . . . . . . . . 6.57 mm
(0.2560.275 in.)
Upper shaft pin protrusion

Helical gear (B) . . . . . . . . . . . . . . . . . . . . . . . . . . 44.5 mm
(0.1570.177 in.)
RG4789
Spur gear (C) . . . . . . . . . . . . . . . . . . . . . . . . . . 7.58.5 mm
(0.2950.335 in.)
-UN-10MAY95
CD30401
CD,3274,G20,25 -19-01FEB94
20
21

060799
PN=144
UPPER IDLER SHAFT INSTALLATION
IMPORTANT: Oil bores in idler shaft must be

properly indexed to provide adequate
lubrication to idler gear bushing.
-UN-06MAR95
Engines with helical gears:
1. Install thrust washer (A) and upper idler shaft with oil
hole oriented between 10 and 11 oclock positions.
CD30255
2. Press shaft into front plate until thrust washer is fully
seated. Spring pin (B, if equipped) must be located in
notch (C).
Engines with spur gears:
-UN-28OCT88
IMPORTANT: Thrust washer ears (D) must not
interfere with countersunk front plate
screw.
If equipped with spring pin, press shaft with thrust
T88706
washer into plate until thrust washer is fully seated.
Otherwise proceed as follows:
1. Install shaft/thrust washer assembly into plate with

ears (D) located to either side of front plate screw (E)
20 and oil bores (F) oriented at 12 and 3 oclock positions.
22
2. Press shaft until thrust washer is fully seated.
-UN-26OCT92
NOTE: Shaft is secured to front plate when idler gear
cap screw is threaded into cylinder block.
AThrust washer
RG6459
BSpring pin
CNotch
DThrust washer ears
EFront plate screw
FOil bores
CD,3274,G20,26 -19-01FEB94

060799
PN=145
LOWER IDLER SHAFT INSTALLATION
1. Install thrust washer (A) and lower idler shaft.
NOTE: In case of shaft with spring pin, position spring
-UN-06MAR95
pin (B) in thrust washer (A) and front plate (C).
2. Drive shaft into plate until thrust washer is fully

seated.
CD30256
NOTE: Shaft is secured to front plate when idler gear
bolt and nut are tightened.
-UN-07MAR95
CD30257
CD,3274,G20,27 -19-10MAR92
20
23

060799
PN=146
FRONT PLATE GASKET
-UN-22FEB99
-UN-22FEB99
CD30712
CD30713
Earlier engines ( -291260CD) Later engines (291261CD- )
The shape of the oil groove casting (A) used to lubricate

the upper idler gear has been modified from engine
serial number (291261CD- ).
20
24
-UN-22FEB99
-UN-22FEB99
CD30714
CD30715
Gasket for engines ( -291260CD) Gasket for ALL engines
The front plate gasket designed for the new oil groove
shape can be used on cylinder blocks with previous oil
groove design while previous gasket cannot match the
new cylinder block design.
CD,3274,G20,47 -19-04JAN99

060799
PN=147
FRONT PLATE INSTALLATION
1. The standard front plate (without auxiliary drive

extension) for service has several injection pump stud
locations as indicated below:
AThreaded bores applicable for attaching Lucas

CAV fuel injection pump on 3 and 6 cyl. engines as well
as on 4 cyl. applications listed below (*)
BThreaded bores applicable for attaching Lucas

CAV fuel injection pump on 4 cyl. engines except for 4
cyl. applications listed below (*)
CFuel injection pump pilot bore
-UN-09DEC88
DBushing applicable for fuel injection pump with
46 mm (1.81 in.) pilot diameter (not used on this
application)
CD7312
* 6100, 6200, 6300, 6400 Tractors and all engines with a Lucas DP200
or DP201 injection pump. CD,3274,G20,48 -19-04JAN99
20
25

060799
PN=148
2. Using Loctite 271 Thread Lock, install injection pump

studs (F) on front plate.
3. On standard front plate only, install the 5/16 plugs

(D) and the 3/8 plugs (E) as shown. Bushing (G) is not
-UN-16JUN98
required for this application.
4. Install oil by-pass valve (B) and spring in cylinder

block. (See also LUBRICATION SYSTEM.)
CD30600
5. Install gasket (H) and front plate. Place new external
tooth washers onto countersunk screws (A) then tighten
to 35 Nm (25 lb-ft).
6. Cut off protruding edge of gasket when timing gear

cover is tightened.
ACountersunk screw
-UN-04MAY98
BOil by-pass valve
DAT21191 Plug (5/16) - Qty: 6
EAT22919 Plug (3/8) - Qty: 2
FStud
GR79854 Bushing (not required for this
application)
CD30598
HGasket
JFront plate
20
26
-UN-19MAY98
CD30597
LOCTITE is a registered trademark of Loctite Corporation. CD,3274,G20,49 -19-04JAN99

060799
PN=149
Camshaft, Balancer Shafts and Timing Gear Train/Gear Train
UPPER TIMING GEAR TRAIN INSTALLATION
1. Adjust No. 1 piston to TDC using JDE83 or JDG820

(formerly JDE81-1) Flywheel Turning Tool and JDE81-4
Timing Pin.
-UN-07MAR95
2. Install camshaft and fuel injection pump.
3. Turn camshaft until timing mark (A) is under JD-254A

Timing Tool.
CD7165
4. Using JD-254A Timing Tool, align timing mark on fuel
injection pump gear (B) with the timing tool.
IMPORTANT: Use timing mark corresponding to the

number of cylinders.
NOTE: Use 4M timing mark (C) on following
-UN-03NOV94
applications:
6100, 6200, 6300, 6400 Tractors
All 4 cyl. engines with Lucas DP200 or DP201
injection pumps
CD7166
20
27
-UN-03NOV94
CD30258
CD,3274,G20,29 -19-04JAN99

060799
PN=150
-UN-19MAY98
-UN-16JUN98
CD30603
CD30604
5. Lubricate shaft and gear bushing with TY6333 7. Install washer, with sharp edge toward timing
grease* (A). cover, and bolt (B) then tighten to 110 Nm (80 lb-ft).
6. Install idler gear on shaft without turning camshaft 8. Recheck gear timing to make sure it is correct.
gear or injection pump gear. On engine with spur
gear, use JDG791A Pilot Tool (C) to guide gear onto
shaft. Install upper idler gear with part number visible.
20
28

060799
PN=151
LOWER TIMING GEAR TRAIN

INSTALLATION
1. Adjust No. 1 piston to TDC using JDE83 or JDG820

(formerly JDE81-1) Flywheel Turning Tool and JDE81-4
-UN-07NOV88
Timing Pin.
2. Install oil pump and balancer shafts (if equipped).
3. On 4-cylinder engines with balancer shafts, turn the
T88710
right-hand shaft so that timing mark (A) is under
JD-254A timing tool.
4. Install lower idler gear without turning balancer shaft.
5. Install new bolt with washer (B) from oil pump side
and new nut on front plate gear side. Tighten nut to
-UN-06MAR95
110 Nm (80 lb-ft).
6. Turn left-hand balancer shaft until timing mark (C) is

under JD-254A timing tool.
CD30259
7. Install oil pump gear on pump shaft, tighten hex. nut
to 75 Nm (55 lb-ft) and secure with three center punch
marks.
8. Recheck gear timing for both balancer shafts.

20
IMPORTANT: Keyway in each balancer shaft must be 29
in the 12 oclock position and timing
-UN-06MAR95
marks must be directed toward
crankshaft when shafts are correctly
timed.
CD30260
CD,3274,G20,30 -19-04JAN99

060799
PN=152
AUXILIARY DRIVE GEAR INSTALLATION

(37 KW)
NOTE: Oil deflector is not used on engines with 37 kW

auxiliary gear drive.
1. Lubricate outer and inner circumferences of collet (A)

with engine oil. Slide collet onto crankshaft with large
-UN-03AUG92
end toward crankshaft gear (B). Position collet against
the gear.
2. If equipped, slip rubber O-ring onto crankshaft and

position against front edge of collet.
RG6339
NOTE: O-ring was previously installed against collet. On
more recent engines the O-ring (D) is installed on
the special washer (E).
3. Lubricate inner circumference of the auxiliary drive

gear (C) with engine oil and place on collet (with
recessed side of gear toward crankshaft pulley).
-UN-10MAY95
4. Using JDG794 tool, push drive gear onto collet by
tightening the nut of special tool to 150 Nm (110 lb-ft) to
seat the gear.
CD30403
ACollet
BCrankshaft gear
20 CAuxiliary drive gear
30 DO-ring (to be installed on washer)
ESpecial washer
CD,3274,G20,39 -19-04JAN99
OIL DEFLECTOR INSTALLATION
Install oil deflector (A) and O-ring (B) when equipped on

crankshaft.
-UN-04MAY98
NOTE: Oil deflector is not used on engine with

crankshaft-gear-driven (37 kW) auxiliary drive
option.
CD30608
CD,3274,G20,32 -19-04JAN99

060799
PN=153
Camshaft, Balancer Shafts and Timing Gear Train/Timing Gear Cover
TIMING GEAR COVER IDENTIFICATION
Four types of timing gear covers are used:
AStandard aluminium cover.
-UN-06MAR95
BComposite material cover. Aluminium cover may
have also this shape.
CAluminium cover for 37 kW auxiliary drive option
CD30261
located on left-hand side of engine.
DAluminium cover for 19 kW auxiliary drive option

(camshaft-gear-driven) located on right-hand side of
engine.
-UN-06MAR95
CD30262
CD,3274,G20,31 -19-01FEB94
20
31

060799
PN=154
INSTALL COMPOSITE MATERIAL TIMING

GEAR COVER
1. Check for cracks around inserts. Replace cover if
-UN-05OCT94
defective.
2. The sealing ring is reusable. When replacement is

needed, proceed as follows:
CD30265
Remove previous sealing ring from cover (do not
use any cutting tool to avoid cover damage).
Clean groove with acetone (follow recommended
precautions and safe operating practices) then dry with
compressed air.
N CAUTION: Do not use any other industrial

solvent which might be not compatible with
-UN-05OCT94
composite material.
Install the new sealing ring starting at one edge of

the cover. Place the thinner area of the sealing ring
CD30266
toward the cover.
If properly installed, the sealing ring may protrude
up to 30 mm (1.18 in.) at the other edge (A). If NOT,
restart procedure.
Cut away excess sealing ring.
20 3. Apply a generous bead of Loctite 515 Sealant on

32 bottom face (B) which is in contact with oil pan.
-UN-05OCT94
NOTE: A tube of Loctite 515 Sealant is provided with
overhaul gasket set. This tube is also available
under part number DD15664.
CD30267
4. Coat the oil pan gasket top face with engine oil where
the timing gear cover will be installed.
5. Install cover and apply following torques and the

sequence shown:
Magnetic pick-up (C): 15 Nm (11 lb-ft)

Plug to access injection pump drive gear nut (D):
30 Nm (22 lb-ft)
Oil pan to timing gear cover, cap screws (1823):
30 Nm (22 lb-ft)
Timing gear cover to front plate, cap screws
(117): 45 Nm (33 lb-ft)
Oil pressure regulating valve plug (E): 30 Nm
(22 lb-ft)
CD,3274,G20,35 -19-04JAN99

060799
PN=155
Camshaft, Balancer Shafts and Timing Gear Train/Aluminum timing gear cover installation
INSTALL ALUMINUM TIMING GEAR COVER
1. Install new gasket on front plate.
2. Install cover on engine and apply the following torques

in sequence:
Cover cap screws (117) . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)

Oil pan cap screws (1823) . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Magnetic pick-up (A) . . . . . . . . . . . . . . . . . . . . 15 Nm (11 lb-ft)
Inj. pump gear plug (B) . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
Oil pressure valve plug (C) . . . . . . . . . . . . . . . 95 Nm (70 lb-ft)
-UN-16JUN98
CD30609
CD,3274,G20,50 -19-04JAN99
20
3. Install oil filler neck or obturation plate then tighten
33
cap screws (A) to:
Aluminum neck . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)

Composite neck . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
-UN-04MAY98
Obturation plate . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
4. Cut off protruding edge of gasket.
CD30610
CD,CTM125,128 -19-01DEC97

060799
PN=156
INSTALLATION OF TIMING GEAR COVER

FOR 37 KW AUXILIARY DRIVE
1. Position new gasket on front plate. Make sure gasket

surfaces on cover and front plate are clean.
-UN-07MAR95
2. Install cover with new built-in crankshaft front oil seal
onto engine.
3. Install the timing gear cover cap screws, nuts and
CD30174
washers and tighten to 50 Nm (35 lb-ft).
Be sure to install the three cap screws and washers (A)
located behind the auxiliary idler and securing the cover
to the front plate and engine block.
CD,3274,G20,40 -19-01FEB94
INSTALL CRANKSHAFT FRONT OIL SEAL
20
34
-UN-04MAY98
-UN-16JUN98
CD30611
CD30698
1. Place new seal onto KJD10164 Seal Installer (A) NOTE: KJD10164 tool set contains also a spacer (C)
with open side toward engine, then slide the to be used only on old applications with short
assembly onto crankshaft nose. nose crankshaft (35 mm length).
2. Install pulley cap screw with washer (B), then

tighten until driver bottoms.
CD,CTM125,129 -19-01DEC97

060799
PN=157
Camshaft, Balancer Shafts and Timing Gear Train/Auxiliary drive (camshaft-gear-driven)
INSTALL WEAR RING
1. When equipped, install the wear ring with chamfered

side (A) toward engine. Be sure that the O-ring is in
place against the oil deflector.
-UN-04MAY98
2. Install shaft key.
CD30612
CD,CTM125,130 -19-01DEC97
INSTALL AUXILIARY EQUIPMENT DRIVEN BY CAMSHAFT GEAR (19 KW AUX. DRIVE)
-UN-16JUN98
-UN-03FEB93
CD30613
20
CD30354
35
1. Install shaft key and gear (A) onto accessory shaft. 2. Install accessory with gasket on engine (arrow).
Tighten nut (B) to 55 Nm (41 lb-ft) then, if equipped,
bend tabs of washer up against nut. 3. Tighten the two fastening cap screws or nuts (C)
CD,3274,G20,44 -19-04JAN99

060799
PN=158
Camshaft, Balancer Shafts and Timing Gear Train/Auxiliary drive (crankshaft-gear-driven)
CRANKSHAFT-GEAR-DRIVEN AUXILIARY
DRIVE (37 KW)
NOTE: O-ring (G), installed against the collet (C), is not

necessary when the washer (F) is machined to
receive an O-ring (see AUXILIARY DRIVE GEAR
INSTALLATION earlier in this group). Refer to
Group 15 for pulley installation.
AAuxiliary drive gear

BCrankshaft gear
CTapered collet
DPulley
ECap screw
FWasher
GO-ring
-UN-30NOV88
RG5175
CD,3274,G20,51 -19-04JAN99
20
36 AUXILIARY DRIVE GEAR REMOVAL (37 KW)
1. Remove crankshaft pulley or damper pulley.
2. Remove auxiliary cover (A) with bearings.
-UN-03AUG92
3. Remove auxiliary idler (B) and output drive (C) gears.
4. Remove timing gear cover (D) and auxiliary drive gear

(E) with collet.
RG6315
5. Replace any bearings which are unserviceable.
6. Clean all covers and inspect for cracks or damage.

Make sure that the bearing seal bores are clean and not
nicked.
AAuxiliary cover
-UN-03AUG92
BAuxiliary idler
COutput drive
DTiming gear cover
EAuxiliary drive gear
RG6316
CD,3274,G20,37 -19-01FEB94

060799
PN=159
BALL BEARING AND DOWEL

INSTALLATION
1. Apply a light coating of engine oil to outer

circumference of the ball bearings (A).
2. Press bearings into timing gear cover and accessory
-UN-03AUG92
gear (front) cover. Press only on outer bearing race; stop
pressing when the bearing bottoms on shoulder of
bearing bore.
3. If dowel pins (B) were removed from the timing gear
RG6337
cover, press in replacement pins so that tops of dowels
are 1112 mm (0.430.47 in.) above surface of cover.
CD,3274,G20,38 -19-01FEB94
AUXILIARY GEAR AND SHAFT

INSTALLATION (37 KW)
1. Lubricate gear shafts with engine oil.
-UN-03AUG92
2. Place idler gear (B) in timing gear cover (D) so that
shaft enters bore of bearing and gear meshes with 20
auxiliary drive gear (E). 37
3. Install ouput gear (C) so 9-tooth spline faces front of
RG6316
engine and 13 or 15-tooth spline faces rear of engine.
Apply high-temperature grease to internal splines.
NOTE: Depending on option, the output gear can be

installed directly on accessory shaft. In this case,
the output ball bearings are not required.
4. Place a new gasket over dowels on timing gear cover.
-UN-03AUG92
Install auxiliary gear cover (A) on timing gear cover.
When both shafts have entered their respective bearings,
align cover with dowel pins and push into place against
timing gear cover.
RG6315
5. Tighten cap screws to 50 Nm (35 lb-ft).
CD,3274,G20,41 -19-01FEB94

060799
PN=160
OUTPUT SHAFT COVER INSTALLATION
1. If studs (A) are used, apply sealant to threads of stud

(timing gear cover end) and install in cover.
-UN-06DEC88
2. If the four threaded holes (B) are not used, apply a
thread sealant to the set screws then install them up to
a recess of 01.0 mm (00.04 in.) from flange surface.
3. If front and/or rear cover plates for output shaft are
RG5182
used, install using new gaskets.
CD,3274,G20,42 -19-01FEB94
20
38

060799
PN=161
Group 25
Lubrication System

RG5183 -UN-13SEP89
Bushing Driver (A) . . . . . . . . . . . . . . . . . . . JD-248A

Handle (B) . . . . . . . . . . . . . . . . . . JDG536(OTC813)
Install oil pressure regulating valve bushing.

CD,JD248A -19-04AUG92
25
1

060799
PN=162
Lubrication System/Specifications
SPECIFICATIONS
Oil pump (standard):
Bore of drive shaft in pump housing . . . . 16.0516.08 mm 0.08 mm

(0.6320.633 in.) (0.003 in.)
Diameter of idler shaft . . . . . . . . . . . . . . 12.3212.34 mm 0.013 mm
(0.4850.486 in.) (0.0005 in.)
Diameter of drive shaft journal . . . . . . . . 16.0216.03 mm 0.025 mm
(0.6300.631 in.) (0.001 in.)
Radial clearance between gear and
pump housing . . . . . . . . . . . . . . . . . . . 0.100.16 mm 0.20 mm
(0.0040.006 in.) (0.008 in.)
Thickness of gears . . . . . . . . . . . . . . . . 41.1541.20 mm 0.05 mm
(1.6201.622 in.) (0.002 in.)
Axial clearance between gears and
pump cover . . . . . . . . . . . . . . . . . . . . . 0.050.17 mm 0.22 mm
(0.0020.007 in.) (0.0085 in.)
Oil pump with high flow capacity:

Bore of drive shaft in pump cover . . . . . . 16.0616.08 mm 0.08 mm
(0.6320.633 in.) (0.003 in.)
Bore of drive shaft in pump housing . . . . 12.2812.31 mm 0.013 mm
(0.48350.4845 in.) (0.0005 in.)
Diameter of drive shaft journal . . . . . . . . 16.0216.03 mm 0.025 mm
(0.6300.631 in.) (0.001 in.)
Thickness of gears . . . . . . . . . . . . . . . . 50.9751.02 mm 0.05 mm
(2.0072.009 in.) (0.002 in.)
25 Radial clearance between gear and
2 pump housing . . . . . . . . . . . . . . . . . . . 0.080.18 mm 0.23 mm
(0.0030.007 in.) (0.009 in.)
Axial clearance between gears and
pump cover . . . . . . . . . . . . . . . . . . . . . 0.040.17 mm 0.22 mm
(0.00150.006 in.) (0.0085 in.)
CD,3274,G25,1 -19-10MAR92

060799
PN=163
Spring of oil pressure regulating valve:

Free length of spring (approx.) . . . . . . . . 120 mm (4.7 in.)
Spring calibration at a length of 42.5 mm

(1.68 in.) . . . . . . . . . . . . . . . . . . . . . . . . 6075 N (13.516.5 lb)
Minimum oil pressure at 800 rpm (slow idle)

and engine oil temperature 90C (194F) . . . 100 kPa (1 bar; 14 psi)
Spring of by-pass valve:

Free length (approx.)
Long spring . . . . . . . . . . . . . . . . . . 59 mm (2.32 in.)
Short spring . . . . . . . . . . . . . . . . . 51 mm (2.00 in.)
Spring calibration
Long spring at a length of 34 mm
(1.34 in.) . . . . . . . . . . . . . . . . . . . 92112 N (2125 lb)
Short spring at a length of 29 mm
(1.14 in.) . . . . . . . . . . . . . . . . . . . 7996.5 N (1822 lb)
CD,3274,G25,2 -19-04JAN99
25
3

060799
PN=164
Dipstick guide height adjustment:
Machine Model No. Engine Model Dipstick guide height
4000-Series Telescopic Handlers:

4400 . . . . . . . . . . . . . . . . . . . . . . . . CD4039TF005 198mm (7.79 in.)
4500 . . . . . . . . . . . . . . . . . . . . . . . . CD4039TF005 198mm (7.79 in.)
5000-Series Tractors:
(Agritalia-built)
5300/5300N . . . . . . . . . . . . . . . . . . . . CD3029DAT01 136 mm (5.35 in.)
5400/5400N . . . . . . . . . . . . . . . . . . . . CD3029TAT02 156 mm (6.14 in.)
5500/5500N . . . . . . . . . . . . . . . . . . . . CD4039TAT01 160 mm (6.30 in.)
(Augusta-built)
5400N . . . . . . . . . . . . . . . . . . . . . . . CD3029TLV01 156 mm (6.14 in.)
5500N . . . . . . . . . . . . . . . . . . . . . . . CD4039TLV01 160 mm (6.30 in.)
(For India)
5300 . . . . . . . . . . . . . . . . . . . . . . . . CD3029DPY01 156 mm (6.14 in.)
6100 . . . . . . . . . . . . . . . . . . . . . . . . CD4045DL001 198 mm (7.79 in.)
CD4045DL002 198 mm (7.79 in.)
6200 . . . . . . . . . . . . . . . . . . . . . . . . CD4039TL001 198 mm (7.79 in.)
CD4039TL004 198 mm (7.79 in.)
6300 . . . . . . . . . . . . . . . . . . . . . . . . CD4039TL003 198 mm (7.79 in.)
25 CD4039TL006 198 mm (7.79 in.)
4 6400 . . . . . . . . . . . . . . . . . . . . . . . . CD4045TL001 198 mm (7.79 in.)
CD4045TL003 198 mm (7.79 in.)
6506 . . . . . . . . . . . . . . . . . . . . . . . . CD6068DL001 196 mm (7.72 in.)
6600 . . . . . . . . . . . . . . . . . . . . . . . . CD6059TL001 196 mm (7.72 in.)
6800 . . . . . . . . . . . . . . . . . . . . . . . . CD6068TL001 196 mm (7.72 in.)
6900 . . . . . . . . . . . . . . . . . . . . . . . . CD6068TL002 196 mm (7.72 in.)
7600 . . . . . . . . . . . . . . . . . . . . . . . . T06068TRW01 194 mm (7.64 in.)
2000-Series Combines:
2054 . . . . . . . . . . . . . . . . . . . . . . . . CD6068HZ001 416 mm (16.4 in.)
2254 . . . . . . . . . . . . . . . . . . . . . . . . CD6068HZ001 416 mm (16.4 in.)
CD,3274,G25,43 -19-04JAN99

060799
PN=165
Dipstick guide height adjustment (contd):
Engine Model Dipstick guide height
Engines for Chinese Combines:

CD6059TYC01 . . . . . . . . . . . . . . . . . . 402 mm (15.83 in.)
CD6059TYC02 . . . . . . . . . . . . . . . . . . 402 mm (15.83 in.)
Engines for GOLDONI Tractors:

CD3029DFG21 . . . . . . . . . . . . . . . . . . 187 mm (7.36 in.)
CD3029DFG22 . . . . . . . . . . . . . . . . . . 187 mm (7.36 in.)
CD3029TFG21 . . . . . . . . . . . . . . . . . . 187 mm (7.36 in.)
SARAN OEM ENGINES Option code Dipstick guide height
CD3029DF . . . . . . . . . . . . . . . . . . . . . 4001,4002 189 mm (7.44 in.)

4003 387 mm (15.24 in.)
4022 176 mm (6.93 in.)
CD3029DF001 . . . . . . . . . . . . . . . . . . . 4001,4002 189 mm (7.44 in.)

4003 387 mm (15.24 in.)
CD3029DF005 . . . . . . . . . . . . . . . . . . . 4001 189 mm (7.44 in.)
CD3029DF031 . . . . . . . . . . . . . . . . . . . 4001,4002 189 mm (7.44 in.)

4003 387 mm (15.24 in.)
4022 141 mm (5.55 in.)
CD3029DF032 . . . . . . . . . . . . . . . . . . . 4022 141 mm (5.55 in.)

25
CD3029DF033 . . . . . . . . . . . . . . . . . . . 4002 189 mm (7.44 in.) 5
CD3029DF034 . . . . . . . . . . . . . . . . . . . 4022 141 mm (5.55 in.)
CD,3274,G25,44 -19-04JAN99

060799
PN=166
CD3029DF120 . . . . . . . . . . . . . . . . . . . 4004 187 mm (7.36 in.)

4005 390 mm (15.35 in.)
4006 205 mm (8.07 in.)
4022 196 mm (7.72 in.)
4024 136 mm (5.35 in.)
CD3029DF121 . . . . . . . . . . . . . . . . . . . 4004 187 mm (7.36 in.)

4005 390 mm (15.35 in.)
CD3029DF122 . . . . . . . . . . . . . . . . . . . 4004 187 mm (7.36 in.)
CD3029DF123 . . . . . . . . . . . . . . . . . . . 4004 187 mm (7.36 in.)
CD3029DF124 . . . . . . . . . . . . . . . . . . . 4004 187 mm (7.36 in.)
CD3029DF128 . . . . . . . . . . . . . . . . . . . 4004 187 mm (7.36 in.)
CD3029DF160 . . . . . . . . . . . . . . . . . . . 4006 205 mm (8.07 in.)

4024 136 mm (5.35 in.)
4033 155 mm (6.10 in.)
CD3029DF161 . . . . . . . . . . . . . . . . . . . 4024 136mm (5.35 in.)
CD3029DF162 . . . . . . . . . . . . . . . . . . . 4006 205 mm (8.07 in.)
25 CD3029DF163 . . . . . . . . . . . . . . . . . . . 4024 136mm (5.35 in.)

6
CD3029DF164 . . . . . . . . . . . . . . . . . . . 4033 155 mm (5.35 in.)
CD3029DF165 . . . . . . . . . . . . . . . . . . . 4024 136mm (5.35 in.)
CD,3274,G25,45 -19-04JAN99

060799
PN=167
CD3029TF . . . . . . . . . . . . . . . . . . . . . . 4001 208 mm (8.19 in.)

4002 189 mm (7.44 in.)
4003 219 mm (8.62 in.)
4009 223 mm (8.78 in.)
CD3029TF001 . . . . . . . . . . . . . . . . . . . 4001 208 mm (8.19 in.)

4002 189 mm (7.44 in.)
4003 219 mm (8.62 in.)
4023 403 mm (15.87 in.)
CD3029TF002 . . . . . . . . . . . . . . . . . . . 4020 507 mm (19.96 in.)

4023 403 mm (15.87 in.)
CD3029TF031 . . . . . . . . . . . . . . . . . . . 4001 208 mm (8.19 in.)

4002 189 mm (7.44 in.)
4003 219 mm (8.62 in.)
4009 223 mm (8.78 in.)
4021 156 mm (6.14 in.)
CD3029TF032 . . . . . . . . . . . . . . . . . . . 4002 189 mm (7.44 in.)

4021 156 mm (6.14 in.)
CD3029TF033 . . . . . . . . . . . . . . . . . . . 4001 208 mm (8.19 in.)
(Continued on next page) 25

7
CD,3274,G25,52 -19-04JAN99

060799
PN=168
CD3029TF120 . . . . . . . . . . . . . . . . . . . 4001 208 mm (8.19 in.)

4006 205 mm (8.07 in.)
4023 212 mm (8.35 in.)
4024 136 mm (5.35 in.)
4025 408 mm (16.06 in.)
CD3029TF121 . . . . . . . . . . . . . . . . . . . 4006 205 mm (8.07 in.)

4025 408 mm (16.06 in.)
CD3029TF123 . . . . . . . . . . . . . . . . . . . 4006 205 mm (8.07 in.)
CD3029TF160 . . . . . . . . . . . . . . . . . . . 4006 205 mm (8.07 in.)

4021 156 mm (6.14 in.)
4024 136 mm (5.35 in.)
4026 156 mm (6.14 in.)
4033 155 mm (6.10 in.)
CD3029TF161 . . . . . . . . . . . . . . . . . . . 4021 156 mm (6.14 in.)

4022 141 mm (5.55 in.)
4024 136 mm (5.35 in.)
4026 141 mm (5.55 in.)
CD3029TF162 . . . . . . . . . . . . . . . . . . . 4001 208 mm (8.19 in.)

4006 205 mm (8.07 in.)
25 CD3029TF163 . . . . . . . . . . . . . . . . . . . 4001 208 mm (8.19 in.)

8 4006 205 mm (8.07 in.)
4024 136 mm (5.35 in.)
CD,3274,G25,53 -19-04JAN99

060799
PN=169
CD4039DF . . . . . . . . . . . . . . . . . . . . . 4001 157 mm (6.18 in.)

4002,4019 200 mm (7.87 in.)
4005 160 mm (6.30 in.)
4006 155 mm (6.10 in.)
4010 418 mm (16.45 in.)
CD4039DF001 . . . . . . . . . . . . . . . . . . . 4001 157 mm (6.18 in.)

4002,4019 200 mm (7.87 in.)
4003 198 mm (7.79 in.)
4004 274 mm (10.79 in.)
4005 160 mm (6.30 in.)
4006 155 mm (6.10 in.)
4010 418 mm (16.45 in.)
4011 405 mm (15.94 in.)
4012 146 mm (5.75 in.)
4031 148 mm (5.83 in.)
CD4039DF002 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)

4005 160 mm (6.30 in.)
CD4039DF004 . . . . . . . . . . . . . . . . . . . 4005 160 mm (6.30 in.)

4015 173 mm (6.81 in.)
CD4039DF005 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)

25
CD4039DF006 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.) 9
CD4039DF007 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)
CD4039DF008 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)
CD4039DF031 . . . . . . . . . . . . . . . . . . . 4001 157 mm (6.18 in.)

4002,4019 200 mm (7.87 in.)
4004 154 mm (6.06 in.)
4005 160 mm (6.30 in.)
4010 418 mm (16.45 in.)
4031 148 mm (5.83 in.)
CD4039DF032 . . . . . . . . . . . . . . . . . . . 4001 157 mm (6.18 in.)

4031 148 mm (5.83 in.)
CD,3274,G25,46 -19-04JAN99

060799
PN=170
CD4039TF . . . . . . . . . . . . . . . . . . . . . . 4002 280 mm (11.02 in.)

4005 408 mm (16.06 in.)
4006 197 mm (7.76 in.)
4008 211 mm (8.31 in.)
4009 214 mm (8.42 in.)
4020 198 mm (7.79 in.)
CD4039TF001 . . . . . . . . . . . . . . . . . . . 4002 280 mm (11.02 in.)

4003,4020 198 mm (7.79 in.)
4004 274 mm (10.79 in.)
4005 408 mm (16.06 in.)
4006 197 mm (7.76 in.)
4008,4012 211 mm (8.31 in.)
4013 217 mm (8.54 in.)
4031 148 mm (5.83 in.)
CD4039TF002 . . . . . . . . . . . . . . . . . . . 4003,4020 198 mm (7.79 in.)
CD4039TF003 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)
CD4039TF004 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)

4006 197 mm (7.76 in.)
4032 203 mm (7.99 in.)
CD4039TF005 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)

25
10 CD4039TF006 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)
CD4039TF007 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)
CD4039TF008 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)
CD4039TF031 . . . . . . . . . . . . . . . . . . . 4002 280 mm (11.02 in.)

4004 274 mm (10.79 in.)
4005 408 mm (16.06 in.)
4006 197 mm (7.76 in.)
4007 123 mm (4.84 in.)
4008 211 mm (8.31 in.)
4013 217 mm (8.54 in.)
4020 198 mm (7.79 in.)
4031 148 mm (5.83 in.)
CD4039TF032 . . . . . . . . . . . . . . . . . . . 4012 211 mm (8.31 in.)
CD,3274,G25,47 -19-04JAN99

060799
PN=171
CD6059DF . . . . . . . . . . . . . . . . . . . . . 4001 194 mm (7.64 in.)

4004 398 mm (15.67 in.)
4005 68 mm (2.68 in.)
4007 210 mm (8.27 in.)
4010 192 mm (7.56 in.)
4011 200 mm (7.87 in.)
4012 406 mm (15.98 in.)
4015 412 mm (16.22 in.)
CD6059DF001 . . . . . . . . . . . . . . . . . . . 4001 194 mm (7.64 in.)

4004 398 mm (15.67 in.)
4005 68 mm (2.68 in.)
4006,4008 185 mm (7.28 in.)
4007 210 mm (8.27 in.)
4010 192 mm (7.56 in.)
4011 200 mm (7.87 in.)
4012 406 mm (15.98 in.)
4015 412 mm (16.22 in.)
CD6059DF002 . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
CD6059DF003 . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)

25
11
CD,3274,G25,48 -19-04JAN99

060799
PN=172
CD6059TF . . . . . . . . . . . . . . . . . . . . . . 4001 194 mm (7.64 in.)

4004 398 mm (15.67 in.)
4007 210 mm (8.27 in.)
4009 68 mm (2.68 in.)
4010 192 mm (7.56 in.)
4011 200 mm (7.87 in.)
4012 406 mm (15.98 in.)
4015 412 mm (16.22 in.)
CD6059TF001 . . . . . . . . . . . . . . . . . . . 4001 194 mm (7.64 in.)

4004 398 mm (15.67 in.)
4006,4008 185 mm (7.28 in.)
4007 210 mm (8.27 in.)
4009 68 mm (2.68 in.)
4010 192 mm (7.56 in.)
4011 200 mm (7.87 in.)
4012 406 mm (15.98 in.)
4015 412 mm (16.22 in.)
CD6059TF002 . . . . . . . . . . . . . . . . . . . 4011 200 mm (7.87 in.)

4013 135 mm (5.31 in.)
CD6059TF003 . . . . . . . . . . . . . . . . . . . 4011 200 mm (7.87 in.)

4013 135 mm (5.31 in.)
25 CD6059TF004 . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)

12
CD6059TF005 . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
CD6059TF006 . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
CD6059TF007 . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
CD6059TF008 . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
CD,3274,G25,49 -19-04JAN99

060799
PN=173
CD4045DF001 . . . . . . . . . . . . . . . . . . . 4003,4020 198 mm (7.79 in.)
CD4045DF031 . . . . . . . . . . . . . . . . . . . 4004 154 mm (6.06 in.)
CD4045TF001 . . . . . . . . . . . . . . . . . . . 4002 280 mm (11.02 in.)

4003,4020 198 mm (7.79 in.)
4005 408 mm (16.06 in.)
4006 197 mm (7.76 in.)
4008 211 mm (8.31 in.)
CD4045TF002 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)
CD4045TF003 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)
CD4045TF008 . . . . . . . . . . . . . . . . . . . 4003 198 mm (7.79 in.)
CD4045TF031 . . . . . . . . . . . . . . . . . . . 4007 123 mm (4.84 in.)
6068DF001 . . . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
6068TF001 . . . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
6068TF002 . . . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
6068TF003 . . . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)

25
6068TF004 . . . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.) 13
6068TF008 . . . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
6068TF009 . . . . . . . . . . . . . . . . . . . . . 4010 192 mm (7.56 in.)
CD,3274,G25,50 -19-04JAN99

060799
PN=174
Lubrication System/Torques for hardware
Oil pump assembly to cylinder block front plate,

cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Drive gear on oil pump shaft, hex. nut (staked) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm (55 lb-ft)
Oil pan to cylinder block and flyweel housing:

Sheet metal pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Aluminium pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Cast iron pan:
SAE 5 screws (3 dashes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
SAE 8 screws (6 dashes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm (50 lb-ft)
Oil pan to timing gear cover:

Aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Composite material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
Plug of oil pressure regulating valve

on aluminium timing gear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Nm (70 lb-ft)
on composite material timing gear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
Oil cooler adapter in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm (25 lb-ft)
Oil cooler lines, banjo bolts ............................................ 100 Nm (74 lb-ft)
Oil filler neck, cap screws:

Aluminium neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Composite material neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
25 Oil drain plug:

14 Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm (50 lb-ft)
Conical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (40 lb-ft)
CD,3274,G25,4 -19-01FEB94

060799
PN=175
Lubrication System/Oil Cooler
OIL COOLER IDENTIFICATION
Two types of oil cooler are installed on engines:
Type 1 (A) is a standard oil cooler which is clamped
-UN-10MAY95
between oil filter and cylinder block or adapter housing.
Type 2 (B) is a high-flow oil cooler which is attached to

the cylinder head or block.
CD30405
AStandard oil cooler with 6, 8 or 10 plates
BHigh-flow oil cooler with 7 plates
-UN-06MAR95
CD30270
CD,3274,G25,5 -19-01FEB94
25
15

060799
PN=176
STANDARD OIL COOLER REMOVAL
-UN-06MAR95
-UN-06MAR95
CD30271
CD30272
-UN-10MAY95
-UN-24JUN98
CD30406
CD30616
25
16
AInlet line from water BOutlet line to water pump CNipple DHolding screw
pump
1. Disconnect inlet line (A) and outlet line (B) at oil 3. Discard packing.
cooler.
2. Remove nipple (C) or holding screw (D) and lift out

oil cooler.
CD,3274,G25,6 -19-04JAN99

060799
PN=177
STANDARD OIL COOLER ADAPTER

REPLACEMENT
1. Remove oil cooler adapter (A).
-UN-06MAR95
2. Press in new adapter so that threaded end faces
outward (farthest point from cylinder block).
3. Install new packing between oil cooler and cylinder

block.
CD30275
4. Attach oil cooler with nipple (B). Tighten to 35 Nm
(25 lb-ft).
5. Connect coolant lines to oil cooler.
-UN-10MAY95
CD30407
CD,3274,G25,8 -19-01FEB94
25
17

060799
PN=178
STANDARD OIL COOLER/OIL FILTER

BRACKETS REPLACEMENT
A. Engine without camshaft-gear-driven auxiliary

drive and bracket installed on sloped base of
cylinder block.
1. Remove oil filter bracket (A) and oil cooler bracket

(B).
2. Clean and check parts.
3. Install oil cooler bracket (B) with a new O-ring (C).

Tighten adapter (D) to 35 Nm (25 lb-ft).
4. Install oil filter bracket (A) with O-rings (G). Tighten

cap screws (3 used) to 50 Nm (35 lb-ft).
NOTE: Apply sealing compound on thread of cap screw

(H).
-UN-25OCT94
5. Install new packing (J) between oil cooler and bracket.
6. Attach oil cooler with holding screw (K), cover (M) and
CD30408
O-rings (L) and (N). Tighten to 35 Nm (25 lb-ft).
8. Install oil filter adapter (P). Tighten to 45 Nm (33 AOil filter bracket
lb-ft). BOil cooler bracket
CO-ring
25 DAdapter
18 EWasher
FO-ring
GO-rings
HCap screw (to be installed with sealing
compound)
JPacking
KHolding screw
LO-ring
MCover
NO-ring
PAdapter
CD,3274,G25,9 -19-01FEB94

060799
PN=179
B. Engine without camshaft-gear-driven auxiliary

drive and bracket installed on vertical base of
cylinder block.
1. Remove oil filter bracket (A) and oil cooler bracket

(B).
3. Install oil cooler bracket (B) with a new gasket (C).

Tighten cap screws to 50 Nm (35 lb-ft).
4. Install oil filter bracket (A) with a new gasket (D).

Tighten cap screws (3 used) to 50 Nm (35 lb-ft).
NOTE: Apply sealing compound on thread of cap screw

(E).
5. Install new packing (F) between oil cooler (G) and

bracket.
-UN-25OCT94
6. Attach oil cooler with holding screw (H), cover (J) and
O-rings (K and L). Tighten to 35 Nm (25 lb-ft).
CD30409
8. Install oil filter adapter (M). Tighten to 45 Nm

(33 lb-ft).
AOil filter bracket
BOil cooler bracket
CGasket
DGasket 25
ECap screw (to be installed with sealing 19
compound)
FPacking
GOil cooler
HHolding screw
JCover
KO-ring
LO-ring
MAdapter
CD,3274,G25,37 -19-01FEB94

060799
PN=180
C. Engine with camshaft-gear-driven auxiliary drive.
1. Remove oil cooler/filter bracket (A).
-UN-25OCT94
3. Install bracket (A) with a new packing (B) or gasket
(C). Tighten holding screw (D) to 35 Nm (25 lb-ft) or
cap screws (E) to 50 Nm (35 lb-ft).
CD30410
4. Install adapter (F) onto bracket. Tighten to 45 Nm
(33 lb-ft).
Short stroke engine
5. Install a new packing (J) between oil cooler (G) and
bracket.
6. Attach oil cooler with nipple (H). Tighten to 35 Nm

(25 lb-ft).
-UN-25OCT94
AOil cooler/filter bracket

BPacking
CGasket
CD30411
DHolding screw
ECap screws (3 used)
FAdapter Long stroke engine
GOil cooler
HNipple
JPacking
KO-rings
25
20
CD,3274,G25,10 -19-01FEB94

060799
PN=181
REPLACE OIL FILTER ADAPTER ON ENGINE WITH REMOTE OIL FILTER
-UN-24JUN98
CD30619
AHolding screw EOil cooler HO-ring Loil hose
BO-ring FPacking JO-ring MFitting
CCover GOil filter adapter KFitting NOil filter
DO-ring
1. Remove special screw (A) holding both the oil 4. Install adapter with a new O-ring (H), then attach
cooler (E) and the oil filter adapter (G). oil cooler with packing (F), cover (C) and O-rings (D)
and (B). Tighten holding screw (A) to 35 Nm
2. Disconnect oil hoses (L) from adapter. (25 lb-ft). 25
21
3. Clean and check parts. 5. Reconnect oil hoses to adapter and coolant lines
to oil cooler.
CD,CTM125,141 -19-01DEC97

060799
PN=182
HIGH-FLOW OIL COOLER REMOVAL
1. Drain oil cooler at coolant drain plug (F).
2. Disconnect coolant lines and remove the two banjo
-UN-06MAR95
bolts.
3. Remove oil cooler from its support.
4. Check that water passage through cooler is not
CD30281
restricted by scale or dirt.
ADistributor base
BOil lines
COil cooler
DBanjo bolts
ECoolant connections
FCoolant drain plug
GOil filter
CD,3274,G25,12 -19-01FEB94
OIL COOLER DISTRIBUTOR BASE

REMOVAL
1. Disconnect oil lines (A).
-UN-06MAR95
2. Remove holding screw (B) and lift out distributor base
(C).
3. Discard packing.
25
CD30283
22
CD,3274,G25,14 -19-04AUG92
OIL COOLER DISTRIBUTOR BASE REPAIR
1. Remove oil cooler relief valve (A) and inspect for

damage.
-UN-07MAR95
2. Replace valve if necessary.
3. Install relief valve.

CD30020
CD,3274,G25,15 -19-30MAR92

060799
PN=183
HIGH-FLOW OIL COOLER/DISTRIBUTOR BASE INSTALLATION
-UN-10MAY95
CD30412
25
AAdapter ECover HCoolant lines LBanjo bolt 23
BDistributor base FO-ring JOil lines MCopper washers
CO-ring GOil cooler KO-rings NCoolant drain plug
DO-ring
1. Hand-tighten adapter (A). 5. Press oil lines (J) into distributor base using new
O-rings (K).
2. Install distributor base (B) with O-rings (C and D).
6. Connect oil lines to oil cooler using banjo bolts (L)
3. Install cover (E) with O-ring (F). Tighten to 35 Nm with new copper washers (M). Tighten to 100 Nm
(25 lb-ft). (74 lb-ft).
4. Attach oil cooler (G) to support and connect

coolant lines (H).
CD,3274,G25,16 -19-01FEB94

060799
PN=184
Lubrication System/Oil Pressure Regulating Valve
OIL PRESSURE REGULATING VALVE

REMOVAL
Remove oil pressure regulating valve plug. Check valve

cone for excessive wear and damaged sealing face.
-UN-07MAR95
Spring tension at a length of 42.5 mm (1.68 in.):
60 to 75 N (13.5 to 16.5 lb).
CD7173
CD,3274,G25,17 -19-30MAR92
OIL PRESSURE REGULATING VALVE SEAT

REPLACEMENT
1. Remove valve seat bushing, using a suitable puller.
-UN-07MAR95
2. Drive in new bushing, using special tools JD-248A
and JDG536 or OTC813 until driver contacts cylinder
block.
IMPORTANT: Do not damage the slightly protruding
CD7175A
edge of the bushing as it is a sealing
face.
25
24
CD,3274,G25,18 -19-30MAR92
OIL PRESSURE REGULATING VALVE

INSTALLATION
NOTE: One or several shims (A) may be used to adjust

the oil pressure.
-UN-10MAY95
1. Install valve, spring, shims, washer and plug in timing
gear cover.
2. Tighten plug to following torque:

CD30413
Aluminium timing gear cover: 95 Nm (70 lb-ft)

Composite material timing gear cover: 30 Nm
(22 lb-ft)
CD,3274,G25,19 -19-01FEB94

060799
PN=185
Lubrication System/Dipstick Guide
DIPSTICK GUIDE REPLACEMENT
A. Dipstick guide fastened onto cylinder block
1. Loosen lock nut and unscrew dipstick guide.
2. Apply sealing compound on thread of new guide.
3. Install new dipstick guide and adjust height (X) in

accordance with specifications.
-UN-08MAR95
Z20746
CD,3274,G25,20 -19-01FEB94
B. Dipstick guide fastened onto oil pan
NOTE: This type of dipstick guide acts also as oil filler 25

neck. 25
-UN-10MAY95
1. Remove dipstick guide.
2. Clean oil pan sealing surface.
3. Apply a bead of LOCTITE 515 Sealant, then install a
CD30414
new dipstick guide.
NOTE: A tube of LOCTITE 515 Sealant is provided with

4. Tighten cap screws to 50 Nm (35 lb-ft).

060799
PN=186
Lubrication System/Oil By-Pass Valve
OIL BY-PASS VALVE REPLACEMENT
1. Remove timing gear cover and front plate.
2. Remove oil by-pass valve and spring. Inspect valve
-UN-09NOV88
and spring for damage.
IMPORTANT: By-pass valves and springs of two

lengths may be installed on engine.
Check the relationship between cylinder
T87436
block bore depth (C), valve length (B)
and free length of spring (A) as
indicated in the chart.
3. Check spring calibration:
92 to 112 N (21 to 25 lb) for the longer spring when

compressed at 34 mm (1.34 in.) length.
79 to 96.5 N (18 to 22 lb) for the shorter spring when

compressed at 29 mm (1.14 in.) length.
4. Install oil by-pass valve and spring.
5. Install front plate and timing gear cover.
ASpring length
BValve length
CCylinder block bore depth
-UN-23JUL96
YLonger configuration (earlier engines)
ZShorter configuration (later engines)
25
26
CD574P1
CD,3274,G25,21 -19-04JAN99

060799
PN=187
Lubrication System/Oil Pump
OIL SUCTION SCREEN REPLACEMENT (ON

STANDARD OIL PUMP)
NOTE: Oil suction screen may have a paint mark (B) as

shown. Install this part on the following engines
-UN-17FEB95
only:
CD3029DRT65, CD4039DRT35, CD4039TRT35,
CD4045DRT35, CD6059TF002 and
CD6059TF003.
RG7299
1. Remove oil pan.
2. Loosen the two lower cap screws (A) and remove oil
suction screen.
3. Install new suction screen with new O-ring and tighten

cap screws to 50 Nm (35 lb-ft).
-UN-22FEB99
4. Reinstall oil pan.
CD30716
CD,3274,G25,22 -19-04JAN99
OIL SUCTION SCREEN REPLACEMENT (ON

HIGH-FLOW OIL PUMP)
25
The replacement of the oil suction screen requires the 27
complete removal and reinstallation of the oil pump.
-UN-07MAR95
Refer to instructions under HIGH-FLOW OIL PUMP in
this Group.
CD30138
CD,3274,G25,23 -19-30MAR92
OIL PUMP IDENTIFICATION
Two types of oil pump are installed on Saran engines.

One type has a higher oil flow capacity than the other.
-UN-23MAY95
NOTE: The standard oil pump can be assembled with 3

or 4 cap screws.
AStandard oil pump

BHigh-flow oil pump
CD7272
CD,3274,G25,24 -19-31MAR92

060799
PN=188
Lubrication System/Standard Oil Pump
STANDARD OIL PUMP REMOVAL
1. Remove oil pan and timing gear cover.
2. Remove nut (A) from pump shaft.
-UN-07MAR95
3. Pull gear (B) from conical shaft of pump, using a
suitable puller.
4. Remove the 3 or 4 cap screws (C) attaching pump
CD7176
housing to front plate.
CD,3274,G25,25 -19-30MAR92
GEAR AXIAL CLEARANCE (STANDARD OIL

PUMP)
Thickness of gears:
41.15 to 41.20 mm (1.62 to 1.622 in.)
-UN-07MAR95
Axial clearance:
0.05 to 0.17 mm (0.002 to 0.007 in.)
Max. permissible axial clearance :
0.22 mm (0.0085 in.)
25
CD7177
28
CD,3274,G25,26 -19-30MAR92
GEAR RADIAL CLEARANCE (STANDARD

OIL PUMP)
Radial clearance between gear and pump housing :

0.10 to 0.16 mm (0.004 to 0.006 in.)
-UN-07MAR95
Max. permissible radial clearance :
0.20 mm (0.008 in.)
CD7178
CD,3274,G25,27 -19-30MAR92

060799
PN=189
STANDARD OIL PUMP SPECIFICATIONS
Bore of drive shaft in pump housing:

16.05 to 16.08 mm (0.632 to 0.633 in.)
-UN-09NOV88
Max. permissible wear: 0.08 mm (0.003 in.)
Drive shaft O.D.:

16.02 to 16.03 mm (0.630 to 0.631 in.)
T81953
Idler shaft O.D.: 12.32 to 12.34 mm (0.485 to 0.486 in.)
-UN-09NOV88
T81781
CD,3274,G25,28 -19-30MAR92
STANDARD OIL PUMP INSTALLATION
25
29
-UN-10MAY95
CD30416
1Cylinder block seal 5Spring pin 9Outlet tube 12Cap screws (3 or 4 used)
2O-ring (outlet tube) 6Gears 10Strainer 13Drive gear
3O-ring (oil strainer tube) 7Shaft 11Cover 14Nut
4Drive shaft 8Housing
CD,3274,G25,29 -19-01FEB94

060799
PN=190
1. Install new seal in cylinder block.
NOTE: Depending on the machining of the cylinder

block, two types of seals can be used:
-UN-09NOV88
Type (A) for cylinder block with bushing (C).
Type (B) for cylinder block without bushing.
T88931
2. Install O-rings in pump cover (for outlet tube) and on
oil strainer tube.
3. Install drive shaft with gear and idler gear in pump

housing. Both gears must turn freely.
-UN-10MAY95
CD30417
CD,3274,G25,39 -19-04JAN99
25
30

060799
PN=191
4. Install outlet tube, strainer and pump cover as follows:
On engines up to 248035CD, it may be necessary to

grind the oil pump cover as shown, to prevent contact
with crankshaft.
Use outlet tube with paint mark (C) on 6200 and 6300
tractors with engines up to 221092CD as well as on all
long stroke engines (4045 and 6068).
ACrankshaft
BOil pump cover area to be ground
CPaint mark
-UN-22FEB99
CD30717
-UN-22FEB99
CD30718
25
31
CD,3274,G25,51 -19-04JAN99

060799
PN=192
Lubrication System/High-Flow Oil Pump
5. Attach oil pump assembly to front plate, tightening cap

screws (C) to 50 Nm (35 lb-ft).
6. Rotate pump shaft, again making sure that pump

gears turn freely.
-UN-07MAR95
7. Install pump drive gear (B) and tighten hex. nut (A) to
75 Nm (55 lb-ft).
8. Secure the nut by applying three center punch marks.
CD7176
NOTE: When installing the oil pump, make sure that
crankshaft gear and gear of left-hand balancer
shaft are not turned (4-cyl. engines only).
-UN-09NOV88
T81782
CD,3274,G25,40 -19-01FEB94
HIGH-FLOW OIL PUMP REMOVAL
25 1. Remove oil pan and timing gear cover.

32
2. Remove nut (A) from pump shaft.
-UN-07MAR95
3. Pull gear (B) from conical shaft of pump, using a
suitable puller.
4. Remove two cap screws (C) attaching pump housing
CD7276
to front plate.
CD,3274,G25,30 -19-30MAR92

060799
PN=193
GEAR AXIAL CLEARANCE (HIGH-FLOW OIL

PUMP)
Thickness of gears:
50.97 to 51.02 mm (2.007 to 2.009 in.)
-UN-25OCT88
Axial clearance:
0.04 to 0.17 mm (0.0015 to 0.006 in.)
Max. permissible axial clearance:
0.22 mm (0.0085 in.)
T91275
CD,3274,G25,31 -19-30MAR92
GEAR RADIAL CLEARANCE (HIGH-FLOW

OIL PUMP)
Radial clearance between gear and pump housing:

0.08 to 0.18 mm (0.003 to 0.007 in.)
-UN-25OCT88
Max. permissible radial clearance:
0.23 mm (0.009 in.)
T91276
CD,3274,G25,32 -19-30MAR92
25
33

060799
PN=194
HIGH-FLOW OIL PUMP SPECIFICATIONS
Bore of drive shaft in pump cover (A) :

16.06 to 16.08 mm (0.632 to 0.633 in.)
-UN-07MAR95
Drive shaft O.D. (B):

16.02 to 16.03 mm (0.630 to 0.631 in.)
CD7279
Drive shaft O.D. (C):

12.256 to 12.266 mm (0.4825 to 0.4829 in.)
Bore of drive shaft in pump housing (D) :
-UN-07MAR95
12.28 to 12.31 mm (0.4835 to 0.4845 in.)
Maximum permissible wear: 0.013 mm (0.0005 in.)
CD7280
-UN-07MAR95
25
34
CD7281
-UN-07MAR95
CD7282
CD,3274,G25,33 -19-30MAR92

060799
PN=195
HIGH-FLOW OIL PUMP INSTALLATION
-UN-10MAY95
CD30418
1Cylinder block O-ring 4Drive shaft 7Outlet tube 10Cap screws (2 used)
2O-ring (outlet tube) 5Gears 8Strainer 11Drive gear
3O-ring (strainer tube) 6Housing 9Pump cover 12Nut
CD,3274,G25,34 -19-01FEB94
1. Install new O-rings in cylinder block, pump housing

(for outlet tube) and on oil strainer tube.
25
2. Install drive shaft with gear and idler gear in pump 35
housing. Both gears must turn freely.
-UN-07MAR95
3. Install outlet tube, strainer and pump cover.
CD7181
CD,3274,G25,41 -19-01FEB94

060799
PN=196
4. Attach oil pump assembly to front plate, tightening cap

screws (A) to 50 Nm (35 lb-ft).
5. Rotate pump shaft, again making sure that pump

gears turn freely.
-UN-07MAR95
6. Install pump drive gear (B) and tighten hex. nut (C) to
75 Nm (55 lb-ft).
7. Secure the nut by applying three center punch marks.
CD7283
NOTE: When installing the oil pump, make sure that
crankshaft gear and gear of left-hand balancer
shaft are not turned (4-cyl. engines only).
-UN-07MAR95
CD7284
CD,3274,G25,42 -19-01FEB94
25
36

060799
PN=197
Lubrication System/Oil Pan
OIL PAN INSTALLATION
1. Place LOCTITE 515 Sealant (or an equivalent

sealant) on oil pan rail where flywheel housing, front
plate and timing gear cover are attached to the cylinder
-UN-10MAY95
block.
NOTE: A tube of LOCTITE 515 Sealant is provided with

CD30419
2. Select and install the correct gasket for the oil pan
being used.
3. Install oil pan and tighten cap screws as follows:
Oil pan (all types) to aluminium

timing gear cover . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Oil pan (all types) to composite
-UN-10MAY95
material timing gear cover . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
Sheet metal oil pan to block
and flywheel housing . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Aluminium oil pan to block and
flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
CD30438
Cast iron pan to block and flywheel
housing:
SAE 5 screws (3 dashes) . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
SAE 8 screws (6 dashes) . . . . . . . . . . . . . . . . . 70 Nm (50 lb-ft)
4. On 3000/3010 Series tractors, tighten the two cap

screws (A) to 320 Nm (235 lb-ft).
5. Install a new seal onto cylindrical drain plug. Tighten

as follows: 25
37
Cylindrical plug . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm (50 lb-ft)
Conical plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (40 lb-ft)

060799
PN=198
Lubrication System/Oil Pan
25
38

060799
PN=199
Group 30
Cooling System

CD30285 -UN-08MAR95
Bearing driver . . . . . . . . . . . . . . . . . . . . . . JD-262A
To install water pump bearing (small bearing).
CD,JD262A -19-04AUG92
CD30286 -UN-08MAR95
Bearing driver . . . . . . . . . . . . . . . . . . . . . . . JDE74
To install water pump bearing (large bearing).
CD,JDE74 -19-07APR92
RG5109 -UN-23AUG88
Seal Remover . . . . . . . . . . . . . . . . . . . . . . . JDG22
Remove oil seals.
S53,JDG22 -19-05APR90
RG5133 -UN-23AUG88
O-Ring Seal Tool Set . . . . . . . . . . . . . . . . . JDG127
Remove O-rings.
S53,JDG127,B -19-05APR90
JDG529 -UN-10MAY95 30
Tension gauge . . . . . . . . . . . . . . . . . . . . . . JDG529 1
Measure V-Belt tension.
CD,JDG529 -19-01FEB94

060799
PN=200
Cooling System/Specifications
SPECIFICATIONS
Clearance between pump housing and

impeller
Engine without rotating assembly . . . . . . . 00.25 mm (00.01 in.)
Engine with rotating assembly . . . . . . . . . 11.3 mm (0.040.05 in.)
Thermostat opening . . . . . . . . . . . . . . . . . 82C (180F)
Fan belt tension (standard V-belts) . . . . . . . 19 mm (0.75 in.) deflection with a

90 N (20 lb) force applied halfway
between the two pulleys.
CD,3274,G30,1 -19-04JAN99
30
2

060799
PN=201
Distance from pulley or hub to pump

housing sealing surface:
Machine Model No. Distance
Mannheim Tractors:
3100 to 3400/3400 X . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . 155 mm (6.10 in.)
3110 to 3410/3410 X . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . 155 mm (6.10 in.)
6100 to 6400 with cast iron pulley . .... . . . . . . . . . . . . . . . . . . . . . . . . 94 mm (3.70 in.)
6100 to 6400 with sheet metal pulley ... . . . . . . . . . . . . . . . . . . . . . . . . 97.5 mm (3.84 in.)
6506 to 6900 . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . 95.5 mm (3.84 in.)
(Agritalia-built)
5300/5300N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 mm (5.35 in.)
5400/5400N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 mm (5.35 in.)
5500/5500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 mm (5.39 in.)
(Augusta-built)
5400N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 mm (5.35 in.)
5500N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 mm (5.39 in.)
(For India)
5300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 mm (5.35 in.)
7600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 mm (3.70 in.)

4400 and 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5.51 in.)
2000-Series Combines: 30
2054 and 2254 (Water pump pulley) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158.5 mm (6.24 in.) 3
2054 and 2254 (Fan pulley) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174.5 mm (6.87 in.)

CD6059TYC01 and CD6059TYC02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.5 mm (7.14 in.)

CD3029DFG21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 mm (5.39 in.)
CD3029DFG22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 mm (5.39 in.)
CD3029TFG21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 mm (5.39 in.)
CD,3274,G30,39 -19-04JAN99

060799
PN=202

SARAN OEM ENGINES Option code Distance
CD3029DF, CD3029DF001 . . . . . . . . . . . 2004, 2005, 2007 140 mm (5.51 in.)

2014 137 mm (5.39 in.)
2033 165 mm (6.50 in.)
CD3029DF005 . . . . . . . . . . . . . . . . . . . 2007 140 mm (5.51 in.)
CD3029DF031 . . . . . . . . . . . . . . . . . . . 2004, 2005 140 mm (5.51 in.)

2007, 2014 137 mm (5.39 in.)
CD3029DF032 . . . . . . . . . . . . . . . . . . . 2004 140 mm (5.51 in.)
CD3029DF033 . . . . . . . . . . . . . . . . . . . 2014 137 mm (5.39 in.)
CD3029DF034 . . . . . . . . . . . . . . . . . . . 2004 140 mm (5.51 in.)
CD3029DF120 . . . . . . . . . . . . . . . . . . . 2010, 2022, 2024 137 mm (5.39 in.)

2020, 2021, 2034 140 mm (5.51 in.)
2023 165 mm (6.50 in.)
CD3029DF121 . . . . . . . . . . . . . . . . . . . 2020 140 mm (5.51 in.)

2023 165 mm (6.50 in.)
CD3029DF122 . . . . . . . . . . . . . . . . . . . 2034 140 mm (5.51 in.)
CD3029DF123 . . . . . . . . . . . . . . . . . . . 2020 140 mm (5.51 in.)
CD3029DF124 . . . . . . . . . . . . . . . . . . . 2034 140 mm (5.51 in.)
30 CD3029DF128 . . . . . . . . . . . . . . . . . . . 2034 140 mm (5.51 in.)

4
CD3029DF160 . . . . . . . . . . . . . . . . . . . 2022 137 mm (5.39 in.)
2020, 2021 140 mm (5.51 in.)
2023 165 mm (6.50 in.)
CD3029DF161 . . . . . . . . . . . . . . . . . . . 2020 140 mm (5.51 in.)
CD3029DF162 . . . . . . . . . . . . . . . . . . . 2024 137 mm (5.39 in.)
CD3029DF163 . . . . . . . . . . . . . . . . . . . 2020 140 mm (5.51 in.)
CD3029DF164 . . . . . . . . . . . . . . . . . . . 2020 140 mm (5.51 in.)
CD3029DF165 . . . . . . . . . . . . . . . . . . . 2024 137 mm (5.39 in.)
CD,3274,G30,40 -19-04JAN99

060799
PN=203

CD3029TF . . . . . . . . . . . . . . . . . . . . . . 2007, 2014 137 mm (5.39 in.)
CD3029TF001 . . . . . . . . . . . . . . . . . . . 2004, 2005, 2011 140 mm (5.51 in.)

2007, 2014 137 mm (5.39 in.)
2033 165 mm (6.50 in.)
CD3029TF002 . . . . . . . . . . . . . . . . . . . 2014 137 mm (5.39 in.)
CD3029TF031 . . . . . . . . . . . . . . . . . . . 2004, 2005, 2011 140 mm (5.51 in.)

2007, 2014 137 mm (5.39 in.)
CD3029TF032 . . . . . . . . . . . . . . . . . . . 2004 140 mm (5.51 in.)
CD3029TF033 . . . . . . . . . . . . . . . . . . . 2014 137 mm (5.39 in.)
CD3029TF120 . . . . . . . . . . . . . . . . . . . 2020, 2021 140 mm (5.51 in.)

2022, 2028 137 mm (5.39 in.)
2023 165 mm (6.50 in.)
CD3029TF121 . . . . . . . . . . . . . . . . . . . 2020 140 mm (5.51 in.)

2023 165 mm (6.50 in.)
CD3029TF123 . . . . . . . . . . . . . . . . . . . 2020 140 mm (5.51 in.)
CD3029TF160 . . . . . . . . . . . . . . . . . . . 2020, 2021 140 mm (5.51 in.)

2022 137 mm (5.39 in.)
2023 165 mm (6.50 in.)
CD3029TF161 . . . . . . . . . . . . . . . . . . . 2020 140 mm (5.51 in.) 30

2022 137 mm (5.39 in.) 5
CD3029TF162 . . . . . . . . . . . . . . . . . . . 2022, 2024 137 mm (5.39 in.)
CD3029TF163 . . . . . . . . . . . . . . . . . . . 2024 137 mm (5.39 in.)
CD,3274,G30,41 -19-04JAN99

060799
PN=204

CD4039DF . . . . . . . . . . . . . . . . . . . . . 2004, 2005, 2007, 2013 140 mm (5.51 in.)

2014 137 mm (5.39 in.)
2021, 2022 163.5 mm (6.44 in.)
2033 165 mm (6.50 in.)
CD4039DF001 . . . . . . . . . . . . . . . . . . . 2004, 2005, 2013 140 mm (5.51 in.)

2007, 2014 137 mm (5.39 in.)
2021, 2022 163.5 mm (6.44 in.)
2033 165 mm (6.50 in.)
CD4039DF002 . . . . . . . . . . . . . . . . . . . 2013, 2026 140 mm (5.51 in.)
CD4039DF004 . . . . . . . . . . . . . . . . . . . 2004 140 mm (5.51 in.)
CD4039DF005 . . . . . . . . . . . . . . . . . . . 2007 140 mm (5.51 in.)
CD4039DF006 . . . . . . . . . . . . . . . . . . . 2007 140 mm (5.51 in.)
CD4039DF007 . . . . . . . . . . . . . . . . . . . 2026 137 mm (5.39 in.)
CD4039DF008 . . . . . . . . . . . . . . . . . . . 2026 137 mm (5.39 in.)
CD4039DF031 . . . . . . . . . . . . . . . . . . . 2004, 2005, 2026 140 mm (5.51 in.)

2007, 2014 137 mm (5.39 in.)
CD4039DF032 . . . . . . . . . . . . . . . . . . . 2014 137 mm (5.51 in.)

30
6
CD,3274,G30,42 -19-04JAN99

060799
PN=205

CD4039TF . . . . . . . . . . . . . . . . . . . . . . 2004, 2021, 2022 163.5 mm (6.44 in.)

2005, 2013, 2026 140 mm (5.51 in.)
2014 137 mm (5.39 in.)
2023 188.5 mm (7.42 in.)
CD4039TF001 . . . . . . . . . . . . . . . . . . . 2004, 2021, 2022 163.5 mm (6.44 in.)

2005, 2013, 2026 140 mm (5.51 in.)
2014 137 mm (5.39 in.)
2023 188.5 mm (7.42 in.)
CD4039TF002 . . . . . . . . . . . . . . . . . . . 2013, 2026 140 mm (5.51 in.)
CD4039TF003 . . . . . . . . . . . . . . . . . . . 2026 140 mm (5.51 in.)
CD4039TF004 . . . . . . . . . . . . . . . . . . . 2026 140 mm (5.51 in.)
CD4039TF005 . . . . . . . . . . . . . . . . . . . 2026 140 mm (5.51 in.)
CD4039TF006 . . . . . . . . . . . . . . . . . . . 2026 140 mm (5.51 in.)
CD4039TF007 . . . . . . . . . . . . . . . . . . . 2027 137 mm (5.39 in.)
CD4039TF008 . . . . . . . . . . . . . . . . . . . 2027 137 mm (5.39 in.)
CD4039TF031 . . . . . . . . . . . . . . . . . . . 2004 163.5 mm (6.44 in.)

2005, 2026 140 mm (5.51 in.)
2014 137 mm (5.39 in.)
CD4039TF032 . . . . . . . . . . . . . . . . . . . 2014 137 mm (5.39 in.) 30

7
CD,3274,G30,43 -19-04JAN99

060799
PN=206

CD6059DF . . . . . . . . . . . . . . . . . . . . . 2004, 2008 163.5 mm (6.44 in.)

2023 188.5 mm (7.42 in.)
2033 165 mm (6.50 in.)
CD6059DF001 . . . . . . . . . . . . . . . . . . . 2004, 2008 163.5 mm (6.44 in.)

2023 188.5 mm (7.42 in.)
2033 165 mm (6.50 in.)
CD6059DF002 . . . . . . . . . . . . . . . . . . . 2004, 2008 163.5 mm (6.44 in.)
CD6059DF003 . . . . . . . . . . . . . . . . . . . 2004 163.5 mm (6.44 in.)
CD6059TF, CD6059TF001 . . . . . . . . . . . 2004, 2008 163.5 mm (6.44 in.)

2023 188.5 mm (7.42 in.)
2033 165 mm (6.50 in.)
CD6059TF002 . . . . . . . . . . . . . . . . . . . 2004, 2005 163.5 mm (6.44 in.)
CD6059TF003 . . . . . . . . . . . . . . . . . . . 2004, 2005 163.5 mm (6.44 in.)
CD6059TF004 . . . . . . . . . . . . . . . . . . . 2004, 2008 163.5 mm (6.44 in.)
CD6059TF005 . . . . . . . . . . . . . . . . . . . 2005 162 mm (6.38 in.)
CD6059TF006 . . . . . . . . . . . . . . . . . . . 2005 162 mm (6.38 in.)
CD6059TF007 . . . . . . . . . . . . . . . . . . . 2004 163.5 mm (6.44 in.)

2023 188.5 mm (7.42 in.)
30
8 CD6059TF008 . . . . . . . . . . . . . . . . . . . 2005 162 mm (6.38 in.)
CD,3274,G30,44 -19-04JAN99

060799
PN=207

CD4045DF001 . . . . . . . . . . . . . . . . . . . 2004, 2019 163.5 mm (6.44 in.)

2016, 2017 140 mm (5.51 in.)
2023 188.5 mm (7.42 in.)
CD4045DF031 . . . . . . . . . . . . . . . . . . . 2004 163.5 mm (6.44 in.)

2016, 2017 140 mm (5.51 in.)
CD4045TF001 . . . . . . . . . . . . . . . . . . . 2004, 2019 163.5 mm (6.44 in.)

2016, 2017 140 mm (5.51 in.)
2023 188.5 mm (7.42 in.)
CD4045TF002 . . . . . . . . . . . . . . . . . . . 2016, 2026 140 mm (5.51 in.)
CD4045TF003 . . . . . . . . . . . . . . . . . . . 2016 140 mm (5.51 in.)
CD4045TF008 . . . . . . . . . . . . . . . . . . . 2016 140 mm (5.51 in.)
CD4045TF031 . . . . . . . . . . . . . . . . . . . 2004 163.5 mm (6.44 in.)

2016, 2017 140 mm (5.51 in.)
CD6068DF001 . . . . . . . . . . . . . . . . . . . 2004, 2008 163.5 mm (6.44 in.)

2023 188.5 mm (7.42 in.)
CD6068TF001 . . . . . . . . . . . . . . . . . . . 2004, 2008 163.5 mm (6.44 in.)

2023 188.5 mm (7.42 in.)
CD6068TF002 . . . . . . . . . . . . . . . . . . . 2004 163.5 mm (6.44 in.)

2023 188.5 mm (7.42 in.)
30
CD6068TF003 . . . . . . . . . . . . . . . . . . . 2005 162 mm (6.38 in.) 9
CD6068TF004 . . . . . . . . . . . . . . . . . . . 2005 162 mm (6.38 in.)
CD6068TF008 . . . . . . . . . . . . . . . . . . . 2005 162 mm (6.38 in.)
CD6068TF009 . . . . . . . . . . . . . . . . . . . 2005 162 mm (6.38 in.)
CD,3274,G30,45 -19-04JAN99

060799
PN=208
Cooling System/Torques for hardware
Water pump to cylinder block:

Cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
Back plate to water pump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (33 lb-ft)
Rotating assembly to water pump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
Sheet metal pulley and fan to pulley hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Fan to cast iron pulley:

5/16 in. cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
3/8 in. cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Thermostat cover to thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lb-ft)
Thermostat or water outlet housing to

cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Fan bracket onto engine (2054/2254 combines)

Cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm (220 lb-ft)
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
CD,3274,G30,3 -19-04JAN99
30
10

060799
PN=209
Cooling System/Water Pump (standard model)
WATER PUMP EXPLODED VIEW
-UN-10MAY95
CD30421
AHousing CSeal EGasket GHub (or pulley)
BBearing shaft DImpeller FRear cover
CD,3274,G30,22 -19-01FEB94
30
WATER PUMP IDENTIFICATION 11
A Standard water pump with one-piece shaft/ball

bearing pressed into housing. Used with separate
thermostat housing and rear cover.
-UN-06MAR95
CD30287
CD,3274,G30,23 -19-01FEB94

060799
PN=210
B Water pump with removable rotating assembly.

The pump housing incorporates also the dual thermostat
housing. A one-piece shaft/ball bearing is pressed into
the rotating assembly.
-UN-06MAR95
CD30288
CD,3274,G30,24 -19-01FEB94
C Water pump with built-in single thermostat

housing. A one-piece shaft/ball bearing pressed into the
pump housing and a rear cover is used.
-UN-06MAR95
CD30289
CD,3274,G30,25 -19-01FEB94
WATER PUMP REMOVAL
1. Remove fan.
2. Disconnect water pump hoses.
-UN-06MAR95
30 3. Remove attaching screws (A) and nut (B) then lift out
12 water pump.
CD30290
CD,3274,G30,5 -19-07APR92

060799
PN=211
DISASSEMBLE WATER PUMP (STANDARD

MODEL)
NOTE: When water pump operation is abnormal or when

coolant drains from the weep hole (G),
disassemble water pump as follows.
1. Remove rear cover (A) and discard gasket.
2. Using a suitable puller, remove pulley (B) or hub from

bearing shaft (C).
3. Support pulley end of housing, then using a 13 mm

(0.5 in.) driver, simultaneously remove impeller (D) from
bearing shaft and bearing shaft from pump housing (E).
Discard bearing and impeller.
-UN-16JUN98
4. Using a suitable driver, remove seal (F) from pump
housing and discard.
5. Inspect water pump housing, cover and pulley for

wear, debris, cracks or other damage. Replace as
CD30630
necessary.
NOTE: Complete or pre-assembled (H) water pumps are

available for service as well as a seal kit
including bearing shaft (C), impeller (D), seal (F)
and gasket set.
ARear cover
BPulley
-UN-04MAY98
CBearing shaft
DImpeller
EHousing
FSeal
GWeep hole
HPre-assembled water pump 30
13
CD30631
-UN-16JUN98
CD30632
Pre-assembled water pump
CD,3274,G30,46 -19-04JAN99

060799
PN=212
WATER PUMP BEARING SHAFT

INSTALLATION
1. Use JD-262A or JDE74 Bearing Driver to install

bearing shaft.
-UN-23FEB89
2. Press into housing until bearing face is flush with
housing hub face.
CD7360
CD,3274,G30,8 -19-07APR92
WATER PUMP SEAL INSTALLATION
NOTE: The unitized (one-piece) water seal (A) has

replaced the previous three-piece water seal (B).
The unitized seal is to be used even if the
-UN-21AUG92
three-piece seal is still included in repair kit. In
this case, order also AR101549 water pump seal
kit.
1. Place pump housing under a press so that the thrust
RG6389
when pressing on seal is received only by the pump
shaft face.
IMPORTANT: Installation tool (C) MUST be used to

drive seal into pump housing. This tool
exerts the correct pressure on seal
faces. Do not use sealant on any
portion of seal.
-UN-03FEB95
2. Using special tool (C) included in repair kit, install
30 water pump seal (A) simultaneously over shaft and into
14 housing until seal bottoms on shoulder of housing (D).
RG6376
CD,3274,G30,9 -19-01FEB94

060799
PN=213
WATER PUMP IMPELLER INSTALLATION
Place water pump under a press so that the thrust when

pressing on impeller is received only by the pump shaft
face.
-UN-06MAR95
Using special tool JD-262A or JDE74, press impeller
onto pump shaft until flush with pump housing face
within a given tolerance of +0 mm (0 in.) and -0.25 mm
(0.01 in.).
CD30292
-UN-17FEB95
CD30293
CD,3274,G30,10 -19-07APR92
INSTALL PULLEY OR HUB
30
15
-UN-04MAY98
-UN-16JUN98
CD30638
CD30652
1. Place pump housing under a press and support on 2. Install pulley or hub to the specified dimension A
impeller end of shaft. (see specifications).
CD,3274,G30,47 -19-04JAN99

060799
PN=214
INSTALL WATER PUMP
1. Attach pump cover to pump housing using a new

gasket and tighten cap screws to 45 Nm (33 lb-ft).
-UN-04MAY98
2. Install water pump, placing a new gasket between the
pump cover and cylinder block. Tighten cap screws (B)
to 50 Nm (35 lb-ft) and nut (C) to 40 Nm (30 lb-ft).
3. Connect coolant hoses (A).
CD30629
CD,CTM125,163 -19-01DEC97
NOTE: Some water pumps may have the cap screw (A)
which protrudes from rear cover. Be sure that the
cylinder block has the corresponding foundry
recess. If necessary, grind the cylinder block as
shown.
-UN-10MAY95
ACap screw
B14 mm (0.55 in.)
C90 mm (3.50 in.)
D4 mm (0.15 in.)
E25 mm (1 in.)
CD30422
-UN-10MAY95
30
16
CD30423
CD,3274,G30,29 -19-01FEB94

060799
PN=215
Cooling System/Water pump with rotating assembly
WATER PUMP WITH ROTATING ASSEMBLY - EXPLODED VIEW
-UN-22FEB99
CD30719
AComplete water pump
BRear housing*
CRotating assembly housing*
DImpeller*
EService seal kit*
FGasket*
GO-ring*
HGasket*
-UN-22FEB99
JO-ring*
KWater pump seal
LBearing shaft
MSeal installation tool
NLock washer*
PCap screw* 30
17
CD30720
QHub*
RThermostat*
SThermostat with valve*
* Parts or kit available for service. Refer to appropriate parts catalogs. CD,3274,G30,48 -19-04JAN99

060799
PN=216
ROTATING ASSEMBLY REMOVAL
NOTE: The rotating assembly (A), including front cover,

impeller, seal and bearing shaft, can be removed
from the pump housing without removing the
-UN-17FEB95
water pump from engine.
1. Mark rotating assembly and pump housing to facilitate

the reinstallation.
CD30294
2. Remove the 8 cap screws (B) and lift out rotating
assembly.
CD,3274,G30,13 -19-04JAN99
DISASSEMBLING ROTATING ASSEMBLY
1. Using a suitable puller, remove hub (A) from shaft.
-UN-17FEB95
CD30342
CD,3274,G30,20 -19-01FEB94
30
18 2. Using a suitable puller, remove impeller (B) from
shaft.
-UN-17FEB95
CD30343
CD,3274,G30,30 -19-01FEB94

060799
PN=217
3. Support hub end of bearing housing. Push against

impeller end of shaft to remove bearing shaft from
housing.
-UN-17FEB95
CD30344
CD,3274,G30,31 -19-01FEB94
REASSEMBLING ROTATING ASSEMBLY
1. Place housing with impeller end side down on a

press.
-UN-17FEB95
NOTE: Bearing shaft is installed from pulley end of pump
housing.
2. Using JD-262A or JDE74 Bearing Driver, press

bearing shaft (A) into housing until bearing face is flush
CD30345
with housing end face.
CD,3274,G30,21 -19-01FEB94
3. Install new one-piece water seal (B) using the

installation tool provided with the seal.
IMPORTANT: The installation tool MUST be used to

drive seal into housing. This tool sets
-UN-17FEB95
the preload on seal faces and protects
seal from eventual damage. Do not use 30
sealant on any portion of the seal. 19
CD30346
CD,3274,G30,32 -19-04JAN99
NOTE: Place water pump under a press so that the

thrust when pressing on impeller is received only
by the pump shaft end.
4. Using special tool JD-262A or JDE74, press impeller

-UN-17FEB95
onto pump shaft until 1 to 1.3 mm (0.04 to 0.05 in.)

clearance (C) is obtained.
CD30347
CD,3274,G30,33 -19-01FEB94

060799
PN=218
5. Using special tool JD-262A or JDE74, press pulley or

hub until specified distance (D) is obtained.
Distance (D) from hub to sealing
-UN-07MAR95
surface:
cast iron pulley . . . . . . . . . . . . . . . . . . . . . . . . 94 mm (3.70 in.)
sheet metal pulley . . . . . . . . . . . . . . . . . . . . . 97.5 mm (3.84 in.)
NOTE: A L100292 spacer (E) can be used to allow the

installation of a sheet metal pulley onto a water
CD30348
pump settled for a cast iron pulley (hub position
= 94 mm; 3.7 in.).
-UN-10MAY95
CD30424
CD,3274,G30,34 -19-01FEB94
ROTATING ASSEMBLY INSTALLATION
1. Install new O-ring (A) in pump housing.
2. Place 2 guide studs diametrically opposed (B), then
-UN-17FEB95
slide rotating assembly by aligning marks previously
30 made.
20
IMPORTANT: Without guide studs, the O-ring could
be damaged when repositioning
CD30295
rotating assembly on pump assembly
to align cap screw holes.
NOTE: The holes are not equally spaced allowing only

one position of the rotating assembly on pump
housing.
3. Apply sealing compound on thread of cap screws (C),

-UN-17FEB95
tighten to 30 Nm (22 lb-ft).

CD30296
CD,3274,G30,14 -19-07APR92

060799
PN=219
Cooling System/Thermostats
THERMOSTAT TEST AND REPLACEMENT
1. Visually inspect area around thermostat housing for

leaks.
-UN-07MAR95
2. Remove thermostat cover (A) and thermostat(s).
NOTE: Engines may be equipped with either one or two

thermostats. It is recommended to replace the
thermostats after every two years of service.
CD7297
3. Test in hot water correct opening and closing (see
Specifications).
-UN-17FEB95
CD30297
CD,3274,G30,15 -19-01FEB94
4. Install thermostat(s) in proper location.
NOTE: Thermostat(s) with extended end (B) must fit with

by-pass hole in housing (C).
-UN-17FEB95
5. Install thermostat cover using new gasket, tighten to
30 Nm (22 lb-ft). 30
21
CD30299
CD,3274,G30,35 -19-04JAN99
NOTE: Some engines may have the thermostat directly

installed in cylinder head (A). The by-pass
function is performed via the tube (B) connected
to water pump (C).
-UN-18MAY95
Install thermostat with jiggle pin on top for a proper

filling.
CD30437
CD,3274,G30,38 -19-01FEB94

060799
PN=220
Cooling System/Cooling sytem deaeration
COOLING SYSTEM DEAERATION
-UN-04MAY98
-UN-16JUN98
CD30643
CD30642
Deaeration is normally accomplished by the jiggle pin cooling system, loosen coolant temperature sensor or
(A) in thermostat flange area. However a pocket of plug at the rear of cylinder head (B) to allow air to
air can stay on the top rear of engine. When refilling escape.
CD,CTM125,165 -19-01DEC97
30
22

060799
PN=221
Cooling System/Fan/alternator Drive Belt Replacement
CHECK FAN/ALTERNATOR BELT TENSION
1. Check belt tension using one of following methods:
NOTE: On engine with dual belts, check tension of front
-UN-04MAY98
belt only.
a) Use of JDG529 Tension Gauge (A)
Tension New Belt Tension Used Belt*
CD30644
Single belt 578622 N 378423 N
(130140 lb) force (8594 lb) force
Dual belts 423467 N 378423 N

(95104 lb) force (8594 lb) force
b) Use of tension tester (B) and straightedge (C)

A 89 N (20 lb) force applied halfway between pulleys
should deflect belt by 19 mm (0.75 in.).
-UN-04MAY98
2. If adjustment is necessary, loosen alternator nuts (D)
and (E). Pull alternator frame outward until belt is
correctly tensioned.
CD30645
IMPORTANT: Do not pry against the alternator rear
frame. Do not tighten or loosen belts
while they are hot.
3. Tighten alternator bracket nuts firmly.
4. Run engine for 10 minutes then recheck belt tension.
-UN-04MAY98
30
23
CD30646
*Belts are considered used after 10 minutes of operation. CD,CTM125,166 -19-28JUN99

060799
PN=222
Cooling System/Fan Installation
INSTALL FAN
-UN-16JUN98
-UN-16JUN98
CD30647
CD30648
Suction fan (top view)
1. Inspect fan blades for bent or damaged condition.

Bent blades reduce cooling system efficiency and throw
the fan out of balance. Replace if necessary.
NOTE: Depending on application, engine may be
-UN-16JUN98
equipped with either suction-type or blower-type
fan. Take care not to install the fan wrongly.
Refer to illustrations to identify the fan type and
the corresponding installation.
CD30649
2. On water pump with hub, install first the sheet metal
pulley.
Blower fan (top view)
3. Install fan (A) with spacer (B) when required.
4. Install cap screws (C) with new lock washers (D) and,
when required, flat washers (E). Tighten as follows:
5/16 in. cap screws ...........30 Nm (22 lb-ft)
30 3/8 in. cap screws ............50 Nm (35 lb-ft)
24
CD,CTM125,167 -19-01DEC97

060799
PN=223
Cooling System/Fan installation on 2054/2254 combines
INSTALL ENGINE FAN PULLEY ON 2054

AND 2254 COMBINES (WITH CD6060HZ001
ENGINES)
1. Press bearing shaft (A) into fan bracket (B) until

bearing face is flush with bracket end face.
2. Place fan bracket under a press so that the thrust

when pressing on pulley is received only by the bearing
shaft end (F). Press pulley until the distance (G) is
obtained.
Distance (G) . . . . . . . . . . . . . . . . . . . . . . . 174.5 mm (6.87 in.)
3. Install fan bracket onto engine. Tighten as follows:
Cap screws (E) . . . . . . . . . . . . . . . . . . . . . . 300 Nm (220 lb-ft)

Nuts (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
-UN-23FEB99
CD30721
30
-UN-22FEB99
25
CD30722
CD,3274,G30,49 -19-04JAN99

060799
PN=224
Cooling System/Coolant heater
COOLANT HEATER OPERATION (4 AND 6

CYL. ENGINES)
The 1000 W electrical heater element (B) heats engine

coolant resulting in a better starting performance.
-UN-07MAR95
Furthermore, the engine will reach its operating
temperature more quickly.
At an ambient temperature of -15C (-4F), the heating
process takes approximatively 2 hours. Extend heating
period if ambient temperature is lower.
LX007471
For operating, connect plug (A) to a 110 or 220 V
electrical power source depending on the coolant heater
element.
APlug
BCoolant heater
CD,3274,G30,37 -19-04JAN99
30
26

060799
PN=225
REPLACING THE COOLANT HEATER (4

AND 6 CYL. ENGINES)
1. Unplug heater from electrical power source.
2. Drain cooling system.
3. Remove electrical cord, hold heater element (F) in

place to prevent that it rotates, then loosen nut (B).
Remove adapter (C) then pull heater element out of
block.
4. Check for heating operation of the element.
N CAUTION: Energize coolant heater only when

heater element is immersed in coolant. Heater
element could burst and result in personal
injury.
NOTE: The heater element cannot be repaired. If

defective, replace it.
5. Assemble coolant heater (110 or 220 V) as shown in

illustration.
-UN-10MAY95
6. Place heater element in block with flats on thread in
vertical position. The element must not touch internal
walls of the block.
7. Tighten nut to 35 Nm (25 lb-ft).
CD30426
NOTE: Heater element may have a tapered surface
instead of a thread. In this case position heater
element properly, then tap into place with a
rubber mallet. ACord
BNut 30
CAdapter 27
DO-Ring
EGasket
FHeater element
CD,3274,G30,19 -19-04JAN99

060799
PN=226
COOLANT HEATER OPERATION (ALL ENGINES)
-UN-23FEB99
CD30723
ACoolant heater CAdapter GHexagonal cap JEngine coolant
BHeater element DElectrical cord HEngine coolant temperature sensor in
RE64803 for 3 and 4 cyl. EClamp temperature sensor in cyl. thermostat housing
(240 V, 1000 W) FCoolant temperature block
RE64804 for 6 cyl. (240 V, sensor for heater
1500 W) regulation
This coolant heater is installed at the rear of cylinder NOTE: Due to the location of the coolant temperature
block coolant gallery. sensor for heater regulation at the rear of the
cylinder head, the engine coolant temperature
30 The coolant heater keeps the temperature between sensor is located either in cyl. block (H) or in
28 26C (80F) and 37C (100F). A temperature sensor thermostat housing (J).
(F), located at the rear of the cylinder head, allows to
leave the coolant heater on power supply indefinitely.
CD,3274,G30,50 -19-04JAN99

060799
PN=227
-UN-31OCT96
-UN-16JUN98
CD563P3
CD30651
Precaution for removal Installation
IMPORTANT: Heater element (A) is bent to avoid 1. Apply Loctite 609 (JD part number: TY15969)
interference with cylinder block Retaining Compound or equivalent to heater element
walls. For removal, DO NOT TURN tapered surface and to conical adapter.
neither the heater element nor the
conical adapter (B). Failure to this 2. Install heater element in cylinder block. Be sure
will irremediably damage the heater that heater element do not touch internal walls of the
element. block.
1. Apply a pulling motion between heater element 3. When heater element is properly positioned, tap
and adapter to release the conical assembly. into place with a rubber mallet.
2. Pull out heater element from cylinder block. It is 4. Connect electrical cord to heater element and fix it
not necessary to remove the conical adapter. with the clamp using a pliers.
CD,CTM125,169 -19-01DEC97
30
29

060799
PN=228
30
30

060799
PN=229
Group 35
Air Intake and Exhaust System
SPECIFICATIONS
Turbocharger boost pressure, minimum

(at rated engine power and speed) . . . . . . 60 kPa (0.6 bar - 9 psi)
Exhaust adapter end play . . . . . . . . . . . . . 0.81.6 mm (0.030.06 in.)
Radial bearing end play:

GARRETT Turbocharger:
TA25 (3-cylinder engines) . ... . . . . . . 0.060.13 mm (0.00240.005 in.)
TA34 (4/6-cylinder engines) .. . . . . . . 0.080.18 mm (0.0030.007 in.)
T300 (4-cylinder engines) . ... . . . . . . 0.080.18 mm (0.0030.007 in.)
T350 (6-cylinder engines) . ... . . . . . . 0.080.18 mm (0.0030.007 in.)
SCHWITZER Turbocharger
S2A Model . . . . . . . . . . . . . . . . . . . . 0.740.81 mm (0.0290.032 in.)
Rotating assembly axial end play:

TA25 (3-cylinder engines) . . . . . . . . . . 0.0250.09 mm (0.0010.0035 in.)
TA34 (4/6-cylinder engines) . . . . . . . . 0.0250.10 mm (0.0010.004 in.)
T300 (4-cylinder engines) . . . . . . . . . . 0.0250.10 mm (0.0010.004 in.)
T350 (6-cylinder engines) . . . . . . . . . . 0.0250.10 mm (0.0010.004 in.)
SCHWITZER Turbocharger
S2A Model . . . . . . . . . . . . . . . . . . . . 0.090.14 mm (0.00350.0055)
TURBOCHARGER MODELS:
Machine Model No. Engine Model Turbocharger Model

Mannheim Tractors:
3400/3410 . . . . . . . . . CD4039TRT35 GARRETT TA31
3410/3410 X . . . . . . . . CD4039TRT35 GARRETT TA31
6200 . . . . . . . . . . . . . CD4039TL001/TL004 ( -120440CD) GARRETT T300
CD4039TL001/TL004 (120441CD-227584CD) SCHWITZER S2A 35
CD4039TL001/TL004 (227585CD- ) GARRETT T300
1
6300 . . . . . . . . . . . . . CD4039TL003/TL006 ( -143092CD) GARRETT T300
CD4039TL003/TL006 (143093CD-227584CD) SCHWITZER S2A
CD4039TL003/TL006 (227585CD- ) GARRETT T300
6400 . . . . . . . . . . . . . CD4045TL001/TL003 GARRETT T300
6500 . . . . . . . . . . . . . CD4045TL004 GARRETT T300
6600 . . . . . . . . . . . . . CD6059TL001 GARRETT T350
6800 . . . . . . . . . . . . . CD6068TL001 GARRETT T350
6900 . . . . . . . . . . . . . CD6059TL002 GARRETT T350
(Continued on next pqge)
CD,3274,G35,1 -19-04JAN99

060799
PN=230
Air Intake and Exhaust System/Specifications
SPECIFICATIONS-CONTINUED
TURBOCHARGER MODELS (Contd):
Machine Model No. Engine Model Turbocharger Model

(Agritalia-built)
5400/5400N . . . . . . . . . . . . . . . CD3029TAT02 GARRETT TA25
5500/5500N . . . . . . . . . . . . . . . CD4039TAT01 GARRETT T300
(Augusta-built)
5400N . . . . . . . . . . . . . . . . . . . CD3029TLV01 GARRETT TA25
5500N . . . . . . . . . . . . . . . . . . . CD4039TLV01 GARRETT T300
7600 . . . . . . . . . . . . . . . . . . . . T06068TRW01 GARRETT T350
4400 and 4500 . . . . . . . . . . . . . CD4039TF005 GARRETT TA31
2000-Series Combines:
2054 and 2254 . . . . . . . . . . . . . CD6068HZ001 GARRETT T350
Engine Model Turbocharger Model

CD6059TYC01 and CD6059TYC02 . . . . . . . . . . . . . . . . . . . . GARRETT TA34

CD3029TFG21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GARRETT TA25

CD,3274,G35,16 -19-04JAN99
35
2

060799
PN=231
Saran OEM Engines Option Codes Turbocharger Model

CD3029TF . . . . . . . . . . 6501, 6502, 6506, 6511 GARRETT TA25
CD3029TF001 . . . . . . . . 6501, 6502, 6504, 6506 GARRETT TA25
CD3029TF002 . . . . . . . . 6503, 6520 GARRETT TA25
CD3029TF031 . . . . . . . . 6501, 6502, 6504, 6506, 6511 GARRETT TA25
CD3029TF032 . . . . . . . . 6504 GARRETT TA25
CD3029TF033 . . . . . . . . 6504 GARRETT TA25
CD3029TF120 . . . . . . . . 6501, 6502, 6504, 6506, 6507 GARRETT TA25
CD3029TF121 . . . . . . . . 6506, 6507 GARRETT TA25
CD3029TF123 . . . . . . . . 6507 GARRETT TA25
CD3029TF160 . . . . . . . . 6501, 6502, 6504, 6506, 6507 GARRETT TA25
CD3029TF161 . . . . . . . . 6507, 6560 GARRETT TA25
CD3029TF162 . . . . . . . . 6507 GARRETT TA25
CD3029TF163 . . . . . . . . 6507, 6560 GARRETT TA25
35
3
CD,3274,G35,17 -19-04JAN99

060799
PN=232

CD4039TF . . . . . . . . . . 6501 GARRETT TA34
6506, 6512 GARRETT TA31
CD4039TF001 . . . . . . . . 6501 GARRETT TA34

6506, 6512, 6513 GARRETT TA31
CD4039TF002 . . . . . . . . 6501 GARRETT TA34
CD4039TF003 . . . . . . . . 6501 GARRETT TA34
CD4039TF004 . . . . . . . . 6501 GARRETT TA34
CD4039TF005 . . . . . . . . 6513 GARRETT TA31
CD4039TF006 . . . . . . . . 6501 GARRETT TA34
CD4039TF007 . . . . . . . . 6576 SCHWITZER S2A
CD4039TF008 . . . . . . . . 6576 SCHWITZER S2A
CD4039TF031 . . . . . . . . 6501 GARRETT TA34

6506, 6513 GARRETT TA31
CD4039TF032 . . . . . . . . 6513 GARRETT TA31
CD4045TF001 . . . . . . . . 6517 GARRETT TA31

6521 GARRETT TA34
CD4045TF002 . . . . . . . . 6521 GARRETT TA34
CD4045TF003 . . . . . . . . 6521 GARRETT TA34
CD4045TF008 . . . . . . . . 6573 GARRETT T300

35
4 CD4045TF031 . . . . . . . . 6517 GARRETT TA31
6521 GARRETT TA34
CD,3274,G35,18 -19-04JAN99

060799
PN=233

CD6059TF . . . . . . . . . . 6501, 6506, 6515 GARRETT TA34
CD6059TF001 . . . . . . . . 6501, 6502, 6503, 6506, 6515 GARRETT TA34
CD6059TF002 . . . . . . . . 6505, 6515 GARRETT TA34
CD6059TF003 . . . . . . . . 6505, 6515 GAREETT TA34
CD6059TF004 . . . . . . . . 6502, 6515 GARRETT TA34
CD6059TF005 . . . . . . . . 6515 GARRETT TA34
CD6059TF006 . . . . . . . . 6515 GARRETT TA34
CD6059TF007 . . . . . . . . 6506 GARRETT TA34
CD6059TF008 . . . . . . . . 6515 GARRETT TA34
CD6068TF001 . . . . . . . . 6506, 6512 GARRETT TA38
CD6068TF002 . . . . . . . . 6506, 6512 GARRETT TA38
CD6068TF003 . . . . . . . . 6505 GARRETT TA34
CD6068TF004 . . . . . . . . 6505 GARRETT TA34
CD6068TF008 . . . . . . . . 6569 GARRETT T350
CD6068TF009 . . . . . . . . 6569 GARRETT T350
35
5
CD,3274,G35,19 -19-04JAN99

060799
PN=234
Air Intake and Exhaust System/Torques for hardware
Intake manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Exhaust manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Turbocharger and exhaust elbow to exhaust

manifold, cap screws:
3-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (20 lb-ft)
4/6-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
Oil inlet line to turbocharger, cap screws or

fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lb-ft)
Oil return line to turbocharger, cap screws or

fitting:
TA25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (60 lb-ft)
TA31, TA34, TA38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (20 lb-ft)
T300, T350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (20 lb-ft)
SCHWITZER Turbocharger:
S2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (20 lb-ft)
Turbine housing to center housing, cap screws:

TA25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (19 lb-ft)
TA31, TA34, TA38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm (13 lb-ft)
T300, T350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm (13 lb-ft)
SCHWITZER Turbocharger:
S2A (V-Clamp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Nm (5 lb-ft)
Compressor housing backplate to compressor

housing, cap screws:
TA31, TA34, TA38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Nm (12.5 lb-ft)
T300, T350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Nm (12.5 lb-ft)
35
6
CD,3274,G35,2 -19-01FEB94

060799
PN=235
Air Intake and Exhaust System/Exhaust Manifold Inspection
INTAKE MANIFOLD INSPECTION
1. On engines with turbocharger, loosen hose clamp (B).
2. Remove cap screws (A) attaching intake manifold to
-UN-17FEB95
cylinder head and lift off manifold.
3. Inspect intake manifold for serviceability and repair or

replace, if it is cracked or otherwise damaged.
CD30300
4. Inspect machined mating surfaces of cylinder head
and intake manifold. Clean as required, using a scraper
and/or wire brush and compressed air.
5. To install intake manifold, reverse removal procedure

and use new gaskets.
6. Make sure that air intake hose is in good condition.

Tighten hose clamps securely (turbocharged engines
only).
7. Tighten intake manifold attaching cap screws to

50 Nm (35 lb-ft).
CD,3274,G35,3 -19-13APR92
EXHAUST MANIFOLD INSPECTION
1. On engines with turbocharger, remove turbocharger.
2. Remove cap screws (A) and lift off exhaust manifold.
-UN-17FEB95
3. Inspect exhaust manifold for serviceability and replace
if it is cracked or otherwise damaged.
4. To install exhaust manifold, reverse removal procedure
CD30301
and use new gaskets. 35
7
NOTE: When using gaskets with one steel-backed side,
the non-steel backed side must face toward the
cylinder head.
5. Tighten exhaust manifold attaching cap screws to

50 Nm (35 lb-ft).
CD,3274,G35,4 -19-13APR92

060799
PN=236
Air Intake and Exhaust System/Turbocharger
TURBOCHARGER REMOVAL
1. Thoroughly clean exterior of turbocharger and

surrounding area.
-UN-10MAY95
2. Remove muffler extension and muffler elbow.
3. Disconnect oil inlet line (A) and return line (B) and
plug immediately. Remove air cleaner to turbocharger
hose.
CD30427
IMPORTANT: Immediately plug all openings to
prevent dirt from entering the
turbocharger.
4. Remove the four cap screws (C) and lift out

turbocharger assembly.
CD,3274,G35,5 -19-01FEB94
RADIAL BEARING END PLAY CHECK

(GARRETT TURBOCHARGER)
1. Using an adapter with indicator extension rod, fasten

a dial indicator to the turbocharger and place indicator
-UN-23MAY95
rod against compressor shaft through lube hole.
2. Move shaft alternately toward and away from

indicator.
CD7195
3. Applying equal pressure to both ends of shaft, range
of travel should not exceed:
TA25: 0.060.13 mm (0.00240.005 in.)
TA31: 0.080.18 mm (0.0030.007 in.)
TA34: 0.080.18 mm (0.0030.007 in.)
TA38: 0.080.18 mm (0.0030.007 in.)
T300: 0.080.18 mm (0.0030.007 in.)
35 T350: 0.080.18 mm (0.0030.007 in.)
8
CD,3274,G35,6 -19-01FEB94

060799
PN=237
Air Intake and Exhaust System/Turbocharger
CHECK RADIAL BEARING CLEARANCE

(SCHWITZER TURBOCHARGER)
1. Remove compressor cover.
-UN-04MAY98
2. Install a dial indicator against shaft end.
2. Move shaft alternately toward and away from

indicator. Range of travel should be within
0.740.81 mm (0.0290.032 in.)
CD30658
If radial clearance is not within specifications, replace
turbocharger.
CD,3274,G35,20 -19-04JAN99
AXIAL END PLAY CHECK
1. Using a dial indicator with indicator rod against shaft,

measure axial end play.
-UN-23MAY95
2. Move shaft axially back and forth by hand. Indicator
reading should be within:
GARRETT TURBOCHARGER
TA25: 0.0250.09 mm (0.0010.0035 in.)
CD7302
TA31: 0.0250.10 mm (0.0010.004 in.)
TA34: 0.0250.10 mm (0.0010.004 in.)
TA38: 0.0250.10 mm (0.0010.004 in.)
T300: 0.0250.10 mm (0.0010.004 in.)
T350: 0.0250.10 mm (0.0010.004 in.)
SCHWITZER TURBOCHARGER
S2A: 0.090.14 mm (0.00350.0055 in.) 35
9
CD,3274,G35,7 -19-04JAN99

060799
PN=238
Air Intake and Exhaust System/GARRETT Turbocharger
TURBOCHARGER REPAIR
IMPORTANT: Repairing a turbocharger requires

special tooling and highly specialized
personnel and thus it is not
recommended that the turbocharger be
disassembled completely.
Turbochargers cannot be serviced, they must be

replaced as a complete assembly. If, after testing, a
turbocharger is found to be defective, replace it.
CD,3274,G35,8 -19-01FEB94
TURBOCHARGER DISASSEMBLY
1. Plug all openings and clean the exterior before

disassembly.
-UN-07MAR95
2. Put locating marks on the turbine housing (A) and
compressor housing (B) in relation to any location on the
central housing (C) (e.g. lube oil inlet or outlet) to enable
proper indexing of new center housing/rotating shaft
assembly when turbocharger is assembled.
CD30180
3. Remove turbine housing cap screws (D) with lock
plates and clamps.
Gently tap the housing with a soft hammer if removal is
difficult.
4. Remove compressor housing snap ring or cap screw

35 (E) with lock plates and clamps and lift off the housing.
10
-UN-07MAR95
IMPORTANT: If turbocharger failed because of
foreign material entering the air intake
system, be sure to examine the system
and clean as necessary to prevent a
CD30181
repeat failure. Also replace the air filter.
CD,3274,G35,9 -19-01FEB94

060799
PN=239
Air Intake and Exhaust System/GARRETT Turbocharger
TURBOCHARGER REASSEMBLY
1. Attach compressor housing (A) to center

housing/rotating shaft assembly (B) with cap screws, lock
plates and clamps or with snap ring.
-UN-07MAR95
Use the locating marks made during disassembly,
orientate compressor housing to center housing and
tighten cap screws (E) to:
Models TA31, TA34, TA38 . . . . . . . . . . . . . . . . 17 Nm (12.5 lb-ft)
CD30182
Models T300, T350 . . . . . . . . . . . . . . . . . . . . . 17 Nm (12.5 lb-ft)
2. Attach turbine housing (C) to center housing (B),

correctly orientate the turbine housing and tighten cap
screws (D) to:
Model TA25 . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (19 lb-ft)

Models TA31, TA34, TA38 . . . . . . . . . . . . . . . . . 18 Nm (13 lb-ft)
-UN-07MAR95
Models T300, T350 . . . . . . . . . . . . . . . . . . . . . . 18 Nm (13 lb-ft)
Bend all locking tabs against heads of cap screws.
3. If not already performed, prime turbocharger
CD30181
lubrication system prior to installing turbocharger on the
engine. Fill center housing with new engine oil through
the oil drain hole. Turn the rotating assembly by hand to
lubricate the bearings.
CD,3274,G35,10 -19-01FEB94
35
11

060799
PN=240
Air Intake and Exhaust System/SCHWITZER Turbocharger
SCHWITZER TURBOCHARGER
MODEL S2A
-UN-10MAY95
CD30428
1Locknut 7Snap ring 13Thrust bearing 19Turbine housing
2Compressor wheel 8O-Ring 14Thrust ring 20Bearing
3Compressor cover 9O-Ring (optional) 15Central housing 21Snap ring
4Flinger sleeve 10Snap ring 16Backplate 22V-clamp
5Piston ring 11Oil deflector 17Piston ring 23Lock nut
6Insert 12Thrust collar 18Shaft & wheel assy.
Disassembly Reassembly
1. Mark the relative position of the compressor cover 1. Attach compressor cover to central housing
and turbine housing to the central housing. assembly with the snap ring (bevelled edge towards
35 the turbine).
12 2. Remove the large snap ring (10) securing the
compressor cover. 2. Fit the central housing assembly into the turbine
housing, orientate to the marks, fit the V-clamp and
3. Lift off the compressor cover. tighten the lock nut to 7 Nm (5 lb-ft).
4. Remove the V-clamp (22-23) securing the turbine 3. Fill central housing with clean engine oil through
housing. the oil drain hole. Turn rotating assembly by hand to
lubricate the bearings.
5. Lift the central housing assembly out of the turbine
housing.
CD,3274,G35,14 -19-01FEB94

060799
PN=241
Air Intake and Exhaust System/SCHWITZER Turbocharger
PRELUBE TURBOCHARGER
IMPORTANT: DO NOT spin the rotor assembly with

compressed air. Rotor may seize due to
high speed reached.
-UN-04MAY98
Fill oil inlet or drain port with clean engine oil and spin
rotating assembly (by hand) to properly lubricate
bearings.
CD30660
CD,CTM125,179 -19-01DEC97
35
13

060799
PN=242
Air Intake and Exhaust System/Turbocharger installation
TURBOCHARGER INSTALLATION
1. Connect air inlet hose to compressor housing and

install turbocharger (E) with new gasket. Tighten cap
screws (F) to:
GARRETT TA25 . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (20 lb-ft)

GARRETT TA31, TA34, TA38 . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
GARRETT T300, T350 . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
SCHWITZER S2A . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lb-ft)
-UN-12APR90
Tighten clamp (A) on air inlet hose.
2. If used, install new gaskets. Connect lubrication oil

inlet line (B) to the turbocharger and tighten to 25 Nm
RG5660
(18 lb-ft).
IMPORTANT: Check turbocharger lubrication oil

supply hose for damage or cracks. If
necessary, replace hose.
3. Connect oil return line (C) and tighten to:
-UN-10MAY95
GARRETT TA25 . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (60 lb-ft)
GARRETT TA31, TA34, TA38 . . . . . . . . . . . . . . . 30 Nm (20 lb-ft)
GARRETT T300, T350 . . . . . . . . . . . . . . . . . . . 30 Nm (20 lb-ft)
SCHWITZER S2A . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (20 lb-ft)
4. If used, install exhaust adapter and exhaust elbow
CD30302
(D). Exhaust elbow must have an end play of
0.81.6 mm (0.030.06 in.). Tighten exhaust elbow
T300 Turbocharger
cap screws to 50 Nm (35 lb-ft).
IMPORTANT: Since the greatest suction force occurs

between air cleaner and turbocharger, it
is essential to ensure that the hose
connections are tight to prevent entry
of dirt into the engine.
-UN-17FEB95
AHose clamp
35 BOil inlet line
14 COil return line
DExhaust elbow
CD30303
ETurbocharger
FCap screws
TA25 Turbocharger in low-profile version
CD,3274,G35,11 -19-01FEB94

060799
PN=243
Air Intake and Exhaust System/Recommendations for turbocharger use
TURBOCHARGER BREAK-IN
IMPORTANT: A new or repaired turbocharger does

not have adequate oil supply. Perform
the following steps to prevent damage
to turbocharger.
1. To avoid engine starts, proceed as follows according

to application:
either push the throttle lever to Stop position,

or hold engine shut-off knob out,
or disconnect electrical cable from fuel injection pump.
2. Crank engine by means of starting motor until needle

of engine oil pressure gauge is in green zone or until
indicator light (engine oil pressure) goes out.
CD,3274,G35,12 -19-13APR92
RECOMMENDATIONS FOR
TURBOCHARGER USE
In most cases, turbocharger damage is caused by

improper start-up and shutdown procedure. Always idle
the engine for at least 30 seconds (no load) after
start-up and before shutdown.
IMPORTANT: Should the engine stall when operating

under load, IMMEDIATELY restart the
engine to prevent overheating of 35
turbocharger parts.
15
CD,3274,G35,15 -19-01FEB94

060799
PN=244
Air Intake and Exhaust System/Recommendations for turbocharger use
35
16

060799
PN=245
Group 40
Fuel System

CD30304 -UN-08MAR95
Seal installing tool . . . . . . . . . . . . . . . . . . . . . JD-258
To install carbon stop seal on nozzle.
CD,JD258 -19-04AUG92
Nozzle Puller Adapter . . . . . . . . . . . . . . . . . JDG716
Use with JDE38-2 and JDE38-3 to pull Stanadyne

9.5 mm injection nozzles.
-UN-07MAR95
CD30338
CD,JDG716 -19-12NOV92
RG5084 -UN-23AUG88
Nozzle Bore Cleaning Tool . . . . . . . . . . . . . . . JDE39
Clean injection nozzle bores in cylinder head.
RG,JDE39 -19-14FEB92
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDF15
Used to install tappet seals in fuel supply pumps.

(In-line fuel injection pump)
-UN-30NOV88
40
1
RG2017
CD,JDF15 -19-04JAN99
RG5154 -UN-23AUG88
3/4 in. Special Crowsfoot Wrench . . . . . . . . . . JDF22
Tighten injection lines at pump and nozzles.
S53,JDF22 -19-10JUL89

060799
PN=246
Fuel System/Special tools
CD30306 -UN-08MAR95
Injection pump removal tool . . . . . . . . . . . . JDG670A
NOTE: Can be used on all engine types.
CD,JDG670A -19-04AUG92
Injection Nozzle Wrench . . . . . . . . . . . . . . . . JDG949
Used to loosen or tighten lift adjusting screws on injec
-UN-23NOV97
RG7644
CD,JDG949 -19-04JAN99
Injection nozzle tester (R. BOSCH) . . . . . . . . JT25510
Check nozzle opening pressure.
-UN-07MAR95
CD30307
CD,JT25510 -19-27APR92
CD30308 -UN-08MAR95
Fuel pressure line . . . . . . . . . . . . . . . . . . . KJD10109
To connect injection nozzle to BOSCH tester.
CD,KJD10109 -19-27APR92
40 CD30309 -UN-08MAR95
2 Injection pump removal tool . . . . . . . . . . . . KJD10159
To remove injection pump on all engines except

for engine with 37 kW auxiliary drive (Use
JDG670A).
CD,KJD10159 -19-27APR92

060799
PN=247
Fuel System/Special tools
Special Wrench . . . . . . . . . . . . . . . . . . . . KJD10213
-UN-19MAY98
Used to loosen and tighten in-line injection pump (MICO)
nuts.
RG9116
CD,KJD10213 -19-04JAN99
TIME-TRAC diesel engine timing tester . . . . . . . . . . . FKM10429A

(or JT07158)
To perform the dynamic timing of engines.
NOTE: FKM10429A contains the following components:

A-FKM10429-1 Meter
B-FKM10429-4 Sensor clamp
C-FKM10429-5 6mm clamp-on transducer
D-FKM10429-8 Instruction manual
E-FKM10429-6 Timing sensor
F-JDE81-4 Timing pin
G-FKM10465-1 Magnetic probe
-UN-10MAY96
H-FKM10465-2 Transducer cable
J-FKM10465-3 1/4 clamp-on transducer
K-JDG793 Magnetic probe adapter
L-JDG821 Magnetic probe adapter
CD30441
FKM10465 kit is also available to convert the previous
FKM10429 TIME-TRAC. Keys G, H, J, K, and L are
the components of FKM10465 conversion kit.
Timing light is not requested for recent engines. However

timing light is still available under part number
FKM10429-2.
40
3
CD,FKM10429A,1 -19-19FEB98

060799
PN=248
Fuel System/Self-Manufactured Tools
TEMPLATE FOR FRONT PLATE REPLACEMENT
-UN-08MAR95
CD30185
CD,3274,G40,1 -19-27APR92
EXAMPLE OF STATIONARY POINTER FOR DYNAMIC TIMING
40
4
-UN-08MAR95
CD30210
CD,3274,G40,2 -19-27APR92

060799
PN=249
Fuel System/Specifications
SPECIFICATIONS
Fuel injection pump static timing:
Lucas CAV injection pumps . . . . . . . . . . . . . . . . . . . . . Align marks on pump flange and

engine front plate
STANADYNE DM4 injection pumps . . . . . . . . . . . . . . . . Align marks on cam ring and governor
weight retainer with engine at TDC
STANADYNE DB2 and DB4 injection
pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Align marks on pump flange and engine
front plate if any, or align internal
marks on cam ring and governor weight
retainer with engine at TDC
MICO in-line injection pump . . . . . . . . . . . . . . . . . . . . . Align marks on pump flange and engine
front plate if any, or centre the
pump within the flange slots
CD,3274,G40,3 -19-04JAN99
40
5

060799
PN=250
Fuel injection pump dynamic timing at

full load rated speed:
Mannheim tractors:
TRACTOR ENGINE ORIGINAL REPLACED RATED SLOW FAST DYNAMIC

MODEL MODEL INJ. PUMP BY SPEED IDLE IDLE TIMING
Part No.(model) Part No.(model) rpm rpm rpm deg
3100 CD3029DRT65 RE61468 (DP200) RE65134 (DP200) 2350 850 2550 17

RE65134 (DP200) 2350 850 2550 17
3110 CD3029DRT65 RE65134 (DP200) 2350 850 2550 17
3200/X CD4039DRT35 RE61492 (DP200) 2350 850 2550 17
3210/X CD4039DRT35 RE61492 (DP200) 2350 850 2550 17
3300/X CD4045DRT35 RE61496 (DP200) RE501884 (DB2) 2350 850 2550 17
RE501884 (DB2)* 2350 850 2550 17
3310/X CD4045DRT35 RE61496 (DP200) RE501884 (DB2) 2350 850 2550 17
RE501884 (DB2)* 2350 850 2550 17
3400/X CD4039TRT35 RE61494 (DP201) RE501886 (DB4) 2350 850 2550 13
RE501886 (DB4)* 2350 850 2550 15
3410/X CD4039TRT35 RE61494 (DP201) RE501886 (DB4) 2350 850 2550 13
RE501886 (DB4)* 2350 850 2550 15
6100 CD4045DL001 RE46123 (DPA2) 2300 885 2495 15

CD4045DL002
6200 CD4039TL001 RE47706 (DPA4) 2300 875 2495 15
CD4039TL004
6300 CD4039TL003 RE50593 (DPA4) 2300 875 2495 15
CD4039TL006 RE50593 (DPA4) RE57671 (DPA4)
CD4039TL006 RE57671 (DPA1) 2300 875 2495 15
6400 CD4045TL001 RE46122 (DPA4) 2300 875 2495 15
CD4045TL003
6506 CD6068DL001 RE64419 (DP201) 2300 925 2495 15
6600 CD6059TL001 RE53414 (DP201) RE58168 (DP201) 2300 875 2495 15
RE58168 (DP201) 2300 875 2495 15
6800 CD6068TL001 RE53415 (DP201) RE58169 (DP201) 2100 875 2290 15
RE58169 (DP201) 2100 875 2290 15
6900 CD6068TL002 RE61860 (DP201) 2100 875 2290 15

40
6
CD,3274,G40,96 -19-04JAN99

060799
PN=251
Fuel injection pump dynamic timing (contd):
5000-Series tractors:
(Agritalia-built)

5300/N CD3029DAT01 RE57288 (DP200) 2400 775 2605 18

5400/N CD3029TAT02 RE67453 (DP200) 2400 775 2605 13
5500/N CD4039TAT01 RE60818 (DP200) 2400 825 2605 17
(Augusta-built)

5400N CD3029TLV01 RE45521 (DPA2) RE57287 (DP200) 2400 775 2605 14

RE57287 (DP200) RE70172 (DB2) 2400 775 2605 14
RE70172 (DB2) 2400 775 2605 14
5500N CD4039TLV01 RE60818 (DP200) RE70174 (DB2) 2400 825 2605 17

RE70174 (DB2) 2400 825 2605 17
(For India)

5300 CD3029DPY01 RE501590 (MICO) 2400 900 2605 14
(Continued on next page) 40

7
CD,3274,G40,66 -19-04JAN99

060799
PN=252

7600 T06068TRW01 RE43020 (DB4) 2100 850 2275 15
4000-Series telescopic handlers:
TELESC. ENGINE ORIGINAL REPLACED RATED SLOW FAST DYNAMIC

HANDLER MODEL INJ. PUMP BY SPEED IDLE IDLE TIMING
MODEL Part No.(model) Part No.(model) rpm rpm rpm deg
4400/ CD4039TF005 RE55565 (DB4) RE69326 (DB4) 2200 800 2390 13

4500 RE69326 (DB4) 2200 800 2390 13
2000-Series combines:
COMBINE ENGINE ORIGINAL REPLACED RATED SLOW FAST DYNAMIC

2054/ CD6068HZ001 RE52901 (DB4) 2200 1250 2390 12

2254
Engines for Chinese combines:
ENGINE ORIGINAL REPLACED RATED SLOW FAST DYNAMIC

MODEL INJ. PUMP BY SPEED IDLE IDLE TIMING
CD6059TYC01 RE69258 (DB4)* 2500 800 2710 13

CD6059TYC02 RE501723 (DB4)* 2500 800 2710 13
40
8 (Continued on next page)
CD,3274,G40,97 -19-04JAN99

060799
PN=253
Engines for Goldoni tractors:
ENGINE ORIGINAL REPLACED RATED SLOW FAST DYNAMIC

MODEL INJ: PUMP BY SPEED. IDLE IDLE TIMING
Part No.(Model) Part No.(Model) rpm rpm rpm deg
CD3029DFG21 RE66492 (DP200) RE503017 (DB2 2300 800 2495 17

RE503017 (DB2)* 2300 800 2495 18
CD3029DFG22 RE57288 (DP200) RE503019 (DB2) 2300 800 2495 18
RE503019 (DB2)* 2300 800 2495 17
CD3029TFG21 RE66496 (DP200) RE503021 (DB2) 2300 800 2495 15
RE503021 (DB2)* 2300 800 2495 15
CD,3274,G40,97A-19-02JUL99
40
9

060799
PN=254
Saran OEM engines:
ENGINE OPTION ORIGINAL REPLACED RATED SLOW FAST DYNAMIC

MODEL CODE INJ. PUMP BY SPEED IDLE IDLE TIMING
CD3029DF 1632 RE51940 (DB2)* 2200 800 2390 17
CD3029DF001 1602 RE53785 (DB2)* 2500 800 2710 17

1603 RE53786 (DB2)* 1800 1880 15
1641 RE53787 (DB2)* RE64241 1500 1565 15
1641 RE64241 (DB2)* 1500 1565 15
1644** RE41939 (DB2)* 1800 1880 15
1648** RE41941 (DB2)* RE64242 1500 1565 15
1648** RE64242 (DB2)* 1500 1565 15
1650 RE41938 (DB2)* 2500 800 2710 17
CD3029DF005 1603 RE53786 (DB2)* 1800 1880 17

1620 RE53787 (DB2)* RE64241 1500 1565 15
1620 RE64241 (DB2)* 1500 1565 15
CD3029DF031 1602 RE53785 (DB2)* 2500 800 2710 17

1632 RE51940 (DB2)* 2200 800 2390 17
1650 RE41938 (DB2)* 2500 800 2710 17
1654 RE63523 (DB2)* 2400 800 2605 17
CD3029DF032 1602 RE53785 (DB2)* 2500 800 2710 17
CD3029DF033 1632 RE51940 (DB2)* 2200 800 2390 17
CD3029DF034 1654 RE63523 (DB2)* 2400 800 2605 17
40
10
CD,3274,G40,67 -19-04JAN99

060799
PN=255
Saran OEM engines:

CD3029DF120 1602 RE53785 (DB2)* 2500 800 2710 17

1603 RE53786 (DB2)* 1800 1880 15
1641 RE64241 (DB2)* 1500 1565 15
1642** RE67271 (DB2)* 2500 800 2710 17
1644** RE41939 (DB2)* 1800 1880 15
1645 RE97003 (DB2)* 2500 850 2710 17
1648** RE64242 (DB2)* 1500 1565 15
1650 RE41938 (DB2)* 2500 800 2710 17
1655 RE53785 (DB2)* 2500 1700 2710 15
CD3029DF121 1602 RE53785 (DB2)* 2500 800 2710 17

1650 RE41938 (DB2)* 2500 800 2710 17
CD3029DF122 1603 RE53786 (DB2)* 1800 1880 15

1641 RE64241 (DB2)* 1500 1565 15
1644** RE41939 (DB2)* 1800 1880 15
1648** RE64242 (DB2)* 1500 1565 15
CD3029DF123 16BS RE53785 (DB2)* 2500 800 2710 17
CD3029DF124 1641 RE64241 (DB2)* 1500 1565 15
CD3029DF160 1602 RE53785 (DB2)* 2500 800 2710 17

1632 RE51940 (DB2)* 2200 800 2390 17
1643** RE67271 (DB2)* 2500 800 2710 17
1650 RE41938 (DB2)* 2500 800 2710 17
CD3029DF161 1602 RE53785 (DB2)* 2500 800 2710 17
CD3029DF162 1632 RE51940 (DB2)* 2200 800 2390 17
CD3029DF163 1654 RE63523 (DB2)* 2400 800 2605 17

40
CD3029DF164 16DV RE53785 (DB2)* 2500 800 2710 17 11
1602 RE53785 (DB2)* 2500 800 2710 17
CD3029DF165 1602 RE53785 (DB2)* 2500 800 2710 17
CD,3274,G40,98 -19-04JAN99

060799
PN=256
Saran OEM engines:

CD3029TF 1633 RE51979 (DB4)* 2200 800 2390 17

1640 RE53958 (DB4)* 2500 800 2710 11
CD3029TF001 1602 RE53783 (DB4)* 2500 800 2710 11

1632** RE58903 (DB4)* 2500 800 2710 11
1640 RE53958 (DB4)* 2500 800 2710 11
CD3029TF002 1645 RE58413 (DB4)* 2100 850 2285 10
CD3029TF031 1602 RE53783 (DB4)* 2500 800 2710 11

1632** RE58903 (DB4)* 2500 800 2710 11
1633 RE51979 (DB4)* 2200 800 2390 17
1634 RE53783 (DB4)* 2500 800 2710 11
1640 RE53958 (DB4)* 2500 800 2710 11
CD3029TF032 1634 RE53783 (DB4)* 2500 800 2710 11
CD3029TF033 1633 RE51979 (DB4)* 2200 800 2390 17
CD3029TF120 1602 RE53783 (DB4)* 2500 800 2710 11

1632** RE58903 (DB4)* 2500 800 2710 11
1640 RE53958 (DB4)* 2500 800 2710 11
CD3029TF121 1602 RE53783 (DB4)* 2500 800 2710 11

1632** RE58903 (DB4)* 2500 800 2710 11
CD3029TF123 16BT RE53783 (DB4)* 2500 800 2710 11
CD3029TF160 1602 RE53783 (DB4)* 2500 800 2710 11

1632** RE58903 (DB4)* 2500 800 2710 11
1633 RE51979 (DB4)* 2200 800 2390 17
1634 RE53783 (DB4)* 2500 800 2710 11
1640 RE53958 (DB4)* 2500 800 2710 11
40
12
CD3029TF161 16EV RE53958 (DB4)* 2500 800 2710 11
1634 RE53783 (DB4)* 2500 800 2710 11
CD3029TF162 1633 RE51979 (DB4)* 2200 800 2390 17
CD3029TF163 1602 RE53783 (DB4)* 2500 800 2710 11
CD,3274,G40,68 -19-04JAN99

060799
PN=257
Saran OEM engines:

CD4039DF 1602 RE37927 (DPA2) RE42348 (DB2) 2500 800 2710 15

1602 RE42348 (DB2)* RE47133 (DB2) 2500 800 2710 17
1602 RE47133 (DB2)* RE49360 (DB2) 2500 800 2710 17
1602 RE49360 (DB2)* 2500 800 2710 15
1603 RE42351 (DB2)* RE47134 (DB2) 1800 1880 15
1603 RE47134 (DB2)* 1800 1880 15
1609 RE52749 (DB2)* 2300 800 2495 15
1614 RE52822 (DB2)* 2900 800 3100 13
1620** RE47176 (DB2)* 1800 1880 15
1623** RE50778 (DB2)* RE42349 (DB2) 2500 800 2710 15
1623** RE42349 (DB2)* RE47798 (DB2) 2500 800 2710 15
1623** RE47798 (DB2)* RE50778 (DB2) 2500 800 2710 15
1623** RE50778 (DB2)* 2500 800 2710 15
1624 RE49360 (DB2)* 2500 800 2710 15
1641 RE42353 (DB2)* RE50828 (DB2) 1500 1565 15
1641 RE50828 (DB2)* RE64243 (DB2) 1500 1565 15
1641 RE64243 (DB2)* 1500 1565 15
1643** RE45358 (DB2)* 2500 800 2710 17
1645 RE42354 (DB2)* RE50829 (DB2) 1500 1565 15
1645** RE50829 (DB2)* RE64244 (DB2) 1500 1565 15
1645** RE64244 (DB2)* 1500 1565 15
1646 RE42352 (DB2)* 1800 1880 15
1664 RE49360 (DB2)* 2500 1600 2710 15
CD4039DF001 1602 RE49360 (DB2)* 2500 800 2710 15

1603 RE47134 (DB2)* 1800 1880 15
1614 RE52822 (DB2)* 2900 800 3100 13
1620** RE47176 (DB2)* 1800 1880 15
1623** RE50778 (DB2)* 2500 800 2710 15
1641 RE42353 (DB2)* RE50828 (DB2) 1500 1565 15
1641 RE64243 (DB2)* 1500 1565 15
1645** RE64244 (DB2)* 1500 1565 15
1664 RE49360 (DB2)* 2500 1600 2710 15 40
13
CD,3274,G40,69 -19-04JAN99

060799
PN=258
Saran OEM engines:

CD4039DF002 1602 RE49360 (DB2)* 2500 800 2710 15

1623** RE50778 (DB2)* 2500 800 2710 15
CD4039DF004 1603 RE47134 (DB2)* 1800 1880 15

1618 RE47134 (DB2)* 1800 1880 15
1620** RE47176 (DB2)* 1800 1880 15
CD4039DF005 1603 RE47134 (DB2)* 1800 1880 15

1620** RE47176 (DB2)* 1800 1880 15
1641 RE64243 (DB2)* 1500 1565 15
1645** RE64244 (DB2)* 1500 1565 15
CD4039DF006 1641 RE64243 (DB2)* 1500 1565 15
CD4039DF007 1641 or RE64243 (DB2)* 1500 1565 15

16KG
CD4039DF031 1602 RE49360 (DB2)* 2500 800 2710 15

1609 RE52749 (DB2)* 2300 800 2495 15
1623** RE50778 (DB2)* 2500 800 2710 15
CD4039DF032 1609 RE52749 (DB2)* 2300 800 2495 15
40
14
CD,3274,G40,99 -19-04JAN99

060799
PN=259
Saran OEM engines:

CD4039TF 1601 RE48484 (DM4) 1800 800 1950 13

1602 RE26858 (DM4)* RE47135 (DB4) 2500 800 2710 13
1602 RE47135 (DB4)* 2500 800 2710 13
1603 RE21515 (DM4)* RE48154 (DB4) 1800 1880 13
1603 RE48154 (DB4)* 1800 1880 13
1605 RE47909 (DM4)* 2900 800 3140 11
1610 RE52750 (DB4)* 2300 800 2495 13
1611** RE55565 (DB4)* 2200 800 2390 13
1619** RE47177 (DB4)* 2500 800 2710 13
1620** RE48155 (DB4)* 1800 1880 13
1623 RE31765 (DM4)* 2500 800 2710 15
1625 RE47135 (DB4)* 2500 800 2710 13
1635 RE31759 (DM4)* RE50808 (DB4) 1500 1565 14
1635** RE50808 (DB4)* 1500 1565 14
1636 RE31766 (DM4)* 1800 1880 13
1641 RE29471 (DM4)* RE50909 (DB4) 1500 1565 14
1641 RE50809 (DB4)* 1500 1565 14
1643 RE45356 (DM4)* 2500 800 2710 15
1650 RE38946 (DM4)* RE50866 (DB4) 2500 800 2710 13
1650** RE50866 (DB4)* 2500 800 2710 13
1651 RE38947 (DM4)* RE50867 (DB4) 2500 800 2710 13
1651** RE50867 (DB4)* 2500 800 2710 13
CD4039TF001 1601 RE48484 (DM4)* 1800 800 1950 13

1602 RE47135 (DB4)* 2500 800 2710 13
1603 RE48154 (DB4)* 1800 1880 13
1605 RE47909 (DM4)* 2900 800 3140 11
1611** RE55565 (DB4)* 2200 800 2390 13
1619** RE47177 (DB4)* 2500 800 2710 13
1620** RE48155 (DB4)* 1800 1880 13
1635** RE50808 (DB4)* 1500 1565 14
1641 RE50809 (DB4)* 1500 1565 14
1650** RE50866 (DB4)* 2500 800 2710 13 40
1651** RE50867 (DB4)* 2500 800 2710 13 15
CD,3274,G40,70 -19-04JAN99

060799
PN=260
Saran OEM engines:

CD4039TF002 1602 RE47135 (DB4)* 2500 800 2710 13

1619** RE47177 (DB4)* 2500 800 2710 13
CD4039TF003 1603 RE48154 (DB4)* 1800 1880 13

1620** RE48155 (DB4)* 1800 1880 13
1635** RE50808 (DB4)* 1500 1565 14
1641 RE50809 (DB4)* 1500 1565 14
CD4039TF004 1603 RE48154 (DB4)* 1800 1880 13

1620** RE48155 (DB4)* 1800 1880 13
CD4039TF005 1611 RE55565 (DB4)* RE69326 (DB4) 2200 800 2390 13

1611 RE69326 (DB4)* 2200 800 2390 13
CD4039TF006 1641 RE50809 (DB4)* 1500 1565 14
CD4039TF007 1641 or RE50809 (DB4)* 1500 1565 14

16KH
CD4039TF031 1602 RE47135 (DB4)* 2500 800 2710 13

1610 RE52750 (DB4)* 2300 800 2495 13
1619** RE47177 (DB4)* 2500 800 2710 13
1650** RE50866 (DB4)* 2500 800 2710 13
1651 RE50867 (DB4)* 2500 800 2710 13
CD4039TF032 1610 RE52750 (DB4)* 2300 800 2495 13
40
16
CD,3274,G40,71 -19-04JAN99

060799
PN=261
Saran OEM engines:

CD4045DF001 1602 RE47179 (DB2)* 2400 800 2605 14

1626 RE55079 (DB2)* 2200 800 2390 15
1635 RE68444 (DB4)* 2200 800 2390 14
CD4045DF031 1602 RE47179 (DB2)* 2400 800 2605 14

1636 RE68444 (DB4)* 2200 800 2390 14
CD4045TF001 1602 RE47180 (DB4)* 2400 800 2605 11

1603 RE64298 (DB4)* 2400 800 2605 11
1620 RE57647 (DB4)* RE66266 (DB4) 1500 1565 14
1620 RE66266 (DB4)* 1500 1565 14
1625 RE58882 (DB4)* 2200 800 2390 14
1627 RE55080 (DB4)* 2200 800 2390 15
1628 RE48156 (DB4)* 1800 1880 14
1629 RE52015 (DB4)* 2400 800 2605 15
1630 RE57717 (DB4)* 2400 800 2605 15
1637 RE68454 (DB4)* 2400 800 2605 11
1638 RE68455 (DB4)* 2400 800 2605 11
1639 RE68456 (DB4)* 1500 1565 14
1640 RE68457 (DB4)* RE65035 (DB4) 1800 1880 14
1640 RE65035 (DB4)* 1800 1880 14
1641 RE68458 (DB4)* 2400 800 2605 15
1642 RE68459 (DB4)* 2400 800 2605 15
CD4045TF002 1620 RE66266 (DB4)* 1500 1565 14

1628 RE48156 (DB4)* 1800 1880 14
1639 RE68456 (DB4)* 1500 1565 14
1640** RE65035 (DB4)* 1800 1880 14
CD4045TF003 1620 RE66266 (DB4)* 1500 1565 14
CD4045TF031 1602 RE47180 (DB4)* 2400 800 2605 11

1631 RE52015 (DB4)* 2400 800 2605 15 40
1632 RE57717 (DB4)* 2400 800 2605 15 17
1643 RE64298 (DB4)* 2400 800 2605 11
1644 RE68454 (DB4)* 2400 800 2605 11
1645 RE68458 (DB4)* 2400 800 2605 15
1646 RE68459 (DB4)* 2400 800 2605 15
CD,3274,G40,72 -19-04JAN99

060799
PN=262
Saran OEM engines:

CD6059DF 1602 RE37935 (DPA2) RE52159 (DB2) 2500 800 2710 15

1602 RE52159 (DB2)* 2500 800 2710 17
1603 RE37933 (DPA2) 1800 1880 14
1623 RE37935 (DPA2) RE52160 (DB2) 2500 800 2710 15
1623** RE52160 (DB2)* 2500 800 2710 17
1636 RE37933 (DPA2) 2500 800 2710 14
1638 RE37934 (DPA2) 1500 1565 13
1641 RE37934 (DPA2) 1500 1565 13
CD6059DF001 1602 RE52159 (DB2)* 2500 800 2710 17

1603 RE37933 (DPA2) 1800 1880 14
1623** RE52160 (DB2)* 2500 800 2710 17
1636 RE37933 (DPA2) 2500 800 2710 14
1638 RE37934 (DPA2) 1500 1565 13
1641 RE37934 (DPA2) 1500 1565 13
CD6059DF002 1602 RE52159 (DB2)* 2500 800 2710 17

1623** RE52160 (DB2)* 2500 800 2710 17
CD6059DF003 16BZ** RE52160 (DB2)* 2500 800 2710 17
CD6059TF 1602 RE19914 (DM4)* RE47137 (DB4) 2500 800 2710 13

1602 RE47137 (DB4)* 2500 800 2710 13
1603 RE19981 (DM4)* RE48159 (DB4) 1800 1880 14
1603 RE48159 (DB4)* 1800 1880 14
1619** RE47178 (DB4)* 2500 800 2710 13
1624** RE48160 (DB4)* 1800 1880 16
1636 RE31760 (DM4)* RE50886 (DB4) 1500 1565 17
1636** RE50886 (DB4)* 1500 1565 15
1641 RE29472 (DM4)* RE50885 (DB4) 1500 1565 17
1641 RE50885 (DB4)* 1500 1565 15
1644 RE48157 (DB4)* 1800 1880 14
1645** RE48158 (DB4)* 1800 1880 14
40
18 1646 RE50892 (DB4)* 1500 1565 13
1647** RE50893 (DB4)* 1500 1565 13
CD,3274,G40,73 -19-04JAN99

060799
PN=263
Saran OEM engines:

CD6059TF001 1602 RE47137 (DB4)* 2500 800 2710 13

1603 RE48159 (DB4)* 1800 1880 14
1619** RE47178 (DB4)* 2500 800 2710 13
1624** RE48160 (DB4)* 1800 1880 16
1636** RE50886 (DB4)* 1500 1565 15
1641 RE50885 (DB4)* 1500 1565 15
1644 RE48157 (DB4)* 1800 1880 14
1645** RE48158 (DB4)* 1800 1880 14
1646 RE50892 (DB4)* 1500 1565 13
1647** RE50893 (DB4)* 1500 1565 13
1652 RE56483 (DB4)* 2500 800 2710 13
1653** RE56484 (DB4)* 2500 800 2710 13
CD6059TF002 1603 RE48159 (DB4)* 1800 1880 14

1624** RE48160 (DB4)* 1800 1880 16
CD6059TF003 1644 RE48157 (DB4)* 1800 1880 14

1645** RE48158 (DB4)* 1800 1880 14
CD6059TF004 1602 RE47137 (DB4)* 2500 800 2710 13

1619** RE47178 (DB4)* 2500 800 2710 13
CD6059TF005 1641 RE50892 (DB4)* 1500 1565 13

1644 RE48157 (DB4)* 1800 1880 14
1645** RE48158 (DB4)* 1800 1880 14
1646 RE50892 (DB4)* 1500 1565 13
1647** RE50893 (DB4)* 1500 1565 13
CD6059TF006 1603 RE48159 (DB4)* 1800 1880 14

1624** RE48160 (DB4)* 1800 1880 16
1636** RE50886 (DB4)* 1500 1565 15
1641 RE50885 (DB4)* 1500 1565 15
40
CD6059TF007 1619** RE47178 (DB4)* 2500 800 2710 13 19
CD6059TF008 1646 RE50892 (DB4)* 1500 1565 13
CD,3274,G40,74 -19-04JAN99

060799
PN=264
Saran OEM engines:

CD6068DF001 1622 RE47182 (DB4)* 2400 800 2605 18

1623 RE47183 (DB4)* 2400 800 2605 18
CD6068TF001 1642** RE47184 (DB4)* 2400 800 2605 14

1643 RE47185 (DB4)* 2400 800 2605 14
CD6068TF002 1643 RE47185 (DB4)* 2400 800 2605 14
CD6068TF003 1605 RE65342 (DB4)* 1500 1565 15

1646 RE67761 (DB4)* 1500 1565 15
CD6068TF004 1605 RE65342 (DB4)* 1500 1565 15
* Pump dynamically timed at the factory. Use dynamic timing when the
pump is overhauled or replaced.
** Can be used with JP5/JP8 Fuel. CD,3274,G40,75 -19-04JAN99
40
20

060799
PN=265
Fuel injection pump dynamic timing at no-load (for

following combine engine):
Zweibrcken combines:
COMBINE ENGINE ORIGINAL REPLACED RATED SLOW FAST DYNAMIC

2054/ 6068HZ001 RE52901 (DB4)* 2200 1250 2350 12

2254
* Pump dynamically timed at the factory. Use dynamic timing when the
pump is overhauled or replaced. CD,3274,G40,65 -19-04JAN99
40
21

060799
PN=266
Aneroid adjustment:
Lever lift-off pressure . . . . . . . . . . . . . . . 76102 mm Hg (34 in. Hg)
1014 kPa (0.100.14 bar/1.52 psi)
Lever full travel pressure . . . . . . . . . . . . 330380 mm Hg (1315 in. Hg)

4451 kPa (0.440.51 bar/6.47.4 psi)
Fuel injection nozzles All 3029D All 3029T

All 4039D All 4039T except 4039TAT01
All 6059D and 4039TLV01 ( -308582CD)
4039TAT01 All 4045D
4039TLV01 ( -308582CD) All 4045T
6068DL001 All 6059T
All 6068D except 6068DL001
All 6068T
Opening pressure of a new or reconditioned

nozzle with new internal parts . . . . . . . . 2230023200 kPa 2575026600 kPa
(223232 bar; (257.5266 bar;
32333364 psi) 37343857 psi)
Opening pressure of an used nozzle . . . 2040021800 kPa 2350025200 kPa

(204218 bar; (235252 bar;
29583161 psi) 34073654 psi)
Maximum opening pressure difference

between cylinders . . . . . . . . . . . . . . . . . 700 kPa (7 bar; 700 kPa (7 bar;
100 psi) 100 psi)
Number of nozzle tip orifices . . . . . . . . . 4 4
Diameter of nozzle tip orifice . . . . . . . . . 0.27 mm (0.0106 in.) 0.29 mm (0.0116 in.)
Seat tightness condition at test pressure

of 2800 to 3500 kPa (28 to 35 bar; 400
to 500 psi) below opening pressure . . . . . Tip dry after a period of 5 Tip dry after a period of 5
seconds (a slight dampness seconds (a slight dampness
is permissible on used is permissible on used
nozzles) nozzles)
40 Return leakage at test pressure of

22 10300 kPa (103 bar; 1500 psi) . . . . . . . . 14 drops per 30 seconds 14 drops per 30 seconds
Valve lift specifications (based on zero

valve lift) . . . . . . . . . . . . . . . . . . . . . . . 1/2 turn counter-clockwise 3/4 turn counter-clockwise
CD,3274,G40,6 -19-04JAN99

060799
PN=267
Fuel System/Torques for hardware
Pump drive gear-to-pump shaft, hex. nut:

Lucas CAV (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (60 lb-ft)
Stanadyne (model DB2):
with 8 mm thick nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (44 lb-ft)
with 10 mm thick nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm (150 lb-ft)
Stanadyne (models DB4 and DM4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm (150 lb-ft)
Fuel injection pump-to-cylinder block front plate:

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lb-ft)
Fuel pressure lines to injection pump:

Lucas CAV (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (23 lb-ft)
Stanadyne (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lb-ft)
Fuel pressure lines to nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (23 lb-ft)
Fuel supply line to injection pump:

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (23 lb-ft)
Fuel return line to injection pump:

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm (12 lb-ft)
Injection pump cover, cap screws:

Lucas CAV (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Nm (2.5 lb-ft)
Stanadyne (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Nm (17 lb-in.)
Shut-off solenoid valve:

Lucas CAV (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1520 Nm (1115 lb-ft)
Adjusting screw for slow and fast idle

speeds, hex. nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Nm (3.5 lb-ft)
Fuel injection nozzles:

Lock nut of pressure adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (7 lb-ft)
Lock nut of lift adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.5 lb-ft) 40
Fuel injection nozzle to cylinder head, cap screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm (27 lb-ft) 23
Fuel leak-off, hex. nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.5 lb-ft)
Oil supply line to injection pump (MICO in-line pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 lb-ft)
CD,3274,G40,7 -19-04JAN99

060799
PN=268
Fuel System/Fuel Filter
RECTANGULAR FUEL FILTER ELEMENT

REPLACEMENT
NOTE: For proper filter servicing and replacement, see

Operators Manual.
-UN-26JUL89
Remove drain plug and drain filter.
Release the filter element retaining spring and pull off

element.
CD7201
Before installing new filter element, inspect the filter plate
where element makes contact. This location must be
completely void of dirt or other contaminants. If
contaminants are found, clean carefully.
IMPORTANT: Any dirt lodged in spring pin groove or

at end of spring pin during cleaning
-UN-26JUL89
will be washed into the injection
system. This may result in severe
damage to the fuel injection pump or
nozzles.
CD7202
Push new element over the spring pin. Hook the top end
of retaining spring first, then hook the bottom end.
After changing the element, install and tighten drain plug

in filter plate. ABleed plug
BFilter element
Bleed fuel system. CRetaining spring
DDrain plug
ESpring pin
CD,3274,G40,8 -19-01FEB94
40
24

060799
PN=269
REPLACE ROUND FUEL FILTER ELEMENT
-UN-04MAY98
-UN-17JUN98
CD30667
CD30664
NOTE: For proper filter servicing and replacement, see
Operators Manual.
1. If equipped, rotate the fuel inlet valve to the closed

position.
2. Unfasten filter retaining ring (A) and remove filter

element (B).
NOTE: For a cleaner service, obturate the previous

element with the plug provided with the new
element.
3. If equipped, remove sediment glass bowl (C) from

filter element and reinstall it onto the new element.
4. Install dust seal (F) as shown.
5. Position new element in proper location then tighten

about 1/3 turn until retaining ring fits into the detent. DO
NOT overtighten.
6. Bleed fuel system.
ARetaining ring
BFilter element
CSediment glass bowl 40
DBleed screw
EDrain screw
25
-UN-16JUN98
FDust seal
CD30665
CD,3274,G40,9 -19-04JAN99

060799
PN=270
REPLACE ROUND FUEL FILTER ASSEMBLY
-UN-16JUN98
CD30666
1. Disconnect fuel lines (A). 5. If equipped, install fuel inlet valve (D) on adaptor
(E), then install the assembly on filter head.
2. Unscrew bolts (B) and remove fuel filter assembly.
6. Install fittings (F) on filter head.
3. Replace parts as necessary, then tighten bolts (B)
to 50 Nm (37 lb-ft). 7. Install fuel lines then tighten to 30 Nm (23 lb-ft).
4. Install plugs (C) on filter head and tighten to

5 Nm (3.5 lb-ft).
CD,3274,G40,76 -19-04JAN99
40
26

060799
PN=271
Fuel System/Fuel pump
FUEL PUMP REPLACEMENT
1. Disconnect fuel lines and plug both connections on

fuel pump and fuel lines.
-UN-17FEB95
2. Remove cap screws (A) and lift out fuel pump.
NOTE: Fuel pump is not repairable, replace if defective.
3. Install new gasket.
CD30315
4. Apply sealing compound on thread of cap screws and
attach the fuel pump to cylinder block. Tighten to 30 Nm SOFABEX fuel pump
(23 lb-ft).
5. Reconnect fuel lines and bleed fuel system.
-UN-12APR90
RG5671
AIRTEX fuel pump
CD,3274,G40,10 -19-01FEB94
40
27

060799
PN=272
Fuel System/Lucas CAV Fuel Injection Pump
LUCAS CAV FUEL INJECTION PUMP

REMOVAL
IMPORTANT: Never steam clean or pour cold water

on a fuel injection pump while the
-UN-17FEB95
pump is running or while it is warm.
Clean the fuel injection pump, lines and area around the
pump with cleaning solvent or a steam cleaner.
CD30316
Disconnect shut-off system and speed control rod.
Disconnect fuel return line (A).
Disconnect fuel supply line (B).
Disconnect fuel injection lines (C).
IMPORTANT: When loosening fuel pressure lines at

fuel injection pump, be sure not to turn
fuel injection pump fittings. Turning of
-UN-07MAR95
these fittings may cause internal pump
damage.
Plug all open connections on pump and fuel lines. Do

not use fibrous material.
CD7204
Remove plug or cover from mounting hole in timing gear
cover.
Remove nut (D) and washer securing the fuel injection

pump drive gear to pump shaft.
Attach special tool JDG670A to gear (or KJD10159 to
-UN-17FEB95
timing gear cover). Remove the three nuts attaching fuel
injection pump to engine front plate.
Turn cap screw of special tool clockwise until pump shaft

is loosened from conical seat of drive gear. On engine
CD30317
with 37 kW auxiliary drive only, remove the center
forcing screw from JDG670A tool and tighten the two
cap screws until gear is pulled against cover. This will
avoid that gear becomes disengaged from upper idler
gear.
40 Check for the presence of timing marks. If necessary,

28 mark both the pump and the front plate.
-UN-07MAR95
Pull the fuel injection pump backward from the three

studs.
NOTE: When removing fuel injection pump be careful not

CD30218
to lose pump shaft Woodruff key.
CD,3274,G40,11 -19-01FEB94

060799
PN=273
REPAIRS TO FUEL INJECTION PUMP
Do not disassemble the Lucas CAV fuel injection pump

further than necessary for installing available parts, not
even for cleaning.
Send fuel injection pump to a specialized workshop for

proper checking and adjustment.
CD,3274,G40,12 -19-27APR92

INSTALLATION
Fit a new gasket or O-ring on pump housing and slide

housing onto the three studs.
-UN-17FEB95
Guide pump drive shaft into bore of drive gear. Tighten
drive gear hex. nut (D) to 80 Nm (60 lb-ft).
NOTE: Make sure that Woodruff key is properly installed.
CD30316
Screw hex. nuts onto the three studs and tighten
fingertight only at this stage. Adjust pump (see Fuel
Injection Pump Static Timing in this group).
Connect fuel injection lines (C). Commence with outlet

(E) and continue around the pump head in
counter-clockwise direction, attaching lines in same order
-UN-07MAR95
as engine firing (1-5-3-6-2-4 on 6 cyl. engines, 1-3-4-2
on 4 cyl. engines and 1-2-3 on 3 cyl. engines).
Tighten fuel pressure lines at pump to 30 Nm (23 lb-ft).
CD7204
IMPORTANT: When tightening fuel pressure lines at
damage.
40
Connect fuel return line (A), fuel supply line (B), shut-off
29
system and speed control rod.
-UN-17FEB95
CD30318
CD,3274,G40,13 -19-01FEB94

060799
PN=274

STATIC TIMING
Loosen attaching hex. nuts of fuel injection pump and

pivot pump housing away from cylinder block as far as
-UN-23MAY95
slots will allow. Then pivot it back again, but only as far
as necessary to align timing mark on pump flange (B)
with timing mark on cylinder block front plate (A).
Tighten the three hex. nuts securing the pump to the
CD7206
front plate to 25 Nm (18 lb-ft).
See also Dynamic timing in this Group.
CD,3274,G40,14 -19-28APR92
40
30

060799
PN=275
Fuel System/Stanadyne DB2 or DB4 Fuel Injection Pump
STANADYNE DB2 OR DB4 FUEL INJECTION

PUMP REMOVAL

-UN-23MAY95
CD7315
Disconnect shut-off system and speed control rod.
Disconnect fuel return line (A).
Disconnect fuel supply line (B).
Disconnect fuel injection lines (C).
IMPORTANT: When loosening fuel pressure lines at

-UN-07MAR95
damage.

not use fibrous material.
CD7204
Remove plug or cover from mounting hole in timing gear
cover.
Remove nut (D) and washer securing the fuel injection

Attach special tool JDG670A to gear (or KJD10159 to
-UN-17FEB95
timing gear cover). Remove the three nuts attaching fuel
injection pump to engine front plate.
Turn cap screw of special tool clockwise until pump shaft

is loosened from conical seat of drive gear. On engine
CD30317
with 37 kW auxiliary drive only, remove the center
forcing screw from JDG670A tool and tighten the two
cap screws until gear is pulled against cover. This will
avoid that gear becomes disengaged from upper idler
gear.
Check for the presence of timing marks. If necessary, 40

mark both the pump and the front plate. 31
-UN-07MAR95
Pull the fuel injection pump backward from the three

studs.
NOTE: When removing fuel injection pump be careful not

CD30218
to lose pump shaft Woodruff key.
CD,3274,G40,17 -19-01FEB94

060799
PN=276
REPAIRS TO FUEL INJECTION PUMP
Do not disassemble the Stanadyne fuel injection pump

even for cleaning.

CD,3274,G40,18 -19-27APR92
REPLACE THROTTLE LEVER (STANADYNE)
1. Remove parts.
2. Inspect parts. Replace as necessary.
-UN-22FEB99
3. Tighten position screw (6) to 33.5 Nm
(2.22.6 lb-ft) and spring screw (1) to 44.5 Nm
(33.3 lb-ft).
1Spring screw
CD30724
2Spring retainer
3Spring
4Lever
5Arm
6Throttle lever position screw
7Throttle lever adjustment spacer
CD,3274,G40,77 -19-04JAN99
40
32

060799
PN=277

PUMP INSTALLATION
Using a new gasket or a new O-ring, slide housing onto

three studs, inserting pump drive shaft in drive gear
-UN-07MAR95
bore.
NOTE: Make sure that Woodruff key is seated properly.
Screw the three hex. nuts onto studs and tighten
CD7317
finger-tight only at this stage.
Tighten drive gear hex. nut (A) to the following torque:
Chrome finish nut with a thickness

of 8 mm (0.315 in.) . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (45 lb-ft)
Black finish nut with a thickness

of 10 mm (0.370 in.) . . . . . . . . . . . . . . . . . . . . . 200 Nm (145 lb-ft)
-UN-23FEB99
IMPORTANT: Do not try to tighten the chrome finish
nut to 200 Nm (145 lb-ft), thread of nut
will be damaged.
CD30725
NOTE: It is recommended, during the refitting, to replace
the chrome finish nut by the black finish nut, then
Connect injection pump pressure lines (C). Commence

with outlet (B) and continue around the pump head in
counter-clockwise direction, attaching lines in same order
as engine firing (1-5-3-6-2-4 on 6 cyl. engines, 1-3-4-2
-UN-07MAR95
on 4 cyl. engines and 1-2-3 on 3 cyl. engines).
Tighten fuel pressure lines at pump to 25 Nm (18 lb-ft)

torque, using line wrench JDF22.
CD30358
damage. ADrive gear lock nut
BOutlet connection to no.1 cylinder
Connect fuel supply line (E), return line (D), shut-off

CFuel pressure lines 40
cable and speed control rod.
DFuel return line 33
EFuel supply line
CD,3274,G40,19 -19-04JAN99

060799
PN=278

PUMP STATIC TIMING
Static timing with external marks
-UN-23MAY95
Loosen attaching hex. nuts of fuel injection pump and
pivot pump housing away from cylinder block as far as
slots will allow. Then pivot it back again, but only far
enough to align timing mark on pump flange (B) exactly
with timing mark on cylinder block front plate (A).
CD7320
Tighten the three hex. nuts securing the pump to front
plate to 25 Nm (18 lb-ft).
See also Dynamic Timing in this Group.
Static timing without timing marks
Make sure piston no. 1 is at TDC on compression
-UN-23MAY95
stroke and remove timing hole cover from injection
pump.
With attaching hex. nuts finger-tight, pivot the pump

housing away from block as far as slots will allow.
CD7321
Then pivot it back until the timing marks (C) on cam
ring and governor weight retainer are aligned.
Tighten pump attaching nuts to 25 Nm (18 lb-ft).
See also Dynamic Timing in this Group.
CD,3274,G40,20 -19-28APR92
40
34

060799
PN=279
ENGINE FRONT PLATE REPLACEMENT
NOTE: The front plate available as a spare part is not

provided with a timing mark.
-UN-17FEB95
IMPORTANT: Before any front plate replacement,
proceed as follows:
Remove timing hole cover from injection pump and

rotate engine until no. 1 piston is at TDC on its
CD30322
compression stroke.
Check whether both the cam ring and governor weight

retainer have timing marks (A).
If yes, proceed to disassembly.
If no and mark only visible on cam ring (1), pencil a
reference line across the governor cage (2) using the
cam ring mark as reference. Only then proceed to
-UN-07MAR95
disassembly.
NOTE: The front plate shows several injection pump stud

locations for the various possible engine
applications. Use holes marked (B).
CD30033
Insert the studs into the holes corresponding to the
required application and plug the remaining holes.
Reinstall front plate and injection pump onto engine (see

STANADYNE DB2 OR DB4 FUEL INJECTION PUMP
INSTALLATION in this group).
Transfer timing mark to new front plate. Install timing

hole cover on injection pump and reassemble engine
parts removed.
AFuel injection pump timing marks

BThreaded holes for STANADYNE DB2 or DB4
-UN-08MAR95
40
35
CD30321
CD,3274,G40,21 -19-27APR92

060799
PN=280
Fuel System/Stanadyne DM4 Fuel Injection Pump
STANADYNE DM4 FUEL INJECTION PUMP

REMOVAL

-UN-07MAR95
CD30144
Remove the timing hole cover.
Rotate the engine until timing mark on governor weight

retainer is in line with timing mark on cam ring.
Disconnect speed control rod and shut-off system.

Disconnect fuel return line (A) and fuel supply line (B).
Disconnect injection lines (C), using line wrench JDF22.
-UN-23MAY95
IMPORTANT: When removing injection lines to
nozzles, do not turn outlet fittings in
the pump. Turning these fittings may
cause internal injection pump damage.
CD7322
Remove mounting hole cover in timing gear cover.
Remove hex. nut and washer securing injection pump
drive gear to pump shaft. Remove hex. nuts (D).
Remove fuel injection pump, taking care not to lose the
Woodruff key.

not use fibrous material. -UN-07MAR95
AFuel return line

BFuel supply line
CFuel pressure lines
CD7323
DPump attaching nuts
CD,3274,G40,23 -19-01FEB94
40
36 REPAIRS TO FUEL INJECTION PUMP
Do not disassemble the Stanadyne fuel injection pump

even for cleaning.

CD,3274,G40,22 -19-27APR92

060799
PN=281
Fuel System/Stanadyne DM4 Fuel Injection Pump
STANADYNE DM4 FUEL INJECTION PUMP

INSTALLATION AND TIMING
Make sure no. 1 piston is at TDC on compression

stroke.
-UN-07MAR95
Rotate pump drive shaft and align timing mark on
governor weight retainer hub with timing mark on cam
ring.
CD30144
Check pump mounting flange packing for damage and
replace, when necessary.
Install injection pump on engine, making sure Woodruff

key enters gear.
Install pump attaching nuts (A) finger-tight.
Install washer and hex. nut on pump shaft and tighten to
-UN-23MAY95
200 Nm (145 lb-ft).
Rotate pump counter-clockwise (as seen from flywheel

end) and then in opposite direction until timing marks on
cam ring and governor weight retainer are aligned.
CD7335
Tighten pump attaching nuts (A) to 25 Nm (18 lb-ft).
Connect injection pump pressure lines (B). Start with

outlet (E) and continue around pump head in
counterclockwise direction, attaching lines in same order
as engine firing (1-5-3-6-2-4 on 6-cylinder engines and
1-3-4-2 on 4-cylinder engines).
-UN-07MAR95
Tighten fuel pressure lines at pump to 25 Nm (18 lb-ft),
using line wrench JDF22.
CD30329
damage.
Connect fuel supply line (C), return line (D), shut-off

system and speed control rod. 40
37
-UN-07MAR95
APump attaching nuts

BFuel pressure lines
CFuel supply line
DFuel return line
EOutlet connection to cylinder no. 1
FEngine block side
CD7337
CD,3274,G40,24 -19-01FEB94

060799
PN=282
Fuel System/MICO In-line Fuel Injection Pump
REMOVE FUEL SUPPLY PUMP ON MICO

IN-LINE FUEL INJECTION PUMP
Thoroughly clean exterior of supply pump. Also clean

around supply pump mounting area on injection pump
housing.
1. Disconnect fuel inlet line (removed on picture) and

outlet line (A). Cap all line openings so contaminates do
not enter fuel system.
-UN-23FEB99
2. Remove mounting nuts (B).
3. Pull fuel supply pump straight out from injection pump

housing. Cover supply pump mounting bore so debris
CD30726
cannot enter injection pump.
CD,3274,G40,78 -19-04JAN99
TEST MICO FUEL SUPPLY PUMP FOR

LEAKS
1. Connect compressed air line (A) to a pressure gauge

(B) and to supply inlet fitting. Air line should have a
regulating valve to control pressure.
2. Cap or plug supply pump outlet fitting (C).
3. Submerge supply pump in a container of clean diesel

fuel. Regulate air pressure to 200 kPa (2 bar; 29 psi).
4. Move tappet in and out by hand. No air bubbles
-UN-03NOV97
should appear around tappet.
NOTE: If bubbles appear, it is an indication that either

the seal is defective or tappet is worn.
RG5894
IMPORTANT: Serious injection pump or engine
damage could occur, if enough diesel
fuel leaks past tappet and seal. Fuel
40
38 leakage past tappet dilutes engine oil.
CD,3274,G40,79 -19-04JAN99

060799
PN=283
DISASSEMBLE MICO FUEL SUPPLY PUMP
-UN-24FEB99
CD30727
AHand primer EPump housing ISpring MSeal washer (2 used)
BGasket FTappet seal JSeal washer NCopper washer (4 used)
CSpring (2 used) GTappet KPlug OBanjo screw (2 used)
DValve (2 used) HPlunger LFitting
Check parts for excessive wear. If necessary, replace

complete supply pump or individual parts when
available.
CD,3274,G40,80 -19-04JAN99
40
39

060799
PN=284
ASSEMBLE MICO FUEL SUPPLY PUMP
IMPORTANT: Hands should be wet with diesel fuel

when assembling internal components
of fuel supply pump.
-UN-22FEB99
1. Install new seal (C) into pump housing (B) using
JDF15 Driver (A). Be sure seal is started straight in
housing bore and drive until driver contacts housing.
CD30728
2. To assemble supply pump, reverse disassembly
procedure using new seal washers.
CD,3274,G40,81 -19-04JAN99
INSTALL FUEL SUPPLY PUMP ON IN-LINE

FUEL INJECTION PUMP
1. Install a new gasket on injection pump flange.
2. Position pump over mounting studs. Tighten nuts to

57 Nm (45 lb-ft).
3. Install fuel inlet (A) and outlet (B) lines. Tighten banjo
screws to 25 Nm (18 lb-ft).
4. Bleed fuel system.
-UN-23FEB99
CD30729
40
40
CD,3274,G40,82 -19-04JAN99

060799
PN=285
SERVICE INJECTION PUMP OVERFLOW

VALVE (IN-LINE INJECTION PUMP)
The overflow valve (A) cannot be adjusted. Replace

valve in case of leakage or bad operation.
-UN-23FEB99
CD30730
CD,3274,G40,83 -19-04JAN99
40
41

060799
PN=286
REMOVE MICO IN-LINE INJECTION PUMP
-UN-23FEB99
CD30743
IMPORTANT: Never steam clean or pour cold 3. Disconnect the following elements:
water on a running or warm fuel Shut-off system and speed control linkage
injection pump. Seizure of internal Fuel inlet line (A) on supply pump
components can occur. Fuel outlet line (B) on supply pump
Fuel supply line (C) on injection pump
1. Clean fuel injection pump, lines and area around Fuel return line (D)
pump with cleaning solvent or a steam cleaner. Oil supply line (E)
Fuel injection lines (F)
2. Check for the presence of timing marks on front
plate, spacer and injection pump flange. If necessary, 4. Plug all open connections on pump and fuel lines.
mark parts before removal. Do not use fibrous material.
40
42
CD,3274,G40,84 -19-04JAN99

060799
PN=287
5. Remove plug from mounting hole in timing gear cover.
6. Remove special nut (A) securing the fuel injection

-UN-23FEB99
7. Using KJD10213 special wrench, loosen the four nuts
holding fuel injection pump to engine front plate.
CD30731
CD,3274,G40,85 -19-04JAN99
8. Install KJD10159 or JDG670A (after modification)

special tool.
9. Turn forcing screw of special tool clockwise until pump

shaft is loosened from conical seat of drive gear.
-UN-17FEB95
10. Remove nuts from studs and pull fuel injection pump
backward. Remove the spacer and O-ring.
NOTE: When removing fuel injection pump, be careful
CD30317
not to lose the shaft key.
-UN-07MAR95
CD30218
CD,3274,G40,86 -19-04JAN99
40
JDG670A MODIFICATION 43
JDG670A special tool can be used to remove the MICO

in-line injection pump when modified as indicated.
-UN-22FEB99
A40 mm (1.57 in.)

B23 mm (0.90 in.)
C7 mm (0.27 in.)
CD30732
CD,3274,G40,87 -19-04JAN99

060799
PN=288
REPAIR MICO IN-LINE FUEL INJECTION PUMP
IMPORTANT: Do not disassemble fuel injection that pump is set to the correct
pump further than necessary for specifications for its intended use.
installing available service parts, not
even for cleaning. For injection pump repair and testing, have an
authorized diesel injection repair station perform the
Be sure that injection pump serial work. Unauthorized repairs made to the injection
number tag is in place and that all pump will void warranty.
identification numbers are legible so
CD,3274,G40,88 -19-04JAN99
INSTALL MICO IN-LINE FUEL INJECTION

PUMP
1. Slide spacer (A) with O-ring (B) over the four studs.
-UN-23FEB99
2. Slide injection pump over studs, inserting shaft in
drive gear.
NOTE: Make sure that the shaft key is seated properly.
CD30733
CD,3274,G40,89 -19-04JAN99
40
44

060799
PN=289
3. Screw the four nuts (B) onto studs and hand-tighten

at this stage.
4. Push drive gear firmly onto shaft taper. Install special

nut (A) then tighten to 85 Nm (62 lb-ft). Install mounting
plug onto timing gear cover.
5. Align timing marks on pump flange, spacer and front

plate then, using KJD10213 special wrench, tighten nuts
NOTE: In case of replacement of injection pump, install

injection pump with studs in middle of flange
slots. Then perform a dynamic timing.
-UN-23FEB99
6. Connect injection lines. Commence with line No.1 (C)
and continue in same order as engine firing (1-2-3).
Tighten to 25 Nm (18 lb-ft).
CD30734
IMPORTANT: DO NOT move delivery valve fittings
while tightening line nuts, injection
pump delivery will be altered. The
injection pump will have to be
recalibrated on a test stand by an
authorized diesel injection pump repair
station.
-UN-23FEB99
7. Connect:
Oil supply line (D). Tighten banjo screw to 15 Nm
(11 lb-ft).
Fuel supply line (E) on injection pump. Tighten banjo
screw to 25 Nm (18 lb-ft).
CD30731
Fuel outlet line (F) on supply pump. Tighten banjo
Fuel inlet line (G) on supply pump. Tighten banjo screw
Fuel return line (H) on injection pump. Tighten banjo
Shut-off system and speed control linkage.
8. Remove oil fill plug (J) from governor housing and

add 300 ml (10.14 fl oz) of clean engine oil.
40
45
CD,3274,G40,90 -19-04JAN99

060799
PN=290
Fuel System/Dynamic Timing
DYNAMIC TIMING (ALL PUMP TYPES)
Two types of dynamic timing are used:
Dynamic timing at full load rated speed when engine

can be connected to a dynamometer (e.g. tractors). This
method is more appropriate, as it corresponds more
closely to the realistic use of the engine.
Dynamic timing at no-load when engine cannot be

connected to dynamometer (e.g. combines).
NOTE: Stroboscopic lamp (M) can be used for all
-UN-10MAY96
engines while the magnetic probe can be used
on recent engines (214170CD- ) only.
AMeter
BSensor clamp
CD30441
C6 mm clamp-on transducer
DInstruction manual
ETiming sensor
FTiming pin
GMagnetic probe
HTransducer cable
J1/4 clamp-on transducer
KMagnetic probe adapter
LMagnetic probe adapter
MStroboscopic lamp
-UN-22FEB99
CD30735
CD,3274,G40,91 -19-04JAN99
40
46

060799
PN=291
INSTALL TIMING SENSOR
Install FKM10429-6 timing sensor (E) between No. 1

nozzle and high pressure fuel line.
-UN-07MAR95
Using two wrenches, tighten sensor and fuel pressure
line to 30 Nm (22 lb-ft).
IMPORTANT: Timing sensor must be installed at

nozzle end of N.1 fuel injection line. If
CD30195
access to N.1 line is restricted, sensor
can be installed on N.4 injection line
(4-cylinder engines) and N.6 injection
line (6-cylinder engines). Sensor MUST
BE installed on N.1 injection line of all
3-cylinder engines.
NOTE: If clearance does not allow proper installation of
-UN-20MAY98
the timing sensor (E), FKM10429-5 or
FKM10465-3 clamp-on transducer (C) can be
installed close to injection nozzle. Remove paint
on injection line before installation.
CD30673
CD,FKM10429A,2 -19-23FEB98
40
47

060799
PN=292
INSTALL MAGNETIC PROBE (FOR USE

WITHOUT STROBOSCOPIC LAMP)
IMPORTANT: Use JDG81-4 timing pin (A) in flywheel
-UN-10MAY96
housing timing hole (B) to ensure
engine is NOT stopped at TOP DEAD
CENTER. If this is not done, flywheel
timing hole will damage the magnetic
probe (D) when engine is started.
CD30442
Installation in flywheel housing with tapped timing
hole:
1. Install JDG793 magnetic probe adapter (C) into

flywheel housing tapped hole (B) until it bottoms.
2. Insert magnetic probe (D) into adapter until it contacts

flywheel. Back out hex head of adapter two flats and
tighten lock nut (E), this will provide the 0,65 mm
(0.025 in.) recommended air gap.
-UN-10MAY96
Installation in flywheel housing with smooth timing
hole:
1. Install JDG821 magnetic probe adapter (F) into
CD30443
flywheel housing smooth hole (B). Lightly tap adapter to
lock into position.
2. Insert magnetic probe (D) into adapter until it contacts

flywheel. Pull magnetic probe back out to provide
0,65 mm (0.025 in.) recommended air gap.
-UN-10MAY96
40
CD30444
48
CD,3274,G40,92 -19-04JAN99

060799
PN=293
INSTALL STATIONARY POINTER (FOR USE

WITH STROBOSCOPIC LAMP)
1. Install stationary pointer (A) on timing gear cover so

that it can be aligned with pulley (e.g. on filler neck
-UN-07MAR95
screw).
N CAUTION: Take great care to avoid contact

with moving parts.
DANGER OF SERIOUS ACCIDENTS
CD30193
2. Rotate engine clockwise (as seen from water pump
end) and position No. 1 piston at top dead center (TDC).
3. Using a scriber, make a TDC mark (B) on the pulley

(C) in line with stationary pointer.
AStationary pointer
-UN-07MAR95
BTDC mark
CPulley
CD30201
CD,3274,G40,27 -19-04JAN99
40
49

060799
PN=294
TIMING SENSOR AND MAGNETIC PROBE

CONNECTION
1. Connect timing sensor (A) or clamp-on transducer to

meter socket SR (B) with FKM10429-4 sensor clamp
-UN-10MAY96
(C) and FKM10465-2 transducer cable (D).
2. Connect ground cable.
3. Connect magnetic probe (E) to meter socket MP (F)
CD30445
or connect stroboscopic lamp to meter socket TL (G).
4. Connect power cable to vehicle battery as follows:

red to positive
black to negative
N CAUTION: Observe correct polarity to avoid

possible damage to unit.
ATiming sensor
BMeter socket for timing sensor (marked SR)
CSensor clamp
DTransducer cable
EMagnetic probe
FMeter socket for magnetic probe (marked
MP)
GMeter socket for stroboscopic lamp (marked
-UN-23FEB99
TL)
CD30736
CD,3274,G40,29 -19-04JAN99
DYNAMIC TIMING AT FULL LOAD RATED

SPEED USING MAGNETIC PROBE
NOTE: To check dynamic timing using stroboscopic

lamp, refer to DYNAMIC TIMING AT NO-LOAD.
-UN-07MAR95
40 1. Switch meter on by pressing the ON/CLEAR key.
50 The display will show Time-Trac, then Model TT1000,
then R = 0.
CD30202
NOTE: At this point, meter can be used as a

tachometer.
2. Start the engine and run for 10 minutes to reach the

operating temperature.
CD,3274,G40,30 -19-04JAN99

060799
PN=295
3. Press MAG PROBE key. A default trig level value

of 30% will appear. Then type in 70 to enter a 70% trig
level and press the ENTER key.
4. A default Offset value of 20.0 will now appear. Type
-UN-10MAY96
in 0.0 to enter a 0.0 Offset value and press the
ENTER key.
CD30447
CD,FKM10429A,6 -19-02MAY96
5. The display will now show Calibrate?. The meter is

now ready to accept a timing sensor signal for
calibration.
6. Press ENTER to perform calibration. Run engine at
-UN-07MAR95
1300 rpm. The display will automatically show the engine
speed.
CD30204
CD,FKM10429A,7 -19-02MAY96
7. Once 1300 rpm is displayed, press ENTER key.

Calibrating ... will then appear on the display for a
short period of time.
NOTE: If the meter loses the engine speed signal or the
-UN-07MAR95
engine is not running, the display will show Eng.
not running. This message flashes three times
before the meter returns to tachometer mode. To
restart the procedure, press MAG PROBE key
(step 3).
CD30205
CD,FKM10429A,8 -19-02MAY96
40
51

060799
PN=296
8. Run engine at fast idle speed then load engine down

gradually to rated speed (see Specifications) using
dynamometer or any other system allowing to load
engine.
-UN-10MAY96
9. Record engine speed and timing degrees.
NOTE: If display shows R + 1500 No Probe, the

magnetic probe has not been installed properly
[air gap exceeds 0.65 mm (0.025 in.)] or there is
CD30448
debris on the back of the flywheel. Check for
proper air gap or to clean the back side of the
flywheel.
CD,FKM10429A,9 -19-02MAY96
10. Stop engine and, if necessary, rotate injection pump

as follows:
If below specification, rotate pump towards engine
block.
If above specification, rotate pump away from engine
-UN-05MAY95
block.
IMPORTANT: Stop engine prior to making timing

adjustments. Injection pump can seize
if adjustment is made with engine CD30198
running.
NOTE: 1 mm offset on the injection pump flange

corresponds approximately to 2 on the meter
-UN-10MAY96
display.
11. Recheck timing until specified timing is obtained.
12. After adjustment, grind the engine front plate mark to
CD30449
avoid any confusion with the original timing adjustment.
40
52 NOTE: If the injection pump has to be removed from
engine and reinstalled without any change, mark
both the front plate and the injection pump flange
to allow the reinstallation of injection pump at the
same location.
In case of repair or replacement of injection
pump, perform again a dynamic timing.
CD,FKM10429A,10-19-02MAY96

060799
PN=297
DYNAMIC TIMING AT NO-LOAD
NOTE: Dynamic timing at no-load can be checked only

by using the stroboscopic lamp while the
stroboscopic lamp can be used also to check
-UN-07MAR95
dynamic timing at full-load.
1. As the value for dynamic timing at no-load is close to

0 and since the timing meter is less accurate for these
values, an additional mark (D) with a 10 offset angle
CD30194
should be made counterclockwise from the TDC mark.
The specifications for No-load in this group include this
10 angle.
Value for X according to pulley diameter: AStationary pointer

BTDC mark
Dia. 142 mm (5.59 in.) . . . . . . . . . . . . . . . . . X = 12.4 mm (0.49 in.) CPulley
Dia. 168 mm (6.61 in.) . . . . . . . . . . . . . . . . . X = 14.6 mm (0.57 in.) DAdditional mark
Dia. 222 mm (8.74 in.) . . . . . . . . . . . . . . . . . X = 19.4 mm (0.76 in.)
Dia. 250 mm (9.84 in.) . . . . . . . . . . . . . . . . . X = 21.8 mm (0.86 in.)
NOTE: If the pulley diameter is not listed in the above

chart, use the following formula to calculate X:
X = diameter x 0.087.
CD,3274,G40,57 -19-04JAN99
2. Switch meter on by pressing the ON/CLEAR key.

The display will show Time-Trac, then Model TT1000,
then R = 0.
NOTE: At this point, meter can be used as a

-UN-07MAR95
tachometer.
40
3. Start the engine and run for 10 minutes to reach the 53
operating temperature.
CD30202
CD,3274,G40,58 -19-04JAN99

060799
PN=298
4. Press TIMING LIGHT key. A default trig level value

of 30% will appear. Then type in 70 to enter a 70% trig
level and press the ENTER key.
5. A default Offset value of 20.0 will now appear. Type
-UN-07MAR95
in 0.0 to enter a 0.0 Offset value and press the
ENTER key.
CD30203
CD,3274,G40,59 -19-27APR92
6. The display will now show Calibrate?. The meter is

now ready to accept a timing sensor signal for
calibration.
7. Press ENTER to perform calibration. Run engine at
-UN-07MAR95
1300 rpm. The display will automatically show the engine
speed.
CD30204
CD,3274,G40,60 -19-04JAN99
8. Once 1300 rpm is displayed, press ENTER key.

Calibrating ... will then appear on the display for a
short period of time.
NOTE: If the meter loses the engine speed signal or the
-UN-07MAR95
engine is not running, the display will show Eng.
not running. This message flashes three times
before the meter returns to tachometer mode. To
restart the procedure, press TIMING LIGHT key
(step 4).
CD30205
9. Run engine at fast idle. Adjust fast idle if necessary
(see SPECIFICATIONS).
40
54
CD,3274,G40,61 -19-04JAN99

060799
PN=299
NOTE: For dynamic timing at no-load, go directly to step

11.
10. Load engine down gradually to rated speed (see

SPECIFICATIONS) using dynamometer or any other
system allowing to load engine.
CD,3274,G40,93 -19-04JAN99
40
55

060799
PN=300
11. Aim stroboscope timing light at pulley, then press the

timing light push button up (A) or down (B) as necessary
to align stationary pointer with reference timing marks
and read the timing degree value on the display.
-UN-07MAR95
-UN-05MAY95
12. Stop engine and, if necessary, rotate injection pump
as follows:
If below specification, rotate pump towards engine
block
If above specification, rotate pump away from
CD30221
CD30198
engine block
N CAUTION: Do not rotate the injection pump as

long as the engine is running. This may cause
the pump to seize and cause severe damage.
NOTE: 1 mm (0.04 in.) offset on the injection pump

flange corresponds to 2 on the meter display.
-UN-07MAR95
13. Recheck timing until specified timing is obtained.
14. After adjustment, grind the engine front plate mark to

avoid any confusion with the original timing adjustment.
CD30211
NOTE: If the injection pump dynamically timed has to be
removed from engine and reinstalled without any
change, mark both the front plate and the
injection pump flange to allow the reinstallation of
injection pump at the same location.
In case of repair or replacement of an injection
pump dynamically timed, perform a dynamic
timing adjustment.
40
56
CD,3274,G40,62 -19-04JAN99

060799
PN=301
Fuel System/Aneroid
ANEROID REPLACEMENT
NOTE: It is not necessary to remove fuel injection pump

when replacing an aneroid.
-UN-23MAY95
1. Remove clamp (A) and hose (B). Remove retaining
ring (C) and attaching screws (D).
2. Remove aneroid and bracket assembly from pump.
CD7324
3. Prepare and adjust new aneroid (see Aneroid
Adjustment in this group).
4. Attach operating rod to pump lever with retaining

ring (C) and fasten bracket to injection pump cover with
screws (D). Tighten screws to 5 Nm (45 lb-in.).
5. Connect hose (B) to aneroid inlet with clamp (A).
CD,3274,G40,35 -19-28APR92
ANEROID FIELD ADJUSTMENT
1. On an inoperative aneroid, screw in operating rod (A)

and count the number of turns until it bottoms.
2. Take the new aneroid, screw in operating rod (A) until

it bottoms then back off by the same number of turns as
were needed for the previous aneroid.
3. Install adjusted aneroid on injection pump.
-UN-08MAR95
40
57
CD30188
CD,3274,G40,36 -19-27APR92

060799
PN=302
Fuel System/Aneroid
ANEROID WORKSHOP ADJUSTMENT
1. Install a new aneroid on the injection pump.
2. Connect a regulated air pressure source to aneroid

inlet and use a mercury manometer in preference to a
gauge, as operating pressures are very low.
3. Note the pressure at which shut-off lever lifts off

forward screw (B) and the pressure required to obtain
full travel until rear screw (C) bottoms.
-UN-08MAR95
4. Pressure specifications are:
Lever lift-off . . . . . . . . . . . . . . . . . . . 76102 mm Hg (34 in. Hg)

1014 kPa (1.52.0 psi)
CD30187
Lever at full travel . . . . . . . . . . . . 330380 mm Hg (1315 in. Hg)
4451 kPa (6.47.4 psi)
NOTE: Lift-off pressure can be checked by inserting a

shim of 0.05 mm (0.002 in.) thickness between
lever and front screw; the shim will slip out as
soon as the lever starts to move.
5. If lever travel requires more pressure than specified,

lengthen the operating rod; if less pressure is required,
shorten operating rod.
6. Once aneroid is set, repeat test to check adjustment.
7. Install injection pump on engine.
IMPORTANT: During aneroid adjustment, do not

touch the forward/rear screw, as these
devices have been adjusted on the test
stand.
CD,3274,G40,37 -19-27APR92
40
58

060799
PN=303
Fuel System/Fuel Injection Nozzles
FUEL INJECTION NOZZLE REMOVAL
Important Notes:
Before removal, carefully remove all dirt from the cylinder
-UN-17FEB95
head around fuel injection nozzles and blow clean with
compressed air in order to prevent any dirt entering the
cylinder or valve seats. Plug the bore in the cylinder
head after fuel injection nozzle has been removed. Cap
fuel line openings as soon as they are removed.
CD30323
Fit protecting caps immediately over the nozzle tips and
the line connections to avoid damage to the nozzles
when handling them.
Do not bend the fuel pressure lines, as this may affect

their durability and breakdowns may occur. When
loosening the fuel pressure lines, hold male union of
-UN-17FEB95
nozzle line.
Removal:
1. Loosen nuts (B) to remove leak-off lines (A) and
CD30324
T-fittings.
2. Disconnect fuel injection lines (D) from nozzles.
3. Remove cap screw (C).
4. Pull injection nozzles out of cylinder head, using

JDG716 injection nozzle puller.
IMPORTANT: Do not use screwdrivers or similar

tools for this, as they may cause
irreparable damage to the injection
nozzles.
CD,3274,G40,38 -19-12NOV92
40
59

060799
PN=304
CLEAN FUEL INJECTION NOZZLE
NOTE: Before testing a fuel injection nozzle with a body and tip with brass wire brush. NEVER use a
nozzle tester, remove both sealing rings and steel wire brush or scraper for this purpose.
thoroughly clean outside of injection nozzle.
IMPORTANT: When removing sealing rings and
Remove the carbon stop seal from groove in nozzle cleaning the nozzle, take care not to
body using suitable pliers. Pull seal washer from the damage the Teflon coating of the
nozzle body and discard carbon stop seal and seal nozzle body above the groove for
washer. the carbon stop seal.
Place fuel injection nozzle in solvent or clean Diesel

fuel until accumulated deposits are saturated. Clean
CD,CTM125,198 -19-01DEC97
FUEL INJECTION NOZZLE TEST
NOTE: Testing the performance of a nozzle while the

engine is running is just a rough test. To obtain a
true check of nozzle performance, use a nozzle
tester JT25510 (1) and pressure line KJD10109
(2), as shown under Special Tools.
Use only carefully filtered diesel fuel for testing

the injection nozzles, since dirty fuel will severely
-UN-08AUG89
damage the precision parts of a nozzle.
N CAUTION: The nozzle tip must always point

away from the operator. The fuel issuing from
an orifice can penetrate clothes and skin and
L30741
thus cause severe infection.
Connect the nozzle to the tester so that the axis of the

nozzle forms an angle of approx. 30 to the vertical and
the spray of fuel is directed downwards. Check all
connections for leaks. Close the gauge shut-off valve
40
60 and flush (bleed) the nozzle by operating test pump
rapidly.
CD,3274,G40,40 -19-27APR92

060799
PN=305
Spray pattern test centerline of the nozzle body, but should be

distributed. For a better check, place a piece of paper
or cardboard at a suitable distance below the nozzle
Close gauge shut-off valve and operate the pump and check the appearance of the damp circular spots
lever at 60 strokes per minute. If the fuel injection made by the fuel. Deviations from the regular spray
nozzle is working properly, the fuel should issue pattern or angle may be due to the complete or
through all nozzle orifices in a fine, evenly shaped partial clogging of a nozzle orifice. In this case the
spray cone. This spray cone is inclined from the fuel issues in a jet rather than in a fine spray.
CD,3274,G40,41 -19-01FEB94
Chatter test characteristic chatter should be heard. If this is not

the case, the nozzle valve may be bent or tight in its
Make sure nozzle orifices are free. When working guide because of the lacquer deposits which have
pump of fuel injection nozzle tester at 60 strokes per accumulated. This can be corrected only by
minute (gauge shut-off valve closed), a definite disassembling the nozzle.
CD,3274,G40,42 -19-01FEB94
Checking valve stem and guide wear constant and observe how much fuel leaks out of the
nozzle return end. After the first drop has formed,
Connect fuel injection nozzle to the nozzle tester with count the drops for 30 seconds; there should be 3 to
the tip raised a little higher than its opposite end. 10 drops.
Cover the tip and pump the tester to a pressure of
10300 kPa (103 bar; 1500 psi). Keep the pressure
CD,3274,G40,43 -19-01FEB94
40
Opening pressure test pressure up to the point where the pressure gauge 61
needle falls rapidly. This point (take reading) is the
NOTE: Absolute opening pressure is less important nozzle valve opening pressure (minimum pressure
than equal opening pressure of all nozzles. see Specifications).
Max. permissible variation see Specifications.
If spray pattern, leakage test, and valve wear test
Close gauge shut-off valve and actuate the pump (see below) are good but the opening pressure test is
several times to allow the nozzle valve to seat unsatisfactory, adjust opening pressure as described
properly. Open gauge shut-off valve. Pump the under Adjustment.
CD,3274,G40,44 -19-01FEB94

060799
PN=306
Checking valve seat pressure (see Specifications for opening pressure).

Keep watching the nozzle. Under these conditions the
Connect the nozzle to tester in horizontal position. nozzle tip has to stay dry (visual check) after a period
Operate the pump lever rapidly to bleed the nozzle of 5 seconds. Work the pump lever quickly several
and allow the valve to seat. Dry the tip of the nozzle times in succession to make the nozzle spray in the
thoroughly. Now operate the pump lever slowly until normal way. After the last stroke of the pump,
the indicated pressure is approx. 2800 to 3500 kPa observe again. If the nozzle is not quite leakproof,
(28 to 35 bar; 400 to 500 psi) below opening disassemble for servicing.
CD,3274,G40,45 -19-01FEB94
FUEL INJECTION NOZZLE DISASSEMBLY
NOTE: If all tests prove that the nozzle performs operating properly and must be disassembled
properly, no further service is necessary and for cleaning and/or reconditioning, see your
the nozzle can be reinstalled (see under Stanadyne dealer.
Installation). If an injection nozzle is not
CD,3274,G40,46 -19-01FEB94
ADJUST FUEL INJECTION NOZZLE
1. Loosen and remove lock nut (A) of lift adjusting screw

(D).
2. Loosen lock nut (B) of pressure adjusting screw (C).
3. Connect nozzle to tester, then using JDG949 Special

Wrench, adjust opening pressure by turning the pressure
adjusting screw (C).
4. Tighten lock nut (B) to 10 Nm (7 lb-ft), then recheck

opening pressure.
40
-UN-16JUN98
62 5. Carefully screw lift adjusting screw (D) until it bottoms

on spring seat (E).
6. Unscrew lift adjusting screw with the number of turns

as specified.
CD30674
7. Tighten lock nut of lift adjusting screw to 5 Nm

(3.5 lb-ft).
8. Recheck opening pressure.
CD,CTM125,199 -19-01DEC97

060799
PN=307
INSTALL FUEL INJECTION NOZZLE
IMPORTANT: Each time an injection nozzle is

removed from cylinder head, replace
the carbon stop seal (E).
-UN-17FEB95
1. Slide seal washer (F) onto nozzle body. Using JD-258
pilot tool, slide the new carbon stop seal until it fits
properly into the groove.
CD30323
IMPORTANT: Before installation, make sure nozzle is
clean and free from oil or grease.
2. Install nozzle in cylinder head. Screw cap screw (C).

Do not tighten at this stage.
3. Connect fuel injection line (D) to nozzle. Tighten

pressure line to 30 Nm (23 lb-ft) using two wrenches as
shown.
4. Tighten cap screws (C) to 37 Nm (27 lb-ft).
5. Install leak-off lines (A) and T-fittings (B). Tighten nut

to 5 Nm (3.5 lb-ft).
ALeak-off line
BT-fitting
CCap screw
DFuel injection line
ECarbon stop seal
-UN-16JUN98
FSeal washer
GProtection cap
HProtection cap
JTube nut
KRubber sleeve
CD30675
-UN-20MAY98
40
63
CD30676
CD,CTM125,200 -19-01DEC97

060799
PN=308
Fuel System/Fuel System Bleed
BLEED THE FUEL SYSTEM AT FUEL FILTER
-UN-20MAY98
-UN-20OCT88
CD30677
T95989
Rectangular Fuel filter Round Fuel filter
N CAUTION: Escaping diesel fuel under pressure

can have sufficient force to penetrate the skin
causing serious personal injury.
If injured by escaping fuel, see a doctor at
-UN-20MAY98
once. Serious infection or reaction can develop
if proper medical treatment is not administered
immediately.
1. Loosen air bleed screw (A).
CD30678
2. Operate primer lever of fuel supply pump (B) or switch
the ignition on (if the vehicle has an electic supply pump)
until fuel flow is free from air bubbles.
NOTE: Round fuel filter may have the hand primer on

filter mounting base (C).
3. Tighten bleed screw (A) by hand or using a coin.
CD,3274,G40,52 -19-04JAN99
40
64

060799
PN=309
BLEED FUEL SYSTEM (LUCAS-CAV)
-UN-10MAY95
-UN-10MAY95
CD30430
CD30429
Lucas CAV - DPA Models Lucas CAV - DP200 Models
1. Loosen bleed screw (A) on pump cover. 2. Operate primer lever of fuel supply pump or switch
on the ignition for vehicle with electric supply pump.
IMPORTANT: Never loosen screw (B) securing
hydraulic head, otherwise pump 3. As soon as fuel flow is free from air bubbles
damage may occur. tighten bleed screw.
CD,3274,G40,53 -19-04JAN99
BLEED FUEL SYSTEM (STANADYNE)
1. Loosen fuel return line (A) at fuel injection pump.
2. Operate primer lever of fuel supply pump or switch on
-UN-04MAY98
the ignition for vehicle with electric supply pump.
3. As soon as fuel flow is free from air bubbles tighten

bleed screw.
CD30679
40
65
CD,3274,G40,64 -19-04JAN99

060799
PN=310
BLEED FUEL SYSTEM (MICO IN-LINE

INJECTION PUMP)
1. Loosen fuel return line (A).
-UN-23FEB99
2. Unscrew hand primer on fuel supply pump until it can
be pulled by hand.
3. Operate the hand primer until fuel flow is free from air
bubbles.
CD30737
4. Simultaneously stroke the hand primer down and
close the fuel return port. This prevents air from entering
the system. Tighten securely.
5. Lock hand primer in position.
CD,3274,G40,94 -19-04JAN99
BLEED FUEL SYSTEM AT FUEL INJECTION

NOZZLES
If engine will not start after the bleeding procedures

described above, continue as follows:
-UN-04MAY98
1. Place throttle lever in fast idle position.
2. Using two open-end wrenches, loosen fuel line on at

least three nozzles.
CD30680
3. Turn over engine with starter motor until fuel flows
free from bubbles out of loosened fuel nozzle
connections. Retighten connections.
CD,3274,G40,54 -19-04JAN99
40
66

060799
PN=311
ADJUST ENGINE SPEED ON DISTRIBUTOR

INJECTION PUMP
NOTE: Before adjusting engine speed, make sure engine

has reached its normal operating temperature.
-UN-17FEB95
All speeds indicated apply to an engine not under
load. The maximum permissible speed variation
is 50 rpm for slow idle speed and + 50 rpm
for fast idle speed.
CD30327
Fast idle checking:
Lucas CAV - DPA Models
1. Disconnect speed control rod at fuel injection pump.
2. Move pump throttle lever against pump fast idle

adjusting screw (A). Check engine speed and compare
with specifications.
-UN-10MAY95
NOTE: Fast idle is settled by the factory then the fast
idle adjusting screw (A) is sealed to prevent from
tampering. Fast idle adjustment can only be done
by an authorized fuel system agent.
CD30431
Slow idle checking:
Lucas CAV - DP200 Models
1. Disconnect speed control rod at fuel injection pump.
2. Move pump throttle lever in slow idle position against

slow idle adjusting screw (B). Check engine speed and
compare with specifications.
-UN-07MAR95
NOTE: Most engines for generator set application (1500
rpm for 50 Hz or 1800 rpm for 60 Hz) run only at
fast idle and therefore they do not have slow idle.
3. In case of incorrect engine speed, turn screw (B)

clockwise to increase and counter-clockwise to decrease
CD7327
engine speed.
STANADYNE injection pump
40
67
CD,3274,G40,55 -19-04JAN99

060799
PN=312
ADJUST ENGINE SPEED ON MICO IN-LINE

INJECTION PUMP
NOTE: Before adjusting engine speed, make sure engine

has reached its normal operating temperature.
-UN-23FEB99
All speeds indicated apply to an engine not under
load. The maximum permissible speed variation
is 50 rpm for slow idle speed and + 50 rpm
for fast idle speed.
CD30738
Fast idle checking:
MICO in-line pump
Move pump throttle lever against pump fast idle adjusting
screw (A). Check engine speed and compare with
specifications.
NOTE: Fast idle is settled by the factory then the fast

idle adjusting screw (A) is sealed to prevent from
tampering. Fast idle adjustment can only be done
by an authorized fuel system agent.
Slow idle checking:
NOTE: Both the slow idle spring screw (B) and the slow
idle speed screw (C) are used to adjust the slow
idle speed. Remove the threaded caps to access
these adjusting screws.
1. Loosen slow idle spring screw (B) as much as

possible.
2. Adjust slow idle speed screw (C) to the specifications

minus 20 rpm.
3. Retighten slow idle spring screw (B) until engine slow

idle speed specification is obtained.
40
68
CD,3274,G40,95 -19-04JAN99

060799
PN=313
Group 205
Engine System - Operation
205
1

060799
PN=314
Engine System - Operation/Engine - Sectional view
ENGINESECTIONAL VIEW
-UN-11JUL95
RG7248
ARocker Arm Shaft FCylinder Block KConnecting Rod PPiston Rings
BCylinder Head GCrankshaft LLiner Packing Rings QValve
CPush Rod HCrankshaft Counterweight MCylinder Liner RFuel Injection Nozzle
DCam Follower IOil Pan NPiston SValve Spring
ECamshaft JBalancer Shafts OPiston Pin TRocker Arm
205
2
S11,2000,EH -19-11JUL95

060799
PN=315
Engine System - Operation/General information
GENERAL INFORMATION
Model 3029, 4039, 4045, 6059 and 6068 engines are The camshaft, supported integrally in cylinder block,
vertical, in-line, valve in head, 4-stroke diesel engines. is driven by an intermediate gear of the timing gear
train via the crankshaft gear. The camshaft cams
The direct fuel injection is effected by means of a determine time and rate of opening of each valve and
distributor-type fuel injection pump, which is driven by actuate the fuel transfer pump.
an intermediate gear in the timing gear train via the
crankshaft gear. The intake and exhaust valves are supported in the
cylinder head. The valve stems slide in bores in the
The wet cylinder liners (liner forms cylinder and is cylinder head. The rocker arm shaft assembly is fitted
surrounded with coolant) can be replaced individually. on top of the cylinder head.
The pistons are forged aluminium alloy. The outer The engine is supplied with lubricating oil by a gear
surface of the pistons is cam ground. The piston pump. The lubricating oil passes through a full-flow oil
crown has a cut-out swirl cup with a truncated cone filter in the main oil circuit. To ensure engine
in the center. Each piston has two compression rings lubrication, the oil filter is provided with a by-pass
which form a seal between combustion chamber and valve which opens when the filter element is
crankshaft housing and an oil control ring which restricted. On most engines, engine oil is cooled by
controls lubrication between piston and wall of liner. means of an oil cooler mounted externally on the
All piston rings are located above the piston pin. cylinder block. Engine oil passes through the oil
cooler before flowing to the oil filter. A by-pass valve
The hardened piston pins are fully-floating and held in located between oil pump and main gallery relieves
position by means of snap rings. any pressure build-up in this area.
The crankshaft is a one-piece, heat treated, steel The engine has a pressurized cooling system,
forging or cast iron. It is supported in replaceable consisting of radiator, water pump, multi-blade fan
two-piece main bearings machined to close and one or two thermostats.
tolerances. The rear thrust bearing has a flange on
each side to support crankshaft thrust and to limit Some engines are equipped with a turbocharger.
end play. Operated by exhaust gases, the turbocharger draws
in filtered air to the combustion chambers.
The connecting rods are provided with a replaceable
bronze bushing as bearing surface for the piston pins. Some other engines are designed and built with a
Whereas the replaceable steel-backed bearing insert turbocharger and an air-to-air aftercooler. Air-to-air
halves are aluminium lined and tin plated. aftercooler cools the turbocharger compressor
discharge air by routing it through a heat exchanger
(usually mounted in front of radiator) before it enters
the intake manifold. The heat exchanger uses no
liquid coolant, but relies on air flow to cool the charge
air.
205
3
CD,3274,G205,1 -19-15MAY92

060799
PN=316
Engine System - Operation/Lubrication System
-UN-08MAR95
CD30330
205
4 1Suction line strainer 8Oil pressure regulating 12Connecting rod bearings 17Oil pressure warning
2Oil pump valve 13Upper idler gear switch
3Oil by-pass valve 9Balancer shaft bushings 14Main oil gallery 18Lower idler gear
4Oil cooler by-pass valve (4-cylinder) 15Camshaft bearings 19Pressure-free oil
5Oil cooler 10Main bearings 16Lubricating oil line to 20Engine lubricating oil
6Oil filter 11Spray jet (1 per cylinder) turbocharger (when
7Oil filter by-pass valve equipped)
CD,3274,G205,2 -19-12NOV92

060799
PN=317
LUBRICATION SYSTEM
The engine has a pressure lubrication system. In the Lube oil holes in Nos. 1, 3, 5 main bearing oil
main it consists of the gear pump (2), filter strainer in grooves are provided to direct oil to the camshaft
the suction pipe, full flow oil filter (6), oil cooler (5), bearings (15). The lower idler gear is lubricated by
adjustable oil pressure regulating valve (8), oil splash oil.
by-pass valve (3) and an electrical pressure warning
switch (17). A drilled passage from the rear camshaft bearing
through the cylinder block and cylinder head supplies
The pump draws lubricating oil from the crankcase lubricating oil to the rocker arm shaft.
through a strainer (1) and suction line and pumps it
through an oil line via the oil cooler (5) to the oil filter Direct oil passages from the main oil gallery provide
(6) and to the main oil gallery (14) of the cylinder lubricating oil to balancer shaft bushings (9) and the
block. shaft of the turbocharger. The front right-hand
balancer shaft bushing is lubricated directly from the
From here oil is forwarded under pressure to the oil pump.
main bearings (10) and spray jets (11) to cool the
pistons. Drilled cross passages in the crankshaft
distribute oil from the main bearings to connecting rod
bearings (12).
CD,3274,G205,10-19-12NOV92
205
5

060799
PN=318
LUBRICATION SYSTEM - CONTINUED
An externally adjustable pressure regulating valve is

located at the front of the cylinder block in the oil gallery.
It controls the oil pressure and provides constant
pressure in the main gallery and in the complete
lubrication system.
The valve consists of a valve cone held against a seat

by means of a spring and plug. Pressure may be
adjusted by changing the number of shims behind the
valve plug. If oil pressure exceeds spring pressure, the
valve cone is raised from the seat, permitting oil to
bypass to the crankcase and maintain constant pressure.
An oil by-pass valve is located in the cylinder block

behind the front plate and near the oil pressure
regulating valve. Should the difference between the
pressures in the main oil gallery and oil pump become
excessive, this valve would open and let oil by-pass the
filter and oil cooler to reach the main gallery faster. This
valve has a permanent setting which cannot be changed.
The oil filter is mounted on the right-hand side of the

engine. It is a full-flow type with a spin-on type
replaceable element. If the filter clogs, a by-pass valve in
the element opens to keep a full flow of oil to vital
engine parts.
NOTE: Some high output engines are equipped with high

flow oil coolers.
-UN-08MAR95
1Oil pressure warning switch
2Oil cooler by-pass valve
3Oil cooler
4Oil filter by-pass valve
5By-pass valve
CD30090
6Oil pump
7Oil pressure regulating valve
8Main oil gallery
9Lubricating oil
10Pressure-free oil
11Coolant from cooling system
205
6
CD,3274,G205,3 -19-03NOV92

060799
PN=319
Engine System - Operation/Cooling system
COOLING SYSTEM (4-CYLINDER ENGINE)
-UN-08MAR95
CD30331
1Thermostats 3Oil cooler 5Return flow to water 6Water pump
2Radiator 4Coolant flow to oil cooler pump
The principal components of the pressure cooling Here it circulates through the block and around the
system are the radiator, water pump, multi-blade fan cylinder liners. From the cylinder block, coolant is
and thermostats. then directed through the cylinder head and into
thermostat housing. With the thermostats open,
During the warm-up period, thermostats (1) remain coolant passes through the housing and upper
closed and coolant is directed through a by-pass to radiator hose into top of radiator (2) where it is
suction side of water pump (6). The coolant then circulated to dissipate heat.
circulates through the cylinder block and water pump
only to provide a uniform and fast warm-up period. On some engines the water pump has two further
hose connectors (4) and (5) which lead to the engine 205
Once the engine has reached operating temperature, oil cooler (3). 7
the thermostats open and coolant is pumped from
bottom of radiator via bottom hose into the cylinder
block.
CD,3274,G205,4 -19-03NOV92

060799
PN=320
Engine System - Operation/How the 37 kW auxiliary drive works
HOW THE 37 KW AUXILIARY DRIVE WORKS
A drive gear (A) on the engine crankshaft transmits

power through an idler gear (B) to the auxiliary (output)
drive gear (C) for driving engine accessories. The output
-UN-30NOV88
shaft at the front (D) is equipped with an SAE
5/8-9 tooth A-spline and 2-bolt mounting. The output
shaft at the rear (E) is equipped with an SAE
7/8-13 tooth B spline which can have either a 2-bolt or
a 4-bolt mounting.
RG5173
ADrive gear
BIdler gear
CAuxiliary (Output) drive gear
DOutput shaft (at front)
EOutput shaft (at rear)
-UN-30NOV88
RG5174
CD,3274,G205,6 -19-15MAY92
Auxiliary crankshaft gear (A) is located in front of the

regular crankshaft gear (B) and mounts on a tapered
collet (C) which provides the press fit necessary for
transmitting power. The amount of press is determined
by the loading of pulley (D) or damper pulley against the
gear on the collet when cap screw (E) is tightened to the
specified torque. A thick washer (F) is used to help
prevent loss of cap screw torque. An O-ring (G) is used
to prevent external seepage of engine lube oil.
NOTE: Engines equipped with the auxiliary gear drive

option have a long-nose crankshaft.
AAuxiliary crankshaft gear

BRegular crankshaft gear
CTapered collet
DPulley
ECap screw
205 FWasher
8 GO-ring
-UN-30NOV88
RG5175
CD,3274,G205,7 -19-15MAY92

060799
PN=321
Both idler gear and output gear are supported by ball

bearings. Gears and bearings are splash-lubricated.
Splash oil collected on top of bearing bosses (A) is
directed down through a hole in each boss to lubricate
the bearings.
-UN-30NOV88
RG5176
CD,3274,G205,8 -19-15MAY92
Auxiliary gear cover (A) supports the outer bearing race

for both the idler and output gear assemblies. Two dowel
pins (B) are used to properly align the auxiliary gear
cover and timing gear cover.
-UN-30NOV88
RG5177
CD,3274,G205,9 -19-15MAY92
205
9

060799
PN=322
205
10

060799
PN=323
Group 210
Engine System - Diagnosis and Tests

Universal pressure test kit . . . . . . . . . . . . . . FKM10002 or JT05470
To measure engine oil pressure.
-UN-28JUL94
FKM10002
CD,FKM10002 -19-01FEB94
Compression test set . . . . . . . . . . . . . . . . . . . . . . . . . . FKM10021
To check engine cylinder compression
-UN-07MAR95
L30722A
CD,FKM10021 -19-15MAY92
210
1

060799
PN=324
Engine System - Diagnosis and Tests/Engine Break-in Instructions
SPECIFICATIONS
Engine compression pressure:

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 kPa (21 bar; 300 psi)
Maximum difference between cylinders . . . . . . . . 350 kPa (3.5 bar; 50 psi)
Minimum engine oil pressure:

at 800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kPa (1 bar; 14 psi)
at rated speed (1500 or 1800 rpm) . . . . . . . . . . . 275 kPa (2.75 bar; 40 psi)
at rated speed (more than 1800 rpm) . . . . . . . . . 350 kPa (3.5 bar; 50 psi)
Engine blow-by at crankcase vent tube,

maximum at full load rated speed:
all engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 liter/kWh (2.8 cu.ft./kWh)
Engine oil consumption (all engines):

Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 0.5 % of fuel consumption rate
Overhaul point . . . . . . . . . . . . . . . . . . . . . . . . Above 0.625 % of fuel consumption rate
NOTE: Oil consumption should be measured over a 100

hour period.
CD,3274,G210,1 -19-04JAN99
ENGINE BREAK-IN INSTRUCTIONS
Use a dynamometer to perform the following break-in

procedure. Fill engine crankcase with oil specified in
Engine break-in oil.
Time Load Engine Speed Remarks
5 minutes No load 800 rpm Check oil pressure,

5 minutes No load 1500 to 2300 rpm coolant temperature
10 minutes 1/4 load 2000 rpm to rated speed and check for leakages
15 minutes 1/2 load 2000 rpm to rated speed
15 minutes 1/2 to 3/4 load 2000 rpm to rated speed
10 minutes 3/4 to full load Rated speed
After break-in, run the engine for 1 or 2 minutes at During the first 100 hours of operation, avoid
1500 rpm, no load, before shutting it off. Check and overloading, excessive idling and no-load operation.
reset the valve clearances. After 100 hours, drain the crankcase oil and change
the oil filter. Fill the crankcase with oil of the specified
NOTE: It is not necessary to retorque the cylinder viscosity.
210 head cap screws once the engine is broken
2 in.
CD,3274,G210,2 -19-01FEB94

060799
PN=325
Engine System - Diagnosis and Tests/Engine Break-in Instructions
ENGINE BREAK-IN OIL
New engines are filled at the factory with John Deere IMPORTANT: Do not use PLUS-50 oil or engine
ENGINE BREAK-IN OIL. During the break-in period, oils meeting API CG4, API CF4,
add John Deere ENGINE BREAK-IN OIL as needed ACEA E3, or ACEA E2 performance
to maintain the specified oil level. levels during the first 100 hours of
operation of a new or rebuilt engine.
Change the oil and filter after the first 100 hours of These oils will not allow the engine
operation of a new or rebuilt engine. to break-in properly.
After engine overhaul, fill the engine with John Deere

ENGINE BREAK-IN OIL.
If John Deere ENGINE BREAK-IN OIL is not

available, use a diesel engine oil meeting one of the
following during the first 100 hours of operation:
API Service Classification CE

After the break-in period, use John Deere PLUS-50

or other diesel engine oil as recommended in this
manual.
DX,ENOIL4 -19-10OCT97
210
3

060799
PN=326
Engine System - Diagnosis and Tests/Diagnosing Engine Malfunctions
DIAGNOSING ENGINE MALFUNCTIONS
Engine will not crank Engine misfiring
Empty batteries Water in fuel

Bad battery connections Mixture of petrol and diesel fuel
Defective main switch or start safety switch Air in fuel system
Starter solenoid defective Defective fuel injection nozzles
Starter defective Defective fuel injection pump
Fuel injection nozzles improperly installed
Leaking fuel injection nozzle seals
Engine hard to start or will not start Engine overheated
Lobes of camshaft worn
Loose or corroded battery connections Weak valve springs
Low battery output Worn or defective fuel transfer pump
Excessive resistance in starter circuit Pre-ignition
Too high viscosity crankcase oil Fuel injection pump incorrectly timed
Water, dirt or air in fuel system Engine compression too low
Fuel filter restricted Improper valve clearance
Stuck shut-off knob Burnt, damaged or stuck valves
Dirty or faulty fuel injection nozzles
Defective fuel injection pump
Defective fuel transfer pump
Fuel injection pump incorrectly timed
Engine runs irregularly or stalls frequently
Coolant temperature too low

Insufficient fuel supply
Fuel injection nozzles defective or leaking
Fuel filter or fuel lines restricted
Defective fuel transfer pump
Improper valve clearance
Cylinder head gasket leaking
Worn or broken compression rings
Valves stuck or burnt
Exhaust system restricted
Engine compression too low
Engine overheated
Defective fuel injection pump
210
4
CD,3274,G210,3 -19-15MAY92

060799
PN=327
DIAGNOSING ENGINE MALFUNCTIONS - CONTINUED
Lack of engine power High oil consumption
Air cleaner restricted or dirty Oil control rings worn or broken

Excessive resistance in air intake system Scored cylinder liners or pistons
Fuel filter restricted Excessive resistance in air intake system
Defective fuel transfer pump Oil flow through oil passages restricted
Defective fuel injection pump Worn valve guides or stems
Defective fuel injection nozzles Too low viscosity crankcase oil
Improper crankcase oil Excessive oil pressure
Engine overheated Piston ring grooves excessively worn
Engine clutch slipping Piston rings sticking in ring grooves
Defective cylinder head gasket Insufficient piston ring tension
Lobes of camshaft worn Piston ring gaps not staggered
Improper valve clearance Excessive main or connecting rod bearing clearance
Improper valve timing Crankcase oil level too high
Burnt, damaged or stuck valves External oil leaks
Weak valve springs Front and/or rear crankshaft oil seal faulty
Fuel injection pump incorrectly timed Glazed cylinder liners (insufficient load during engine
Piston rings and cylinder liners excessively worn break-in)
Engine compression too low
Improper coolant temperature
Engine overheats
Lack of coolant in cooling system

Radiator core and/or side screens dirty
Loose or defective fan belt
Defective thermostat(s)
Cooling system limed up
Engine overloaded
Fuel injection pump delivers too much fuel
Damaged cylinder head gasket
Defective water pump
Too low crankcase oil level
Defective radiator cap
CD,3274,G210,4 -19-15MAY92
210
5

060799
PN=328
Low oil pressure White exhaust smoke
Low crankcase oil level Engine compression too low

Leakage at internal oil passages Defective fuel injection nozzles
Defective oil pump Fuel injection pump incorrectly timed
Excessive main and connecting rod bearing clearance Defective thermostat(s) (does not close)
Improper regulating valve adjustment
Improper crankcase oil
Defective oil pressure warning switch or engine oil Coolant in crankcase
pressure indicator light
Cylinder head gasket defective
Cylinder head or block cracked
High oil pressure Cylinder liner seals leaking
Oil pressure regulating valve bushing loose (wanders)

Stuck or improperly adjusted regulating valve Abnormal engine noise
Stuck or damaged filter by-pass valve
Worn main or connecting rod bearings
Excessive fuel consumption Excessive crankshaft end play
Loose main bearing caps
Engine overloaded Foreign material in combustion chamber
Compression too low Worn connecting rod bushings and piston pins
Leaks in fuel system Scored pistons
Air cleaner restricted or dirty Worn timing gears
Fuel injection nozzles dirty or faulty Excessive valve clearance
Fuel injection pump defective (delivers too much fuel) Worn cam followers
Fuel injection pump incorrectly timed Bent push rods
Worn camshaft
Worn rocker arm shaft
Black or grey exhaust smoke Insufficient engine lubrication
Worn turbocharger bearings
Excess fuel
Engine overloaded
Air cleaner restricted or dirty
Defective muffler (causing back-pressure)
Fuel injection nozzles dirty or faulty
Incorrect engine timing
CD,3274,G210,5 -19-15MAY92
210
6

060799
PN=329
Detonation or pre-ignition Water pump leaking
Oil picked up by intake air stream (intake manifold) Seal ring or pump shaft worn
Dirty or faulty fuel injection nozzles
Incorrect fuel injection pump timing
Fuel injection nozzle tip holes enlarged Coolant temperature below normal
Fuel injection nozzle tips broken
Carbon build-up in compression chamber Defective thermostat(s)
Coolant temperature gauge defective
Engine vibrating
Fan blades bent

Pump shaft worn
CD,3274,G210,6 -19-15MAY92
210
7

060799
PN=330
Engine System - Diagnosis and Tests/Checking Engine Compression
CHECKING ENGINE COMPRESSION
NOTE: Before beginning check, ensure that battery is

fully charged and injection nozzle area is
thoroughly cleaned.
-UN-10FEB89
Start engine and run at slow idle for 10 to 15 minutes.
Remove fuel injection nozzles (see Group 40).
CD7215
Install 19.58-90.578* adapter (A) in injection nozzle bore
with R73788* nozzle spacer (B) and 2 R92352* nozzle
seals (C). Attach test gauge FKM10022* to adapter.
Push throttle lever to STOP position. Turn crankshaft

for a few seconds with starting motor.
Compression pressure must be 2100 kPa (21 bar;
-UN-10MAY95
300 psi) minimum. The difference between the highest
and lowest cylinder must be less than 350 kPa (3.5 bar;
50 psi). This test must be performed at a minimum
cranking speed of 150 rpm.
CD30432
A19.58-90.578 adapter*
BR73788 nozzle spacer*
CR92352 nozzle seal*
DHolding plate*
* Part of FKM10021 compression test kit CD,3274,G210,7 -19-01FEB94
210
8

060799
PN=331
Engine System - Diagnosis and Tests/Measuring Engine Blow-by
CHECKING ENGINE OIL PRESSURE
1. Before checking oil pressure, warm up engine to allow

the lubricating oil to reach operating temperature.
-UN-21AUG92
2. Attach pressure gauge.
NOTE: Use gauge from FKM10002 or JT05470 Universal

pressure test kit if available. Otherwise, use
gauge with a reading range of 0600 kPa
RG6415
(06 bar ; 087 psi) minimum.
3. At 93C (200F) operating temperature, gauge should

show a minimum pressure of:
at 800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kPa

(1 bar; 14 psi)
at rated speed (1500 or 1800 rpm) . . . . . . . . . . . . . . . . . 275 kPa
(2.75 bar; 40 psi)
at rated speed (more than 1800 rpm) . . . . . . . . . . . . . . . 350 kPa
(3.5 bar; 50 psi)
CD,3274,G210,8 -19-04JAN99
MEASURING ENGINE BLOW-BY
Place a hose with a standard gas gauge over end of

crankcase vent tube.
Run engine at rated speed (engine at operating

temperature and run-in, with at least 100 operating
hours).
Measure blow-by over a period of 5 minutes. Multiply

figure obtained by 12 (hourly rate) and check against
specified figure shown in Specifications.
If blow-by is lower, there is no undue wear between

piston rings and liners. For a further check, carry out
compression test. If blow-by is higher, there is excessive
wear between piston rings and liners, resulting in loss of
engine power. Overhaul the engine.
210
9
CD,3274,G210,9 -19-15MAY92

060799
PN=332
Engine System - Diagnosis and Tests/Using STANADYNE TIME-TRAC as Tachometer
USING STANADYNE TIME-TRAC AS

TACHOMETER
The STANADYNE TIME-TRAC meter can be used as a

tachometer by using clamp-on transducer FKM10429-5
-UN-07MAR95
(A) on any high-pressure line.
Operating instructions
1. Remove paint and thoroughly clean the area of the
CD30206
high-pressure line to which the clamp-on transducer is to
be attached.
2. Install transducer (A) and connect cable

FKM10429-3 (B) between transducer and socket
meter (C). Also connect ground wire.
3. Switch on the meter by pressing the ON/CLEAR key
-UN-07MAR95
and start the engine.
AClamp-on transducer FKM10429-5

BCable FKM10429-3
CTiming meter FKM10429-1
CD30207
CD,3274,G210,10-19-15MAY92
210
10

060799
PN=333
INSPECT THERMOSTAT AND TEST

OPENING TEMPERATURE
Visually inspect thermostat for corrosion or damage.

Replace as necessary.
Test thermostat as follows:
N CAUTION: DO NOT allow thermostat or

thermometer to rest against the side or bottom
of container when heating water. Either may
rupture if overheated.
1. Remove thermostat.
-UN-23NOV97
2. Suspend thermostat and a thermometer in a container
of water.
3. Stir the water as it heats. Observe opening action of
RG5971
thermometer and compare temperatures with
specification given in chart below.
NOTE: Due to varying tolerances of different suppliers,

initial opening and full open temperatures may
vary slightly from specified temperatures.
THERMOSTAT TEST SPECIFICATIONS
Rating Initial Opening Full Open

(Range) (Nominal)
71C (160F) 6972C (156162F) 84C (182F)

77C (170F) 7478C (166172F) 89C (192F)
82C (180F) 8084C (175182F) 94C (202F)
89C (192F) 8690C (187194F) 101C (214F)
90C (195F) 8993C (192199F) 103C (218F)
92C (197F) 8993C (193200F) 105C (221F)
96C (205F) 9497C (201207F) 100C (213F)
99C (210F) 96100C (205212F) 111C (232F)
4. Remove thermostat and observe its closing action as

it cools. In ambient air the thermostat should close
completely. Closing action should be smooth and slow.
5. If any thermostat is defective on a multiple thermostat

engine, replace all thermostats.
210
11
CD,CTM125,229 -19-01DEC97

060799
PN=334
210
12

060799
PN=335
Group 215
Air Intake System - Operation and Tests

Universal pressure test kit . . . . . . . . . . . . . . FKM10002 or JT05470
To test engine intake manifold pressure.
-UN-28JUL94
FKM10002
CD,FKM10002A -19-01FEB94
SPECIFICATIONS
Turbocharger minimum boost pressure

at engine rated speed and rated power . . . . . . . . . . 60 kPa (0.6 bar ; 9 psi)
CD,3274,G215,1 -19-15MAY92
TURBOCHARGER OPERATION
The turbine wheel (3) is driven by the hot engine

exhaust gases. These gases flowing through the turbine
housing (2) act on the turbine wheel causing shaft (1) to
turn.
Compressor wheel (5) sucks in filtered air and

-UN-23MAY95
discharges the compressed air into the intake manifold

where it is then delivered to engine cylinders.
Engine oil under pressure from the engine lubrication

system is forced through passages in center housing (4)
L30869
to the bearings.
1Shaft 4Center housing

2Turbine housing 5Compressor wheel
3Turbine wheel 6Compressor housing
215
1
CD,3274,G215,2 -19-16MAY92

060799
PN=336
Air Intake System - Operation and Tests/Turbocharger Boost Pressure Check
TURBOCHARGER BOOST PRESSURE

CHECK
Attach pressure gauge.
-UN-22MAY95
Before checking boost pressure, warm up engine to
allow the lubricating oil to reach operating temperature.
Observe pressure reading on gauge. Reading should be

at least 60 kPa (0.6 bar ; 9 psi) when engine is
CD7217
developing rated horse power at full load speed. If the
reading is low, check the following:
Restriction in the air cleaner

Leak in air intake system between turbocharger and
cylinder head
Defective turbocharger
CD,3274,G215,3 -19-15MAY92
215
2

060799
PN=337
Air Intake System - Operation and Tests/Turbocharger Malfunctions Diagnosing
DIAGNOSING TURBOCHARGER MALFUNCTIONS
Lack of engine power Noise or vibration
Clogged manifold system (Do not confuse the whine heard during rundown with
Foreign material lodged in compressor, impeller or noise which indicates a bearing failure).
turbine
Excessive dirt build-up in compressor Bearings not lubricated (insufficient oil pressure)
Leak in engine intake or exhaust manifold Air leak in engine intake or exhaust manifold
Rotating assembly bearing failure Improper clearance between turbine wheel and
turbine housing
Broken blades (or other wheel failures)
Engine emits black or grey smoke
Excessive build-up in compressor or turbine Drag in turbine wheel

Turbine housing cracked or attaching screws loose
Exhaust manifold gaskets blowing Carbon build-up behind turbine wheel caused by
coked oil or combustion deposits
Dirt build-up behind compressor wheel caused by air
Oil on compressor wheel or in compressor intake leaks
housing (Oil being forced through center housing) Bearing seizure or dirty or worn bearings caused by
excessive temperatures, unbalanced wheel, dirty oil,
Excessive crankcase pressure oil starvation, or insufficient lubrication.
Air intake restriction
Oil dripping from housing in intake or exhaust

manifold
Damaged or worn journal bearings

Rotating assembly unbalanced
Damage to turbine or compressor wheel or blade
Dirt or carbon build-up on wheel or wheels
Bearing wear
Oil starvation or insufficient lubrication
Shaft seals worn
Excessive crankcase pressure
CD,3274,G215,4 -19-15MAY92
215
3

060799
PN=338
Air Intake System - Operation and Tests/Air-to-air Aftercooler Operation
AIR-TO-AIR AFTERCOOLER OPERATION
-UN-08MAR95
CD30332
AHeat exchanger BIntake manifold CHot air flow DCooled air flow
Intake air, which has been compressed (and heated) This increased volume of air, when combined with a
by the turbocharger is routed, before entering the predetermined quantity of additional fuel, enables
intake manifold (B), toward a heat exchanger (A) more power to be produced.
(usually mounted in front of radiator) to lower the air
temperature. The heat exchanger uses no liquid coolant but relies
on air flow to cool the charge air.
Lowering the air temperature makes the air more
dense and permits an even greater volume of air to
be delivered to engine cylinders for combustion.
CD,3274,G215,5 -19-15MAY92
215
4

060799
PN=339
Group 220
Fuel System - Operation and Tests
FUEL FILTER OPERATION
Fuel enters the filter at (3) and flows through a first

stage filter medium (5) and a second stage filter 220
medium (6) before flowing through outlet (1) to the fuel 1
injection pump. The filter media are housed in a metal
sediment bowl and are glued to the bowl as one
assembly.
-UN-23MAY95
Since water and other contaminants may settle at the
bottom of the sediment bowl, a drain plug (4) is provided
to permit their removal.
L57057A
An air vent (2) enables air in the system to be expelled
to the outside through the filters when the bleed plug is
removed. Rectangular filter
NOTE: On recent engines the round fuel filter may have

an one-stage element.
1Fuel outlet
2Air vent plug
3Fuel inlet
4Drain plug
5First stage filter
6Second stage filter
-UN-08MAR95
CD30335
Round filter
CD,3274,G220,4 -19-04JAN99

060799
PN=340
Fuel System - Operation and Tests/Distributor Injection Pump
SPECIFICATIONS
220
2 Engine speeds . . . . . . . . . . . . . . . . . . . . . . . . . . See specifications in Group 40
Fuel transfer pump pressure at engine slow idle . . . . 2030 kPa (0.200.30 bar; 2.94.35 psi)
CD,3274,G220,1 -19-01FEB94

060799
PN=341
FUEL SYSTEM OPERATION - DISTRIBUTOR INJECTION PUMP
220
3
-UN-08MAR95
CD30333
1Fuel transfer pump 4Fuel injection nozzle 7Fuel injection pump 8Return fuel pressure
2Fuel filter 5Gravity pressure pressure
3Fuel injection pump 6Fuel transfer pump
pressure
The fuel transfer pump (1) draws fuel from the tank Incorporated into the fuel system is a means of
and pressurizes it. This pressure permits the fuel to returning excess (or unused) fuel back to the fuel
flow through the filter (2) and charge the transfer tank. Excess fuel comes from two sources:
pump of the injection pump (3).
1. Fuel injection pump: A quantity of fuel greater than
With the fuel injection pump charged with fuel by the that required by the engine is supplied to the fuel
fuel transfer pump, the injection pump plungers injection pump.
pressurize the fuel to approximately 50000 kPa
(500 bar; 7255 psi). Delivery (pressure) lines are 2. Fuel injection nozzles: A small amount of fuel
used to route this high pressure fuel to the fuel seeps past the nozzle valve for lubrication purposes.
injection nozzles (4).
To get the excess fuel back to the tank, a return line
Fuel enters the injection nozzle at a pressure which from the injection pump is connected to the middle of
easily overcomes the pressure required to open the the nozzle leak-off line. Fuel from both sources is
nozzle valve. When the nozzle valve opens, fuel is then returned to the tank by a return pipe connected
forced out through the orifices in the nozzle tip and to the front end of the leak-off pipe.
atomizes as it enters the combustion chamber.
CD,3274,G220,2 -19-04JAN99

060799
PN=342
FUEL TRANSFER PUMP OPERATION

(DISTRIBUTOR INJECTION PUMP)
Fuel flows from the fuel tank at gravity pressure to the

220
4 inlet side of the diaphragm-type pump. This pump
-UN-17FEB95
increases the fuel pressure to 20 to 30 kPa (0.20 to
0.3 bar ; 2.9 to 4.35 psi) at slow idle speed and forces
fuel through the filter to the fuel injection pump.
The fuel transfer pump is operated by an eccentric lobe
CD30334
on the engine camshaft.
CD,3274,G220,3 -19-04JAN99

060799
PN=343
220
5

060799
PN=344
LUCAS CAV FUEL INJECTION PUMP - SECTIONAL VIEW
220
6
-UN-18JAN95
CD30130
1Pump housing 14Pump head 23Bleed spring 33Cam ring
2Drive shaft 15Pump and distributor 24End plate 34Plunger
3Seal ring rotor 25Cap screw 35Front adjusting plate
4Leak-off adapter 16Eccentric sleeve of 26Rotor blades of transfer 36Drive plate
5Governor housing transfer pump pump 37Cam roller
6Shut-off lever 17Fuel inlet 27Discharge port 38Pump shaft
7Governor spring 18Seal 28Inlet passage (one bore 39Internal chamber of
8Speed control lever 19Rotor of transfer pump for each cylinder) pump housing
9Fast idle adjusting screw 20Filter 29Pressurizing valve (one 40Governor cage
10Rear adjusting plate 21Pressure regulating for each cylinder) 41Flyweights
11Metering valve valve sleeve 30Hollow screw 42Slow idle adjusting
12Metering valve chamber 22Pressure regulating 31Race screw
13Inlet passage valve piston 32Automatic advance
CD,3274,G220,5 -19-04NOV92

060799
PN=345
LUCAS CAV FUEL INJECTION PUMP - OPERATION
General information A pressurizing valve is located at each outlet in the

The Lucas CAV fuel injection pump is a horizontally pump head (as on in-line type fuel injection pumps) 220
installed distributor pump with mechanical governor where the pressure line leading to the fuel injection 7
and automatic hydraulic speed advance. The moving nozzle is connected. After injection the pressure
parts of the pump are simultaneously lubricated and regulating valve closes again and with its small relief
cooled by the diesel fuel flowing through the pump. piston sucks a quantity of fuel from the pressure line.
No lubricant is required. Four pump models are used: The resulting relief in pressure in the pressure line
DPA2 - 2 plungers causes a quick and firm shutting of the nozzle valve,
DPA4 - 4 plungers thus preventing fuel from leaking into the combustion
These pumps are progressively replaced by the chamber.
following pumps which are designed to meet future
emission requirements: The quantity of fuel which is needed at any given
DP200 - 2 plungers moment for each cylinder and combustion cycle is
DP201 - 4 plungers regulated by a metering valve which is controlled via
speed control rod and control lever (8), by the
Transfer pump and metering governor inside housing (5).
The diesel fuel for injection is fed to the cylinders -
regardless of their number - by a single unit. Its In the engine shut-off position, the metering valve
pump and distributor rotor is fitted with two opposed completely cuts off the supply of fuel from transfer
plungers controlled by a cam ring. On the other end pump to the rotor.
of the rotor, opposite the two pump plungers, there is
a transfer pump which delivers the fuel, drawn from At idling speed or under load, the transfer pump
the fuel filter, through the metering valve into the inlet feeds more fuel to the metering valve than is needed
passage (13) in the pump head, at a pressure which for injection. The excessive fuel flows through the
varies with engine speed. pressure regulating valve back to the suction side of
the transfer pump. A very small amount of this
Filling process: surplus fuel escapes through the top of the governor
As rotor (15) rotates, inlet passage (13) in pump housing.
head aligns with inlet passage (28) in the rotor. Fuel
coming from the transfer pump reaches the pump Automatic advance (speed responsive)
plunger chamber through inlet passage (28),
regulated by the metering valve and forces the two To obtain the best possible performance over the
plungers (34) apart. entire speed range, the fuel injection pump is fitted
with an automatic advance system, hydraulically
Pumping and delivery process: actuacted (32). It is pre-set at the factory.
During further rotation of rotor (15), inlet
passage (13) in the pump head is closed and The speed advance adjusts timing of the fuel injection
discharge port (27) in the rotor eventually aligns with pump in relation to engine speed and load.
one of the outlet bores in the pump head. Meanwhile
the pump plungers (34) have reached the cam so IMPORTANT: Remember that all adjustments to
that they move towards each other. The trapped, the injection pump - except for slow
metered fuel is forced, under high pressure, through idle - must be carried out on a test
discharge port (27) in the rotor and outlet opening in bench by a specialist injection pump
the pump head, through pressurizing valve and repair station only. Internal
connected pressure line, to the fuel injection nozzle adjustments in the field are not
and into the appropriate cylinder. permitted, as this pump is a sealed
unit.
CD,3274,G220,6 -19-01FEB94

060799
PN=346
TEST SHUT-OFF SOLENOID ON LUCAS-CAV

INJECTION PUMP
1. With the pump installed on engine, check for an

220
8 audible click when the ignition is switched on.
2. If a click cannot be heard, check for operating

voltage from the terminal.
3. If no voltage, check corresponding electrical circuit

(fuse, switch, wire...).
4. If voltage is correct, remove the solenoid carefully,

ensuring that the plunger (4) and spring (3) do not fall
out. Cover the exposed threaded bore in the pump to
-UN-22FEB99
prevent dirt ingress.
5. Check that the plunger moves freely in the solenoid

body.
CD30739
6. Check the condition of the spring and the rubber valve
seat.
7. Connect the assembled solenoid to ground and apply

the appropriate voltage (12 V or 24 V) in order to check 1Solenoid body
if the solenoid operates correctly. Replace solenoid if test 2O-ring seal
is not satisfactory. 3Spring
4Plunger
8. Refit the solenoid assembly in the hydraulic head and

9. Reconnect the electrical supply and check for

satisfactory operation.
CD,3274,G220,17-19-04JAN99

060799
PN=347
220
9

060799
PN=348
STANADYNE FUEL INJECTION PUMP (TYPE DM4) - SECTIONAL VIEW
220
10
-UN-08MAR95
CD7332
1Transfer pump inlet 6Passage 10Metering valve 14Governor arm
2Screen 7Charging circuit 11Pumping plungers 15Governor spring and link
3Pump 8Advance circuit 12Charging ring 16Governor spring lever
4Regulator assembly 9Inlet passages 13Drive shaft 17Throttle lever
5Rotor retainer
CD,3274,G220,7 -19-15MAY92

060799
PN=349
STANADYNE FUEL INJECTION PUMP (DM4) - OPERATION
Fuel is delivered to the transfer pump inlet (1) where The speed advance adjusts timing of the fuel injection
it passes through inlet screen (2) and enters the pump in relation to engine speed and load. 220
vane-type pump (3). Since the transfer pump 11
displacement greatly exceeds the injection With the exception of the drive shaft bearing on DM4
requirements, a large percentage of fuel is by-passed models, lubrication of pump working parts is achieved
through the regulator assembly (4) to the suction by means of fuel by-passed from the transfer pump
side. This positive displacement pump causes fuel before it is returned to the fuel tank. The drive shaft
flow to increase with speed and, because of the bearing on DM4 models is lubricated by engine oil
regulating piston, pump pressure also increases with from the timing gear housing.
speed.
As fuel leaves the transfer pump, it is directed
Fuel under transfer pump pressure flows past rotor through a passageway leading to an annulus in the
retainers (5) into an annulus on the rotor. It then hydraulic head. Connected to this passageway is a
flows through a connecting passage (6) in the head vent passage located behind the metering valve bore.
to the advance (8) and charging circuit (7). The fuel This vent passage contains a vent wire to prevent
flows around the annulus through a connecting excessive return fuel flow and high pressure loss. A
passage to the metering valve (10). The radial short passage connects vent passage with governor
position of metering valve (controlled by the governor) linkage compartment. Should air enter the transfer
regulates flow of fuel into charging ring (12) which pump, it immediately passes to the vent passage. Air
incorporates the inlet passages. and a small quantity of fuel then flow from the
housing to the fuel tank by way of the return pipe.
As rotor revolves, the two inlet passages (9) register
with inlet passages in hydraulic head, allowing fuel to IMPORTANT: Remember that all adjustments to
flow into the pumping cylinders. With further rotation, the injection pump - except for slow
inlet passages move out of registry and discharge idle - must be carried out on a test
port of rotor registers with one of the head outlets. bench by a specialist injection pump
While discharge port is opened, rollers contact cam repair station only. Internal
lobes, forcing plungers together. Fuel trapped adjustments in the field are not
between plungers is then delivered to the fuel permitted, as this pump is a sealed
injection nozzle. unit.
To obtain the best possible performance over the

entire speed range, the fuel injection pump is fitted
with an automatic advance system, hydraulically
actuated. It is pre-set at the factory.
CD,3274,G220,8 -19-01FEB94

060799
PN=350
STANADYNE FUEL INJECTION PUMP (TYPE DB2/DB4) - SECTIONAL VIEW
220
12
-UN-08MAR95
CD30039
1Drive shaft 6Pressure regulator 11Governor 16Rollers
2Distributor rotor 7Discharge fitting 12Governor weights 17Transfer pump inlet
3Hydraulic head 8Metering valve 13Automatic advance 18Inlet passages
4Delivery valve 9Pumping plungers 14Drive shaft bushing 19Throttle lever
5Transfer pump 10Internal cam ring 15Housing
CD,3274,G220,9 -19-04NOV92

060799
PN=351
STANADYNE FUEL INJECTION PUMP (DB2/DB4) - OPERATION
The main rotating components are the drive shaft (1), This pump contains its own all-speed mechanical
distributor rotor (2), transfer pump (5) and governor (11). The centrifugal force of weights (12) in 220
governor (11). their retainer is transmitted through a sleeve to a 13
governor arm and through a positive linkage hook to
The drive shaft engages the distributor rotor in the the metering valve. The metering valve can be closed
hydraulic head (3). The drive end of the rotor to shut off fuel through a solid linkage by an
incorporates the transfer pump. independently operated shut-off lever.
The plungers (9) are actuated towards each other The automatic speed advance (13) either advances
simultaneously by an internal cam ring (10) via or retards hydraulically the beginning of fuel delivery
rollers (16) and shoes which are carried in slots at from the pump. This can respond either to speed
the drive end of rotor. The number of cam lobes alone or to a combination of speed and load
normally equals the number of engine cylinders. changes.
The transfer pump at the rear of the rotor is of a IMPORTANT: Remember that all adjustments to
positive displacement vane type and is enclosed in the injection pump - except for slow
the end caps. These end caps also house transfer idle - must be carried out on a test
pump inlet (17), fuel strainer and pressure bench by a specialist injection pump
regulator (6). Transfer pump pressure is automatically repair station only. Internal
compensated for changes in viscosity due to adjustments in the field are not
temperature and variations in fuel grade. permitted, as this pump is a sealed
unit.
The distributor rotor incorporates two inlet
passages (18) and a single axial bore with one
delivery valve (4) to serve all discharge fittings (7) to
the injection lines. The hydraulic head contains the
bore in which the rotor revolves, the metering
valve (8) bore, the charging ports and head discharge
fittings.
CD,3274,G220,10-19-01FEB94

060799
PN=352
220
14

060799
PN=353
Fuel System - Operation and Tests/In-line Injection Pump
SPECIFICATIONS (IN-LINE PUMP)
220
Engine speeds . . . . . . . . . . . . . . . . . . . . . . . . . . See specifications in Group 40 15
Fuel transfer pump pressure . . . . . . . . . . . . . . . . . 350 kPa (3.5 bar; 50 psi)
CD,3274,G220,18-19-04JAN99

060799
PN=354
FUEL SYSTEM OPERATION - IN-LINE INJECTION PUMP (6 CYL. SHOWN)
220
16
-UN-24FEB99
RG7789T
AFinal fuel filter DAneroid inlet line GFuel injection pump JSupply pump pressure
BPrimary fuel filter/Water (optional) HFuel shut-off solenoid fuel
separator (optional) EFuel return (leak-off) line (optional) KInjection pressure fuel
CInjection nozzles FFuel supply pump ISuction fuel from tank LReturn (leak-off) line
CD,3274,G220,19-19-04JAN99

060799
PN=355
FUEL SYSTEM OPERATIONIN-LINE INJECTION PUMP
The supply pump (F) draws fuel from the vented fuel The high pressure fuel (K) opens the nozzle valve
tank through the primary filter (B) when equipped. and forces fuel out the small orifices in the nozzle tip. 220
This atomizes the fuel as it enters the combustion 17
The supply pump pressurizes the fuel so that it flows chamber.
through the filter (A) to the injection pump galley.
Supply pump output pressure will vary depending on There are two sources of excess fuel incorporated
load and application. into the system. The supply pump supplies more fuel
to the pump than is required by the engine, and the
The galley is kept full by the supply pump. Injection nozzle requires excess fuel to lubricate the nozzle
pump plungers further pressurize the fuel. Injection valve. A leak-off line (L) returns this excess fuel to
pressure lines route the fuel to the nozzles (C). the tank from both the pump and nozzles.
CD,3274,G220,20-19-04JAN99
FUEL TRANSFER PUMP OPERATION

(IN-LINE INJECTION PUMP)
The plunger-type MICO fuel supply pump is mounted on

the side of the injection pump housing and is driven by
the injection pump camshaft. Fuel enters the supply
pump at (A), is pressurized by the plunger (B) to
350 kPa (3.5 bar; 50 psi), and discharged through outlet
-UN-23FEB99
(C). The hand primer (D) provides manual pump
operation for bleeding the fuel system.
AFuel inlet
BPlunger
CD30740
CFuel outlet
DHand primer
CD,3274,G220,21-19-04JAN99

060799
PN=356
FUEL TRANSFER PUMP OPERATION (IN-LINE INJECTION PUMP) - CONTD
220
18
-UN-06AUG91
RG5787
ACamshaft EPlunger Spring ISuction Valve MIntermediate Stroke
BRoller Tappet FSuction Chamber JFuel Inlet Position
CPressure Spindle GPressure Valve KHand Primer Pump NSuction and Discharge
DPlunger HPressure Chamber LFuel Outlet Stroke Position
As the pump camshaft (A) rotates toward the high Movement of the plunger pushes the fuel from the
cam intermediate stroke position (M), the roller pressure chamber and delivers it to the fuel filters
tappet (B) and pressure spindle (C) cause the and injection pump. At the same time, plunger suction
plunger (D) to compress the plunger spring (E). pressure is permitting fuel to enter the suction
chamber through the suction valve (I). With the
Plunger movement forces the fuel out of the suction suction chamber charged with fuel, the pumping cycle
chamber (F), through the pressure valve (G) and into begins again.
the pressure chamber (H). The amount of fuel
discharged from the suction chamber is equal to the Fuel is allowed to flow in around the pressure spindle
amount of fuel delivered for each stroke of the to lubricate the spindle as it moves back and forth in
plunger. Towards the end of the intermediate stroke, housing. To prevent the fuel from entering the pump
the spring-loaded pressure valve closes again. camshaft case, a rubber seal is positioned in the
spindle bore of housing at the roller tappet end.
As the camshaft rotates toward the low cam or
suction and discharge position (N), plunger spring Unscrewing the knurled knob on the hand primer
pressure causes the plunger, pressure spindle and pump (K) and pulling upward causes the suction
roller tappet to follow the camshaft. valve to open and fuel to flow into the suction
chamber. When the hand plunger is pushed
downward, the suction valve closes and fuel is forced
out of the pressure valve.
CD,3274,G220,22-19-04JAN99

060799
PN=357
DIAGNOSE FUEL SUPPLY PUMP MALFUNCTIONSIN-LINE INJECTION PUMP
IMPORTANT: Visually inspect the fuel inlet fitting

and pump filter for possible 220
plugging before disassembling to 19
determine cause of malfunction.
Symptom Problem Solution
Low Supply Pump Output Restriction at fuel inlet fitting. Thoroughly clean fuel tank, lines,
Pressure or Pump Not filters, and inlet fitting.
Functioning Correctly
Hand primer not screwed down Advise customer to tighten hand
tight, allowing dirt to enter hand primer after use.
primer plunger chamber.
Worn or pitted valves caused by Replace valves or complete pump

foreign material lodging in valve. depending on service part
availability.
Missing or broken spring(s). Replace spring(s) or complete pump

depending on service part
availability.
Broken spindle. Replace pump.
Out of fuel. Add fuel to fuel tank.
Fuel shut off at tank. Open fuel shut off valve.
Restricted fuel line. Clean as required.
Air leak in fuel line between pump Repair as required.

and tank.
Loose or damaged fuel line Repair.

connetions.
Hand primer left in upward position. Bleed fuel system, gently push hand
primer down and tighten securely.
Worn or damaged valve Repair or replace.

assemblies.
Broken valve spring(s) Repair or replace.
Diesel Fuel Leaking Into Injection Worn spindle and/or pump housing. Replace pump.
Pump Camshaft Case
Defective seal. Replace seal.
CD,3274,G220,23-19-04JAN99

060799
PN=358
IN-LINE FUEL INJECTION PUMP

OPERATION
Filtered fuel under pressure by the supply pump fills the

220
20 injection pump fuel gallery (C). As the camshaft rotates,
roller tappets (G) riding on the camshaft (H) lobes
operate the plungers (D) to supply high pressure fuel
through the delivery valves (B) to the injection nozzles.
A governor-operated control rack (E) is connected to the

control sleeves (F) and plungers to regulate the quantity
of fuel delivered to the engine.
Engine lubricating oil is piped to the injection pump

camshaft case (J) to provide splash lubrication of the
working parts. Drain hole at the front end of the pump
determines the level of oil maintained in the camshaft
case. Excess oil drains out of this hole and returns back
to the engine through the timing gear cover.
AFuel delivery pipe

BDelivery valve
CFuel gallery
-UN-22FEB99
DBarrel and plunger
EControl rack
FControl sleeve
GRoller tappet
HCamshaft
CD30741
JCamshaft case
CD,3274,G220,24-19-04JAN99

060799
PN=359
GOVERNOR OPERATION (IN-LINE PUMP)
Governor maintains a set engine speed under varying

loads. 220
21
The injection pump governor is a mechanical centrifugal
flyweight type contained in a housing assembled to the
injection pump and serviced with the pump.
The flyweights (L) are mounted on the injection pump

camshaft. The flyweights move the thrust sleeve (k) in
and out with changes in engine rpm. The thrust sleeve
works against the tensioning lever (C). The tensioning
lever is connected to the injection pump control rack (Q)
by the link (P). The governor spring (E) connects the
tensioning lever assembly to the throttle lever (T).
AGovernor cover
-UN-22FEB99
BSlow idle speed screw
CTensioning lever
DGuide lever
EMain governor spring
FSlow idle spring screw
CD30742
GTorque control spring
HFull load adjusting screw
JFulcrum lever
KThrust sleeve
LFlyweight
MSwivel lever
NRocker
PLink
QControl rack
RGovernor housing
SStarting spring
TThrottle lever
CD,3274,G220,26-19-04JAN99

060799
PN=360
DIAGNOSE IN-LINE FUEL INJECTION PUMP

MALFUNCTIONS
220 Symptom Problem Solution

22
Engine Starts Hard or Wont Start Incorrect fuel shut-off lever position Adjust shut-off cable as required.
(pump control rack not moving all
the way forward)
Defective injection pump Remove pump from engine and

repair (see Group 40)
Injection pump not correctly timed Check pump timing
Slow Idle Speed Irregular Slow idle stop screw improperly Recheck stop screw adjustment
adjusted
Supplementary idling spring Recheck adjustment

improperly adjusted

repair (See Group 40)
Engine Horsepower Low Pump not properly timed Check timing

repair (See Group 40)
CD,3274,G220,25-19-04JAN99

060799
PN=361
Fuel System - Operation and Tests/Fuel Injection Nozzles
FUEL INJECTION NOZZLES -

GENERAL INFORMATION
Fuel injection nozzles are of the multi-orifice type. 220

23
The nozzle spray tip (1) forms an integral unit with
nozzle body (4) from which it cannot be separated. The
injection nozzle is secured in the cylinder head by three
superimposed spring clamps which press on a location
clamp and a cap screw. The contact pressure is limited
by a spacer ring. The nozzle is sealed in the cylinder
head at its lower end with a carbon stop seal (2). The
top end is sealed with seal washer (5). Clamp (19)
ensures correct position of the complete fuel injection
nozzle in the cylinder head. The leak-off line is
connected by T-piece (14), which is fitted on the nozzle
body and secured with grommet (18) and hex. nut (17).
The fuel injection nozzle works basically in the same
-UN-08MAR95
way as a normal spray type nozzle. Its opening pressure
is adjusted by the pressure adjusting screw (16). The
valve lift of nozzle valve (3) is adjusted by screw (12)
located in pressure adjusting screw (16).
CD30040
The carbon stop seal (2) prevents carbon from collecting
around nozzle in cylinder head. The fuel injection
nozzles have four orifices.
1Spray tip 12Lift adjusting screw

2Carbon stop seal 13Lock nut
3Nozzle valve 14T-piece
4Nozzle body 15Lock nut
5Seal washer 16Pressure adjusting
6Connection for screw
injection line 17Hex. nut
7Nozzle valve guide 18Grommet
8Union nut 19Location clamp
9Spring seat 20Nipple
10Adjustable pressure 21Filter screen
spring 22Fuel pressure line
11Spacer washer
CD,3274,G220,11-19-15MAY92

060799
PN=362
DIAGNOSING FUEL SYSTEM MALFUNCTIONS
Fuel not reaching fuel injection nozzles Poor engine idling

220
24 Fuel filter clogged Air in fuel system
Fuel line clogged or restricted Fuel injection nozzles dirty or faulty
Fuel transfer pump pressure too low Incorrect timing
Air in fuel system Automatic advance of fuel injection pump faulty or not
Fuel return line restricted operating
Loss of fuel through leakage Fuel lines clogged or restricted
Water in fuel
Engine hard to start or wont start Fuel injection pump return line restricted
Fuel injection nozzle leak-off line clogged
Water, dirt or air in fuel system
Fuel filter clogged Lack of engine power
Shut-off knob stuck
Fuel lines clogged or restricted Air cleaner restricted
Fuel injection nozzles dirty or faulty Incorrect timing
Fuel injection pump faulty Automatic advance of fuel injection pump faulty or not
Fuel transfer pump faulty operating
Incorrect timing Fuel filter clogged
Fuel injection pump metering valve stuck in closed Fuel injection nozzle leak-off line clogged
position (check speed-control linkage) Fuel injection nozzles faulty or nozzle valve sticking
Fuel injection pump return line restricted
Engine starts and stops Fuel injection pump housing is not full of fuel
Water in fuel
Water in fuel Speed control linkage incorrectly adjusted
Filter clogged
Air in fuel system Engine emits black or grey smoke
Fuel lines clogged or restricted
Fuel injection pump return line damaged Fuel injection nozzles faulty or nozzle valves sticking
Incorrect timing
Engine runs irregularly or stalls frequently Automatic advance of fuel injection pump faulty or not
operating
Filter clogged Air cleaner element clogged or dirty
Air in fuel system
Fuel injection nozzles faulty or dirty Engine emits blue or white smoke
Fuel lines clogged or restricted
Incorrect timing Cranking speed too low
Water in fuel Incorrect timing
Fuel injection pump return line restricted Automatic advance of injection pump faulty or not
Fuel injection nozzle leak-off line clogged operating
Injection nozzles faulty or nozzle valves sticking
Excessive wear in liners and/or stuck piston rings
Engine does not get hot
Excessive wear in valve guides
CD,3274,G220,12-19-15MAY92

060799
PN=363
TESTING FUEL INJECTION NOZZLES ON A

RUNNING ENGINE
Run engine at intermediate speed under no load. Slowly 220

loosen fuel pressure line at one of the injection nozzles 25
so that the fuel escapes at the line connection and is not
forced through the nozzle (nozzle not opening). If there
is a change in engine speed, this indicates that the
nozzle is in order. If there is no change in engine speed,
nozzle is faulty.
Repeat test consecutively at each of the remaining

nozzles.
When a faulty fuel injection nozzle is found, remove it

and check thoroughly as described in Group 40.
CD,3274,G220,16-19-15MAY92

060799
PN=364
Fuel System - Operation and Tests/Timing of Fuel Injection Pump
TIMING OF FUEL INJECTION PUMPS ON DIESEL ENGINES USING STROBOSCOPIC

LAMP
220
26
-UN-08MAR95
CD30192
AStationary pointer BTiming sensor CTiming meter DStroboscopic lamp
The ever-increasing tightening of the specifications Dynamic timing operation

relating to engine exhaust emissions (e.g. smoke
level) call for greater accuracy in the timing of the A timing sensor (B) mounted on the nozzle inlet
fuel injection pump. measures the pressure variation, and thus the start of
fuel injection.
In order to guarantee the specified engine
performance, however, it is necessary to measure the Coupled to a timing meter (C), the timing sensor
start of fuel injection. pulse signal actuates a stroboscopic lamp (D) which
indicates the position of the reference piston on the
Static timing pulley, when injection occurs.
The static timing of a stationary diesel engine is a The timing meter instantly displays engine speed (in
slow process which provides only an approximate rpm) and fuel injection timing (in degrees).
reading and usually requires a certain amount of
disassembly work. To obtain the proper timing value, stop engine and
rotate the fuel injection pump accordingly within the
Dynamic timing slots in its flange.
The alternative, dynamic timing of a running diesel

engine, involves measuring the angular difference
between the start of fuel injection and the top dead
center (TDC) position of the reference piston (usually
piston No.1).
This approach allows more precise timing and can be

carried out quickly and simply.
CD,3274,G220,15-19-04JAN99

060799
PN=365
Contents
Page Page
00
Group 00Safety . . . . . . . . . . . . . . . . . . . 00-1
Checking cylinder head flatness . . . . . . . . . 05-10
Group 01General information Cleaning valve seats . . . . . . . . . . . . . . . . 05-11
Engine identification . . . . . . . . . . . . . . . . . . 01-1 Cleaning valve guides . . . . . . . . . . . . . . . . 05-11 01
Engine plate information . . . . . . . . . . . . . . . 01-1 Measure valve guides . . . . . . . . . . . . . . . . 05-12
Repower engine plate . . . . . . . . . . . . . . . . . 01-2 Valve seats
OEM engine option code label . . . . . . . . . . . 01-3 Lapping valve seats . . . . . . . . . . . . . . . . 05-12 02
Engine references . . . . . . . . . . . . . . . . . . . 01-3 Check valve recess . . . . . . . . . . . . . . . . 05-13
Basic engine specifications (3029 - 4039 Remove valve seat inserts . . . . . . . . . . . 05-14
& 6059) . . . . . . . . . . . . . . . . . . . . . . . . . 01-4 Valve seat insert installation . . . . . . . . . . 05-15
Basic engine specifications (4045 & Valves 03
6068) . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5 Check valves . . . . . . . . . . . . . . . . . . . . 05-16
Fuel specifications . . . . . . . . . . . . . . . . . . . 01-6 Grind valves . . . . . . . . . . . . . . . . . . . . . 05-16
Oil specifications . . . . . . . . . . . . . . . . . . . . 01-7 Check valve spring tension . . . . . . . . . . . 05-16
Inspect valve rotators . . . . . . . . . . . . . . . 05-17
05
Coolant specifications . . . . . . . . . . . . . . . . . 01-8
Metric cap screw torque values . . . . . . . . . . 01-9 Installation . . . . . . . . . . . . . . . . . . . . . . 05-17
Inch cap screw torque values . . . . . . . . . . . 01-10 Install cylinder head . . . . . . . . . . . . . . . . . 05-18
Torque turn tightening method . . . . . . . . . . 05-19 10
Rocker arm shaft
Group 02Engine mounting
Checking rocker arm shaft . . . . . . . . . . . 05-20
Engine repair stand . . . . . . . . . . . . . . . . . . 02-1
Installation . . . . . . . . . . . . . . . . . . . . . . 05-21
Safety precautions . . . . . . . . . . . . . . . . . . . 02-2 15
Valve clearance . . . . . . . . . . . . . . . . . . . . 05-21
Engine lifting procedure . . . . . . . . . . . . . . . . 02-2
Valve adjustment sequence . . . . . . . . . . . . 05-22
Clean engine . . . . . . . . . . . . . . . . . . . . . . . 02-3
Install rocker arm cover . . . . . . . . . . . . . . . 05-23
Disconnect turbocharger oil line . . . . . . . . . . 02-3
Final work . . . . . . . . . . . . . . . . . . . . . . . . 05-23 20
Group 03Engine rebuild guide Group 10Cyl. Block, Liners, Pistons & Rods
Engine disassembly sequence . . . . . . . . . . . 03-1 Special tools . . . . . . . . . . . . . . . . . . . . . . . 10-1
Sealant application guidelines . . . . . . . . . . . . 03-3 Specifications . . . . . . . . . . . . . . . . . . . . . . 10-4 25
Engine assembly sequence . . . . . . . . . . . . . 03-4 Torques for hardware . . . . . . . . . . . . . . . . . 10-8
Exploded view . . . . . . . . . . . . . . . . . . . . . . 10-9
Group 05Cylinder head and Valves Pistons & connecting rods removal . . . . . . . 10-10
Special tools . . . . . . . . . . . . . . . . . . . . . . . 05-1
30
Cylinder liner
Specifications . . . . . . . . . . . . . . . . . . . . . . 05-4 Bore measure . . . . . . . . . . . . . . . . . . . 10-11
Torques for hardware . . . . . . . . . . . . . . . . . 05-6 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-11
Cylinder head exploded view . . . . . . . . . . . . 05-6 Deglazing . . . . . . . . . . . . . . . . . . . . . . 10-12 35
Check valve lift . . . . . . . . . . . . . . . . . . . . . 05-7 Cylinder block
Removing cylinder head . . . . . . . . . . . . . . . 05-8 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 10-12
Cleaning injection nozzle bores . . . . . . . . . . 05-8 Piston cooling jets checking . . . . . . . . . . 10-13
Valve actuating exploded view . . . . . . . . . . . 05-9 40
Remove valves & valve springs . . . . . . . . . 05-10 Continued on next page
All information, illustrations and specifications in this manual are based on 205
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
CTM3274-19-01JUL99
210
COPYRIGHT 1999
DEERE & COMPANY
European Office Mannheim
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
215
Copyright 1995, 1992 Deere & Company
CTM3274 (01JUL99) i Saran Liter Engines

060799
PN=366
Contents
Page Page
00
Cylinder blockContinued Pulley (with front PTO)
Cam follower bore measure . . . . . . . . . . 10-13 Vibration damper or pulley checking . . . . . . 15-9
01 Camshaft bore measure . . . . . . . . . . . . . 10-13 Removal . . . . . . . . . . . . . . . . . . . . . . . 15-10
Camshaft bushing replacement tool . . . . . 10-14 Installation . . . . . . . . . . . . . . . . . . . . . . 15-11
Camshaft bushing removal . . . . . . . . . . . 10-15 Damper/Pulley installation (engine with
aux. drive) . . . . . . . . . . . . . . . . . . . . . . 15-12
02 Camshaft bushing installation . . . . . . . . . 10-15
Flywheel
Crankshaft bore measure . . . . . . . . . . . . 10-16
Crankshaft bearing cap replacement . . . . . 10-16 Removal . . . . . . . . . . . . . . . . . . . . . . . 15-12
Ring gear replacement . . . . . . . . . . . . . . 15-13
Top desk flatness . . . . . . . . . . . . . . . . . 10-17
03 Balancer shaft bore measure . . . . . . . . . 10-17
Ball bearing installation . . . . . . . . . . . . . 15-13
Installation . . . . . . . . . . . . . . . . . . . . . . 15-14
Balancer shaft bushing replacement . . . . . 10-18
Crankshaft wear sleeve
Oversize balancer shaft bushings . . . . . . . 10-19
Removal . . . . . . . . . . . . . . . . . . . . . . . 15-14
05 Cylinder liner Flywheel housing replacement . . . . . . . . . . 15-16
Protrusion measure . . . . . . . . . . . . . . . . 10-20 Oil seal/wear sleeve installation . . . . . . . . . 15-17
Packing installation . . . . . . . . . . . . . . . . 10-20 Crankshaft
O-ring installation . . . . . . . . . . . . . . . . . 10-21 End play measure . . . . . . . . . . . . . . . . . 15-18
10 Installation . . . . . . . . . . . . . . . . . . . . . . 10-21 Removal . . . . . . . . . . . . . . . . . . . . . . . 15-18
Connecting rod Identification . . . . . . . . . . . . . . . . . . . . . 15-19
Bearing measure . . . . . . . . . . . . . . . . . 10-22 Inspection . . . . . . . . . . . . . . . . . . . . . . 15-19
15 Bearing clearance . . . . . . . . . . . . . . . . . 10-22 Journal OD check . . . . . . . . . . . . . . . . . 15-20
Bushing Internal diameter . . . . . . . . . . . . 10-23 Checking main bearing clearance . . . . . . 15-21
Bushing replacement . . . . . . . . . . . . . . . 10-24 Plastigage . . . . . . . . . . . . . . . . . . . . . . 15-21
Piston Regrinding . . . . . . . . . . . . . . . . . . . . . . 15-22
20 Pin measure . . . . . . . . . . . . . . . . . . . . 10-27 Regrinding guidelines . . . . . . . . . . . . . . . 15-23
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 10-27 Micro-finishing specifications . . . . . . . . . . 15-24
Pin bore measure . . . . . . . . . . . . . . . . . 10-28 Gear replacement . . . . . . . . . . . . . . . . . 15-24
25 Top ring groove . . . . . . . . . . . . . . . . . . 10-28 Main bearing insert installation . . . . . . . . . . 15-25
2nd & 3rd piston ring grooves . . . . . . . . . 10-29 2-piece thrust bearing installation . . . . . . . . 15-25
Piston head and skirt checking . . . . . . . . 10-29 5/6-piece thrust bearing installation . . . . . . . 15-25
Piston ring identification . . . . . . . . . . . . . 10-29 Crankshaft installation . . . . . . . . . . . . . . . . 15-26
30
Piston ring staggering . . . . . . . . . . . . . . 10-30
Piston and liner set . . . . . . . . . . . . . . . . . 10-31 Group 20Camshaft, Balancer Shafts and
Piston & connecting rod assembly . . . . . . . 10-31 Timing Gear Train
35 Piston & connect. rod installation . . . . . . . . 10-32 Special tools . . . . . . . . . . . . . . . . . . . . . . . 20-1
Torque-turn method . . . . . . . . . . . . . . . . . 10-33 Specifications . . . . . . . . . . . . . . . . . . . . . . 20-4
Piston protrusion measure . . . . . . . . . . . . . 10-34 Auxiliary drive specifications (37 kW) . . . . . . . 20-7
Final verifications . . . . . . . . . . . . . . . . . . . 10-34 Torques for hardware . . . . . . . . . . . . . . . . . 20-8
40 Timing gear backlash measure . . . . . . . . . . . 20-9
Complete final assembly . . . . . . . . . . . . . . 10-35
Camshaft
End play measure . . . . . . . . . . . . . . . . . . 20-9
Group 15Crankshaft, Main Bearings and Removal . . . . . . . . . . . . . . . . . . . . . . . 20-10
205 Flywheel Journal measure . . . . . . . . . . . . . . . . . . 20-10
Special tools . . . . . . . . . . . . . . . . . . . . . . . 15-1 Lobe height measure . . . . . . . . . . . . . . . 20-11
Self-Manufactured Tools . . . . . . . . . . . . . . . 15-3 Gear replacement . . . . . . . . . . . . . . . . . 20-11
210 Specifications . . . . . . . . . . . . . . . . . . . . . . 15-4 Tachometer pick-up pin removal . . . . . . . 20-11
Torques for hardware . . . . . . . . . . . . . . . . . 15-6 Fuel supply pump rear cam . . . . . . . . . . 20-12
Pulley (without front PTO) Installation . . . . . . . . . . . . . . . . . . . . . . 20-12
Vibration damper checking . . . . . . . . . . . . 15-7 Cam follower checking . . . . . . . . . . . . . . 20-13
215 Removal . . . . . . . . . . . . . . . . . . . . . . . . 15-7
Installation . . . . . . . . . . . . . . . . . . . . . . . 15-8 Continued on next page
CTM3274 (01JUL99) ii Saran Liter Engines

060799
PN=367
Contents
Page Page
Balancer Shafts Oil CoolerContinued 220

Standard oil cooler adapter
Identification . . . . . . . . . . . . . . . . . . . . . 20-13
replacement . . . . . . . . . . . . . . . . . . . 25-17
End play measure . . . . . . . . . . . . . . . . . 20-14
Standard oil cooler-oil filter bracket
Removal . . . . . . . . . . . . . . . . . . . . . . . 20-14 INDX
replacement. . . . . . . . . . . . . . . . . . . . . 25-18
Journal measure . . . . . . . . . . . . . . . . . . 20-15 High-flow oil cooler removal . . . . . . . . . . 25-22
Gear replacement . . . . . . . . . . . . . . . . . 20-16 Oil cooler distributor base removal . . . . . . 25-22
Installation . . . . . . . . . . . . . . . . . . . . . . 20-17 Distributor base repair . . . . . . . . . . . . . . 25-22
Idler Gears and front plate High-flow oil cooler-distributor base
End play measure . . . . . . . . . . . . . . . . . 20-17 installation . . . . . . . . . . . . . . . . . . . . 25-23
Front plate removal . . . . . . . . . . . . . . . . 20-18 Oil Pressure Regulating Valve
Bushing and shaft measure . . . . . . . . . . 20-19 Removal . . . . . . . . . . . . . . . . . . . . . . . 25-24
Valve seat replacement . . . . . . . . . . . . . 25-24
Bushing replacement . . . . . . . . . . . . . . . 20-20
Installation . . . . . . . . . . . . . . . . . . . . . . 25-24
Idler shaft removal . . . . . . . . . . . . . . . . 20-20
Dipstick Guide
Spring pin installation . . . . . . . . . . . . . . . 20-21 Replacement . . . . . . . . . . . . . . . . . . . . 25-25
Upper idler shaft installation . . . . . . . . . . 20-22 Oil By-Pass Valve
Lower idler shaft installation . . . . . . . . . . 20-23 Replacement . . . . . . . . . . . . . . . . . . . . 25-26
Front plate gasket . . . . . . . . . . . . . . . . . 20-24 Oil suction screen
Front plate installation . . . . . . . . . . . . . . 20-25 Replacement (on standard oil pump) . . . . 25-27
Gear Train Replacement (on high-flow oil pump) . . . . 25-27
Upper timing gear train installation . . . . . . 20-27 Oil Pump
Lower timing gear train installation . . . . . . 20-29 Identification . . . . . . . . . . . . . . . . . . . . . 25-27
Standard Oil Pump
Gear installation . . . . . . . . . . . . . . . . . . 20-30
Removal . . . . . . . . . . . . . . . . . . . . . . . 25-28
Oil deflector installation . . . . . . . . . . . . . 20-30 Gear axial clearance . . . . . . . . . . . . . . . 25-28
Timing Gear Cover Gear radial clearance . . . . . . . . . . . . . . 25-28
Identification . . . . . . . . . . . . . . . . . . . . . 20-31 Specifications . . . . . . . . . . . . . . . . . . . . 25-29
Composite material timing gear cover Installation . . . . . . . . . . . . . . . . . . . . . . 25-29
installation . . . . . . . . . . . . . . . . . . . . 20-32 High-Flow Oil Pump
Aluminum timing gear cover installation . . . . 20-33 Removal . . . . . . . . . . . . . . . . . . . . . . . 25-32
Installation (37 kW aux. drive) . . . . . . . . . 20-34 Gear axial clearance . . . . . . . . . . . . . . . 25-33
Oil seal installation . . . . . . . . . . . . . . . . 20-34 Gear radial clearance . . . . . . . . . . . . . . 25-33
Wear ring installation . . . . . . . . . . . . . . . 20-35 Specifications . . . . . . . . . . . . . . . . . . . . 25-34
Installation . . . . . . . . . . . . . . . . . . . . . . 25-35
Auxiliary drive (camshaft-gear-driven)
Oil Pan
Installation . . . . . . . . . . . . . . . . . . . . . . 20-35 Installation . . . . . . . . . . . . . . . . . . . . . . 25-37
Auxiliary drive (crankshaft-gear-driven)
Overview . . . . . . . . . . . . . . . . . . . . . . . 20-36 Group 30Cooling System
Gear removal . . . . . . . . . . . . . . . . . . . . 20-36 Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-1
Ball bearing & dowel installation . . . . . . . 20-37 Specifications . . . . . . . . . . . . . . . . . . . . . . 30-2
Gear and shaft installation . . . . . . . . . . . 20-37 Torques for hardware . . . . . . . . . . . . . . . . 30-10
Output shaft cover installation . . . . . . . . . 20-38 Water Pump (standard model)
Exploded view (standard model) . . . . . . . 30-11
Identification . . . . . . . . . . . . . . . . . . . . . 30-11
Group 25Lubrication System
Removal . . . . . . . . . . . . . . . . . . . . . . . 30-12
Special tools . . . . . . . . . . . . . . . . . . . . . . . 25-1
Disassembly (standard model) . . . . . . . . . 30-13
Specifications . . . . . . . . . . . . . . . . . . . . . . 25-2 Bearing shaft installation . . . . . . . . . . . . 30-14
Torques for hardware . . . . . . . . . . . . . . . . 25-14 Seal installation . . . . . . . . . . . . . . . . . . 30-14
Oil Cooler Impeller installation . . . . . . . . . . . . . . . . 30-15
Identification . . . . . . . . . . . . . . . . . . . . . 25-15
Standard oil cooler removal . . . . . . . . . . 25-16 Continued on next page
CTM3274 (01JUL99) iii Saran Liter Engines

060799
PN=368
Contents
Page Page
220 Water Pump (standard model)Continued Lucas CAV Fuel Injection Pump
Pulley or hub installation . . . . . . . . . . . . 30-15 Removal . . . . . . . . . . . . . . . . . . . . . . . 40-28
Installation . . . . . . . . . . . . . . . . . . . . . . 30-16 Repairs . . . . . . . . . . . . . . . . . . . . . . . . 40-29
Water pump with rotating assembly Installation . . . . . . . . . . . . . . . . . . . . . . 40-29
INDX Static timing . . . . . . . . . . . . . . . . . . . . . 40-30
Exploded view . . . . . . . . . . . . . . . . . . . 30-17
Stanadyne DB2 or DB4 Fuel Injection
Removal . . . . . . . . . . . . . . . . . . . . . . . 30-18
Pump
Disassembling . . . . . . . . . . . . . . . . . . . 30-18
Removal . . . . . . . . . . . . . . . . . . . . . . . 40-31
Reassembling . . . . . . . . . . . . . . . . . . . . 30-19
Repairs . . . . . . . . . . . . . . . . . . . . . . . . 40-32
Installation . . . . . . . . . . . . . . . . . . . . . . 30-20 Lever replacement . . . . . . . . . . . . . . . . . 40-32
Thermostats Installation . . . . . . . . . . . . . . . . . . . . . . 40-33
Test and replacement . . . . . . . . . . . . . . 30-21 Static timing . . . . . . . . . . . . . . . . . . . . . 40-34
Cooling sytem deaeration . . . . . . . . . . . . . 30-22 Engine front plate replacement . . . . . . . . 40-35
Fan/alternator Drive Belt Replacement . . . . . 30-23 Stanadyne DM4 Fuel Injection Pump
Fan Installation . . . . . . . . . . . . . . . . . . . . 30-24 Removal . . . . . . . . . . . . . . . . . . . . . . . 40-36
Fan installation on 2054/2254 combines . . . . 30-25 Repairs . . . . . . . . . . . . . . . . . . . . . . . . 40-36
Coolant heater Installation and timing . . . . . . . . . . . . . . 40-37
Coolant heater operation (4 and 6 cyl. MICO In-line Fuel Injection Pump
engines) . . . . . . . . . . . . . . . . . . . . . . 30-26 Remove fuel supply pump . . . . . . . . . . . 40-38
Replacement (4 and 6 cyl.) . . . . . . . . . . . 30-27 Disassemble fuel supply pump . . . . . . . . 40-39
Coolant heater operation (all engines) . . . 30-28 Assemble fuel supply pump . . . . . . . . . . 40-40
Install fuel supply pump . . . . . . . . . . . . . 40-40
Overflow valve . . . . . . . . . . . . . . . . . . . 40-41
Group 35Air Intake and Exhaust System
Remove . . . . . . . . . . . . . . . . . . . . . . . 40-42
Specifications . . . . . . . . . . . . . . . . . . . . . . 35-1
JDG670A Modification . . . . . . . . . . . . . . 40-43
Torques for hardware . . . . . . . . . . . . . . . . . 35-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . 40-44
Intake Manifold Inspection . . . . . . . . . . . . . . 35-7 Installation on engine . . . . . . . . . . . . . . . 40-44
Exhaust Manifold Inspection . . . . . . . . . . . . . 35-7 Dynamic Timing
Turbocharger Information . . . . . . . . . . . . . . . . . . . . . . 40-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . 35-8 Install timing sensor . . . . . . . . . . . . . . . . 40-47
Radial bearing end play check . . . . . . . . . 35-8 Install magnetic probe . . . . . . . . . . . . . . 40-48
Axial end play check . . . . . . . . . . . . . . . . 35-9 Install stationary pointer . . . . . . . . . . . . . 40-49
Turbocharger repair . . . . . . . . . . . . . . . . 35-10 Connection . . . . . . . . . . . . . . . . . . . . . 40-50
GARRETT Turbocharger Full load rated speed . . . . . . . . . . . . . . . 40-50
Turbocharger disassembly . . . . . . . . . . . 35-10 No-load . . . . . . . . . . . . . . . . . . . . . . . . 40-53
Turbocharger reassembly . . . . . . . . . . . . 35-11 Aneroid
SCHWITZER Turbocharger Replacement . . . . . . . . . . . . . . . . . . . . 40-57
Disassembly and reassembly . . . . . . . . . 35-12 Field adjustment . . . . . . . . . . . . . . . . . . 40-57
Turbocharger installation . . . . . . . . . . . . . . 35-14 Workshop adjustment . . . . . . . . . . . . . . 40-58
Turbocharger Break-In . . . . . . . . . . . . . . . 35-15 Fuel Injection Nozzles
Recommendations for turbocharger use . . . . 35-15 Removal . . . . . . . . . . . . . . . . . . . . . . . 40-59
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 40-60
Test . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60
Group 40Fuel System Spray pattern test . . . . . . . . . . . . . . . . . 40-61
Special tools . . . . . . . . . . . . . . . . . . . . . . . 40-1 Chatter test . . . . . . . . . . . . . . . . . . . . . 40-61
Self-Manufactured Tools . . . . . . . . . . . . . . . 40-4 Valve stem and guide wear checking . . . . 40-61
Specifications . . . . . . . . . . . . . . . . . . . . . . 40-5 Opening pressure test . . . . . . . . . . . . . . 40-61
Torques for hardware . . . . . . . . . . . . . . . . 40-23 Valve seat checking . . . . . . . . . . . . . . . 40-62
Fuel Filter Disassembly . . . . . . . . . . . . . . . . . . . . . 40-62
Element replacement . . . . . . . . . . . . . . . 40-24 Adjustment . . . . . . . . . . . . . . . . . . . . . . 40-62
Fuel pump
Replacement . . . . . . . . . . . . . . . . . . . . 40-27 Continued on next page
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Contents
Page Page
Fuel Injection NozzlesContinued In-line Injection PumpContinued

Installation . . . . . . . . . . . . . . . . . . . . . . 40-63 Governor operation . . . . . . . . . . . . . . . 220-21
Fuel System Bleed . . . . . . . . . . . . . . . . . . 40-64 Diagnose injection pump . . . . . . . . . . . 220-22
Engine Speed Adjustment Fuel Injection Nozzles . . . . . . . . . . . . . . . 220-23
Timing of Fuel Injection Pump . . . . . . . . . 220-26
Group 205Engine System - Operation
Engine - Sectional view . . . . . . . . . . . . . . . 205-2 Index
General information . . . . . . . . . . . . . . . . . 205-3
Lubrication System . . . . . . . . . . . . . . . . . . 205-4
Cooling system . . . . . . . . . . . . . . . . . . . . 205-7
How the 37 kW auxiliary drive works . . . . . . 205-8
Group 210Engine System - Diagnosis and

Tests
Special tools . . . . . . . . . . . . . . . . . . . . . . 210-1
Specifications . . . . . . . . . . . . . . . . . . . . . 210-2
Engine Break-in Instructions . . . . . . . . . . . . 210-2
Diagnosing Engine Malfunctions . . . . . . . . . 210-4
Checking Engine Compression . . . . . . . . . . 210-8
Checking Engine Oil Pressure . . . . . . . . . . 210-9
Measuring Engine Blow-by . . . . . . . . . . . . 210-9
Using STANADYNE TIME-TRAC as
Tachometer . . . . . . . . . . . . . . . . . . . . 210-10
Group 215Air Intake System - Operation and

Tests
Special tools . . . . . . . . . . . . . . . . . . . . . . 215-1
Specifications . . . . . . . . . . . . . . . . . . . . . 215-1
Turbocharger Operation . . . . . . . . . . . . . . 215-1
Turbocharger Boost Pressure Check . . . . . . 215-2
Turbocharger Malfunctions Diagnosing . . . . . 215-3
Air-to-air Aftercooler Operation . . . . . . . . . . 215-4
Group 220Fuel System - Operation and Tests

Fuel Filter Operation . . . . . . . . . . . . . . . . . 220-1
Distributor Injection Pump
Specifications . . . . . . . . . . . . . . . . . . . . 220-2
Operation . . . . . . . . . . . . . . . . . . . . . . 220-3
Fuel Transfer Pump Operation . . . . . . . . 220-4
Lucas CAV Fuel Injection Pump . . . . . . . 220-6
Test shut-off solenoid (Lucas-CAV) . . . . . 220-8
STANADYNE DM4 Fuel Injection Pump . . 220-10
STANADYNE DB2/DB4 Fuel Injection
Pump . . . . . . . . . . . . . . . . . . . . . . . 220-12
In-line Injection Pump
Specifications . . . . . . . . . . . . . . . . . . . 220-15
Fuel system operation . . . . . . . . . . . . . 220-16
Fuel Transfer Pump Operation . . . . . . . 220-17
Diagnose fuel supply pump . . . . . . . . . . 220-19
Fuel injection pump operation . . . . . . . . 220-20
CTM3274 (01JUL99) v Saran Liter Engines

060799
PN=370
Contents
CTM3274 (01JUL99) vi Saran Liter Engines

060799
PN=371
Index
Page Page
CamshaftContinued
Cam follower checking . . . . . . . . . . . . . . 20-13
A End play measure . . . . . . . . . . . . . . . . . . 20-9
Gear replacement . . . . . . . . . . . . . . . . . 20-11
Air intake system
Installation . . . . . . . . . . . . . . . . . . . . . . 20-12
Specifications . . . . . . . . . . . . . . . . . . . . . 35-1
Journal OD measure . . . . . . . . . . . . . . . 20-10
Torque values . . . . . . . . . . . . . . . . . . . . 35-6
Lobe height measure . . . . . . . . . . . . . . . 20-11
Air intake system - Operation and tests
Removal . . . . . . . . . . . . . . . . . . . . . . . 20-10
Air-to-air Aftercooler . . . . . . . . . . . . . . . . 215-4
Specifications . . . . . . . . . . . . . . . . . . . . . 20-4
Specifications . . . . . . . . . . . . . . . . . . . . 215-1
Tachometer pick-up pin removal . . . . . . . 20-11
Turbocharger malfunctions . . . . . . . . . . . 215-3 INDX
Torque values . . . . . . . . . . . . . . . . . . . . 20-8 1
Turbocharger operation . . . . . . . . . . . . . 215-1
Clean engine . . . . . . . . . . . . . . . . . . . . . . . 02-3
Aneroid
Connecting rods
Field adjustment . . . . . . . . . . . . . . . . . . 40-57
Assembly . . . . . . . . . . . . . . . . . . . . . . . 10-31
Replacement . . . . . . . . . . . . . . . . . . . . 40-57
Bearing clearance . . . . . . . . . . . . . . . . . 10-22
Workshop adjustment . . . . . . . . . . . . . . 40-58
Bearing inspection . . . . . . . . . . . . . . . . . 10-22
Assembly sequence . . . . . . . . . . . . . . . . . . 03-4
Auxiliary drive (37 kW) Bushing ID . . . . . . . . . . . . . . . . . . . . . . 10-23
Ball bearing and dowel installation . . . . . . 20-37 Bushing replacement (Straight pin-e . . . . . 10-24
Gear and shaft installation . . . . . . . . . . . 20-37 Bushing replacement (Tapered pin-en . . . . 10-25
Gear installation . . . . . . . . . . . . . . . . . . 20-30 Installation . . . . . . . . . . . . . . . . . . . . . . 10-32
Gear removal . . . . . . . . . . . . . . . . . . . . 20-36 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-10
Output shaft cover installation . . . . . . . . . 20-38 Specifications . . . . . . . . . . . . . . . . . . . . . 10-4
Overview . . . . . . . . . . . . . . . . . . . . . . . 20-36 Torque values . . . . . . . . . . . . . . . . . . . . 10-8
Specifications . . . . . . . . . . . . . . . . . . . . . 20-7 Torque-turn method . . . . . . . . . . . . . . . . 10-33
Timing gear cover installation . . . . . . . . . 20-34 Coolant
Auxiliary equipment (19 kW) Diesel engine . . . . . . . . . . . . . . . . . . . . . 01-8
Installation . . . . . . . . . . . . . . . . . . . . . . 20-35 Coolant heater (all engines)
Operation . . . . . . . . . . . . . . . . . . . . . . 30-28
Coolant heater (4 and 6 cyl.)
Operation . . . . . . . . . . . . . . . . . . . . . . 30-26
B
Replacement . . . . . . . . . . . . . . . . . . . . 30-27
Balancer shafts Cooling system
End play measure . . . . . . . . . . . . . . . . . 20-14 Deaeration . . . . . . . . . . . . . . . . . . . . . . 30-22
Gear replacement . . . . . . . . . . . . . . . . . 20-16 Specifications . . . . . . . . . . . . . . . . . . . . . 30-2
Identification . . . . . . . . . . . . . . . . . . . . . 20-13 Torque values . . . . . . . . . . . . . . . . . . . 30-10
Installation . . . . . . . . . . . . . . . . . . . . . . 20-17 Crankshaft
Journal OD measure . . . . . . . . . . . . . . . 20-15 Bearing inserts installation . . . . . . . . . . . 15-25
Removal . . . . . . . . . . . . . . . . . . . . . . . 20-14
End play measure . . . . . . . . . . . . . . . . . 15-18
Specifications . . . . . . . . . . . . . . . . . . . . . 20-4
Gear replacement . . . . . . . . . . . . . . . . . 15-24
Torque values . . . . . . . . . . . . . . . . . . . . 20-8
Identification . . . . . . . . . . . . . . . . . . . . . 15-19
Break-in engine oil . . . . . . . . . . . . . . . . . . 210-3
Inspection . . . . . . . . . . . . . . . . . . . . . . 15-19
Installation . . . . . . . . . . . . . . . . . . . . . . 15-26
Journal OD check . . . . . . . . . . . . . . . . . 15-20
C Main bearing clearance . . . . . . . . . . . . . 15-21
Cam follower bore measure . . . . . . . . . . . . 10-13 Micro-finishing specifications . . . . . . . . . . 15-24
Camshaft Oil seal/wear sleeve installation . . . . . . . . 15-17
Bore measure . . . . . . . . . . . . . . . . . . . 10-13 Regrinding . . . . . . . . . . . . . . . . . . . . . . 15-22
Bushing installation . . . . . . . . . . . . . . . . 10-15 Regrinding guidelines . . . . . . . . . . . . . . . 15-23
Bushing removal . . . . . . . . . . . . . . . . . . 10-15 Removal . . . . . . . . . . . . . . . . . . . . . . . 15-18
Bushing replacement tool . . . . . . . . . . . . 10-14 Specifications . . . . . . . . . . . . . . . . . . . . . 15-4
Index-1 060799
PN=372
Index
Page Page
CrankshaftContinued
Wear sleeve removal . . . . . . . . . . . . . . . 15-14
2-piece thrust bearing inst. . . . . . . . . . . . 15-25 E
5/6-piece thrust bearing inst. . . . . . . . . . . 15-25
Engine
Crankshaft front oil seal installation . . . . . . . 20-34
Sectional view . . . . . . . . . . . . . . . . . . . 205-2
Cylinder block
Engine oil
Balancer shaft bore measure . . . . . . . . . 10-17
Break-In . . . . . . . . . . . . . . . . . . . . . . . 210-3
Balancer shaft bushing replacement . . . . . 10-18
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
Bearing cap replacement . . . . . . . . . . . . 10-16
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 10-12 Engine speed adjustment
INDX Crankshaft bore measure . . . . . . . . . . . . 10-16 Distributor pump . . . . . . . . . . . . . . . . . . 40-67
2 ID of assembled main bearings . . . . . . . . 15-21 Mico in-line pump . . . . . . . . . . . . . . . . . 40-68
Oversize balancer shaft bushings . . . . . . . 10-19 Engine system - Diagnosis and tests
Specifications . . . . . . . . . . . . . . . . . . . . . 10-4 Diagnosing engine malfunctions . . . . . . . . 210-4
Top desk flatness . . . . . . . . . . . . . . . . . 10-17 Engine blow-by measure . . . . . . . . . . . . 210-9
Torque values . . . . . . . . . . . . . . . . . . . . 10-8 Engine break-in . . . . . . . . . . . . . . . . . . 210-2
Cylinder head Engine compression checking . . . . . . . . . 210-8
Check flatness . . . . . . . . . . . . . . . . . . . 05-10 Engine oil pressure checking . . . . . . . . . 210-9
Final work . . . . . . . . . . . . . . . . . . . . . . 05-23 Engine speed checking . . . . . . . . . . . . 210-10
Installation . . . . . . . . . . . . . . . . . . . . . . 05-18 Specifications . . . . . . . . . . . . . . . . . . . . 210-2
Measure valve guide . . . . . . . . . . . . . . . 05-12 Engine system - Operation
Removal . . . . . . . . . . . . . . . . . . . . . . . . 05-8 Auxiliary drive (37 kW) operation . . . . . . . 205-8
Remove valve seat inserts . . . . . . . . . . . 05-14 Cooling System . . . . . . . . . . . . . . . . . . 205-7
Torque turn tightening method . . . . . . . . . 05-19 General information . . . . . . . . . . . . . . . . 205-3
Cylinder head and valves Lubrication system . . . . . . . . . . . . . . . . 205-5
Specifications . . . . . . . . . . . . . . . . . . . . . 05-4 Exhaust manifold
Torques for hardware . . . . . . . . . . . . . . . 05-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . 35-7
Cylinder liners Exhaust system
Bore measure . . . . . . . . . . . . . . . . . . . 10-11 Specifications . . . . . . . . . . . . . . . . . . . . . 35-1
Deglazing . . . . . . . . . . . . . . . . . . . . . . 10-12 Torque values . . . . . . . . . . . . . . . . . . . . 35-6
Installation . . . . . . . . . . . . . . . . . . . . . . 10-21
O-ring installation . . . . . . . . . . . . . . . . . 10-21
Packing installation . . . . . . . . . . . . . . . . 10-20 F
Protrusion . . . . . . . . . . . . . . . . . . . . . . 10-20 Fan installation . . . . . . . . . . . . . . . . . . . . 30-24
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-11 Fan/Alternator belt tension . . . . . . . . . . . . . 30-23
Specifications . . . . . . . . . . . . . . . . . . . . . 10-4 Flywheel
Torque values . . . . . . . . . . . . . . . . . . . . 10-8 Ball bearing installation . . . . . . . . . . . . . 15-13
Installation . . . . . . . . . . . . . . . . . . . . . . 15-14
Removal . . . . . . . . . . . . . . . . . . . . . . . 15-12
D Ring gear replacement . . . . . . . . . . . . . . 15-13
Diesel engine oil . . . . . . . . . . . . . . . . . . . . 01-7 Specifications . . . . . . . . . . . . . . . . . . . . . 15-4
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . 01-6 Torque values . . . . . . . . . . . . . . . . . . . . 15-6
Dipstick guide replacement . . . . . . . . . . . . 25-25 Flywheel housing
Disassembly sequence . . . . . . . . . . . . . . . . 03-1 Torque values . . . . . . . . . . . . . . . . . . . . 15-6
Dynamic timing Front plate
Connection . . . . . . . . . . . . . . . . . . . . . 40-50 Gasket . . . . . . . . . . . . . . . . . . . . . . . . 20-24
Full load rated speed . . . . . . . . . . . . . . . 40-50 Installation . . . . . . . . . . . . . . . . . . . . . . 20-25
Information . . . . . . . . . . . . . . . . . . . . . . 40-46 Removal . . . . . . . . . . . . . . . . . . . . . . . 20-18
Magnetic probe . . . . . . . . . . . . . . . . . . . 40-48 Replacement . . . . . . . . . . . . . . . . . . . . 40-35
No-load . . . . . . . . . . . . . . . . . . . . . . . . 40-53 Fuel
Stationary pointer . . . . . . . . . . . . . . . . . 40-49 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
Index-2 060799
PN=373
Index
Page Page
Fuel filter Identification

Replace element (round) . . . . . . . . . . . . 40-25 Option code label . . . . . . . . . . . . . . . . . . 01-3
Fuel filter element replacement . . . . . . . . . . 40-24 Engine information . . . . . . . . . . . . . . . . . 01-1
Fuel injection nozzle Engine plate information . . . . . . . . . . . . . . 01-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . 40-62 Repower engine plate . . . . . . . . . . . . . . . 01-2
Bore cleaning . . . . . . . . . . . . . . . . . . . . . 05-8 Idler gears
Chatter test . . . . . . . . . . . . . . . . . . . . . 40-61 Bushing and shaft measure . . . . . . . . . . 20-19
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 40-60 Bushing replacement . . . . . . . . . . . . . . . 20-20
Disassembly . . . . . . . . . . . . . . . . . . . . . 40-62 End play measure . . . . . . . . . . . . . . . . . 20-17
Installation . . . . . . . . . . . . . . . . . . . . . . 40-63
INDX
Lower idler shaft installation . . . . . . . . . . 20-23 3
Opening pressure test . . . . . . . . . . . . . . 40-61 Shaft removal . . . . . . . . . . . . . . . . . . . . 20-20
Removal . . . . . . . . . . . . . . . . . . . . . . . 40-59 Spring pin installation . . . . . . . . . . . . . . . 20-21
Spray pattern test . . . . . . . . . . . . . . . . . 40-61 Upper idler shaft installation . . . . . . . . . . 20-22
Test . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60 Inch torque values . . . . . . . . . . . . . . . . . . 01-10
Valve seat checking . . . . . . . . . . . . . . . 40-62 Intake manifold
Valve stem and guide wear checking . . . . 40-61 Inspection . . . . . . . . . . . . . . . . . . . . . . . 35-7
Fuel pump replacement . . . . . . . . . . . . . . . 40-27
Fuel system
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
L
Specifications . . . . . . . . . . . . . . . . . . . . . 40-5
Torque values . . . . . . . . . . . . . . . . . . . 40-23 Lubrication system
Fuel system - Operation and tests Specifications . . . . . . . . . . . . . . . . . . . . . 25-2
Diagnose fuel supply pump (in-line) . . . . 220-19 Torque values . . . . . . . . . . . . . . . . . . . 25-14
Diagnose in-line fuel injection pum . . . . . 220-22 Lucas CAV fuel injection pump
Distrbutor injection pump . . . . . . . . . . . . 220-3 Installation . . . . . . . . . . . . . . . . . . . . . . 40-29
Fuel filter operation . . . . . . . . . . . . . . . . 220-1 Removal . . . . . . . . . . . . . . . . . . . . . . . 40-28
Fuel injection nozzles . . . . . . . . . . . . . 220-23 Repairs . . . . . . . . . . . . . . . . . . . . . . . . 40-29
Fuel injection pump operation . . . . . . . . 220-20 Static timing . . . . . . . . . . . . . . . . . . . . . 40-30
Fuel system operation (in-line) . . . . . . . . 220-16
Fuel transfer pump operation . . . 220-4, 220-17
Governor operation (in-line pump) . . . . . 220-21 M
Lucas CAV fuel injection pump . . . . . . . . 220-6 Main bearings
Lucas-CAV shut-off solenoid . . . . . . . . . . 220-8 Specifications . . . . . . . . . . . . . . . . . . . . . 15-4
Specifications . . . . . . . . . . . . . . . . . . . . 220-2 Torque values . . . . . . . . . . . . . . . . . . . . 15-6
Specifications (in-line pump) . . . . . . . . . 220-15 Metric torque values . . . . . . . . . . . . . . . . . . 01-9
Stanadyne DB2/DB4 injection pump . . . . 220-12 MICO in-line injection pump
Stanadyne DM4 fuel injection pump . . . . 220-10 Assemble fuel supply pump . . . . . . . . . . 40-40
Disassemble fuel supply pump . . . . . . . . 40-39
Install supply pump . . . . . . . . . . . . . . . . 40-40
H Installation . . . . . . . . . . . . . . . . . . . . . . 40-44
High-flow oil pump JDG670A modification . . . . . . . . . . . . . . 40-43
Gear axial clearance .. . . . . . . . . . . . . . 25-33 Overflow valve . . . . . . . . . . . . . . . . . . . 40-41
Gear radial clearance . . . . . . . . . . . . . . 25-33 Remove . . . . . . . . . . . . . . . . . . . . . . . 40-42
Installation . . . . . . . .. . . . . . . . . . . . . . 25-35 Remove fuel supply pump . . . . . . . . . . . 40-38
Removal . . . . . . . . .. . . . . . . . . . . . . . 25-32 Repair . . . . . . . . . . . . . . . . . . . . . . . . . 40-44
Specifications . . . . . .. . . . . . . . . . . . . . 25-34
O
I Oil by-pass replacement . . . . . . . . . . . . . . 25-26
Index-3 060799
PN=374
Index
Page Page
Oil cooler
Adapter replacement . . . . . . . . . . . . . . . 25-17 R
Bracket replacement . . . . . . . . . . . . . . . 25-18 Repair stand . . . . . . . . . . . . . . . . . . . . . . . 02-1
Distributor base removal . . . . . . . . . . . . . 25-22
Repair stand
Distributor base repair . . . . . . . . . . . . . . 25-22
Lifting procedure . . . . . . . . . . . . . . . . . . . 02-2
High-flow installation . . . . . . . . . . . . . . . 25-23 Safety precautions . . . . . . . . . . . . . . . . . . 02-2
High-flow oil cooler removal . . . . . . . . . . 25-22 Rocker arm assembly
Identification . . . . . . . . . . . . . . . . . . . . . 25-15 Installation . . . . . . . . . . . . . . . . . . . . . . 05-21
INDX Standard oil cooler removal . . . . . . . . . . 25-16 Rocker arm cover installation . . . . . . . . . . . 05-23
4 Oil deflector installation . . . . . . . . . . . . . . . 20-30 Rocker arm shaft
Oil filter Inspect . . . . . . . . . . . . . . . . . . . . . . . . 05-20
Adapter installation . . . . . . . . . . . . . . . . 25-21 Rotating assembly
Oil pan installation . . . . . . . . . . . . . . . . . . 25-37 Disassembling . . . . . . . . . . . . . . . . . . . 30-18
Oil pressure regulating valve Installation . . . . . . . . . . . . . . . . . . . . . . 30-20
Installation . . . . . . . . . . . . . . . . . . . . . . 25-24 Reassembling . . . . . . . . . . . . . . . . . . . . 30-19
Removal . . . . . . . . . . . . . . . . . . . . . . . 25-24 Removal . . . . . . . . . . . . . . . . . . . . . . . 30-18
Valve seat replacement . . . . . . . . . . . . . 25-24
Oil pump identification . . . . . . . . . . . . . . . . 25-27
Oil suction screen S
Replacement (on high-flow oil pump) . . . . 25-27
Sealant guidelines . . . . . . . . . . . . . . . . . . . 03-3
Replacement (on standard oil pump) . . . . 25-27
Specifications
Air intake system . . . . . . . . . . . . . . . . . . 35-1
Auxiliary drive (37 kW) . . . . . . . . . . . . . . . 20-7
P Balancer shafts . . . . . . . . . . . . . . . . . . . . 20-4
Piston cooling jets checking . . . . . . . . . . . . 10-13 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Pistons Connecting rods . . . . . . . . . . . . . . . . . . . 10-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . 10-31 Cooling system . . . . . . . . . . . . . . . . . . . . 30-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 10-27 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . 15-4
Crankshaft micro-finishing . . . . . . . . . . . . 15-24
Head and skirt checking . . . . . . . . . . . . . 10-29
Cylinder block . . . . . . . . . . . . . . . . . . . . 10-4
Installation . . . . . . . . . . . . . . . . . . . . . . 10-32
Cylinder head and valves . . . . . . . . . . . . . 05-4
Pin bore measure . . . . . . . . . . . . . . . . . 10-28
Cylinder liners . . . . . . . . . . . . . . . . . . . . 10-4
Pin OD measure . . . . . . . . . . . . . . . . . . 10-27
Engine references . . . . . . . . . . . . . . . . . . 01-3
Piston rings staggering . . . . . . . . . . . . . . 10-30
Exhaust system . . . . . . . . . . . . . . . . . . . 35-1
Protrusion . . . . . . . . . . . . . . . . . . . . . . 10-34
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . 15-4
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-10 Fuel system . . . . . . . . . . . . . . . . . . . . . . 40-5
Ring installation . . . . . . . . . . . . . . . . . . 10-30 Lubrication system . . . . . . . . . . . . . . . . . 25-2
Rings identification . . . . . . . . . . . . . . . . 10-29 Main bearings . . . . . . . . . . . . . . . . . . . . 15-4
Second and third ring grooves . . . . . . . . . 10-29 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Specifications . . . . . . . . . . . . . . . . . . . . . 10-4 Timing gear train . . . . . . . . . . . . . . . . . . 20-4
Top ring groove . . . . . . . . . . . . . . . . . . 10-28 3029, 4039 & 6059 engines spec. . . . . . . . 01-4
Torque values . . . . . . . . . . . . . . . . . . . . 10-8 4045 & 6068 engines spec. . . . . . . . . . . . 01-5
Pulley Stanadyne DB2/DB4 fuel injection pump
Installation . . . . . . . . . . . . . . . . . . . . . . . 15-8 Installation . . . . . . . . . . . . . . . . . . . . . . 40-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . 15-7 Removal . . . . . . . . . . . . . . . . . . . . . . . 40-31
Pulley for front PTO Repairs . . . . . . . . . . . . . . . . . . . . . . . . 40-32
Inspection . . . . . . . . . . . . . . . . . . . . . . . 15-9 Replace lever throttle . . . . . . . . . . . . . . . 40-32
Removal . . . . . . . . . . . . . . . . . . . . . . . 15-10 Static timing . . . . . . . . . . . . . . . . . . . . . 40-34
Index-4 060799
PN=375
Index
Page Page
TurbochargerContinued
Stanadyne DM4 fuel injection pump Installation . . . . . . . . . . . . . . . . . . . . . . 35-14
Installation . . . . . . . . . . . ..... . . . . . . 40-37 Pre-lubrication . . . . . . . . . . . . . . . . . . . 35-13
Removal . . . . . . . . . . . . ..... . . . . . . 40-36 Radial bearing clearance (Schwitzer . . . . . . 35-9
Repairs . . . . . . . . . . . . . ..... . . . . . . 40-36 Radial bearing end play check . . . . . . . . . 35-8
Static timing . . . . . . . . . . ..... . . . . . . 40-37 Recommendation for use . . . . . . . . . . . . 35-15
Standard oil pump Removal . . . . . . . . . . . . . . . . . . . . . . . . 35-8
Gear axial clearance . . . . . . . . . . . . . . . 25-28 Repair . . . . . . . . . . . . . . . . . . . . . . . . . 35-10
Gear radial clearance . . . . . . . . . . . . . . 25-28 Turbocharger (GARRETT)
Installation . . . . . . . . . . . . . . . . . . . . . . 25-29 Disassembly . . . . . . . . . . . . . . . . . . . . . 35-10
Removal . . . . . . . . . . . . . . . . . . . . . . . 25-28 Reassembly . . . . . . . . . . . . . . . . . . . . . 35-11 INDX
Specifications . . . . . . . . . . . . . . . . . . . . 25-29 Turbocharger (SCHWITZER) 5
Disassembly and reassembly . . . . . . . . . 35-12
T
Thermostat V
Inspect and test . . . . . . . . . . . . . . . . . 210-11 Valve and rocker arm
Thermostats Check valve . . . . . . . . . . . . . . . . . . . . . 05-16
Test and replacement . . . . . . . . . . . . . . 30-21 Valve clearance adjustment . . . . . . . . . . 05-21
Timing gear cover Valve clearance
Installation (aluminum) . . . . . . . . . . . . . . 20-33 Adjustment sequence . . . . . . . . . . . . . . . 05-22
Identification . . . . . . . . . . . . . . . . . . . . . 20-31 Valve guides
Installation (composite material) . . . . . . . . 20-32 Clean valve guides . . . . . . . . . . . . . . . . 05-11
Timing gear train Valve lift
Lower timing gear installation . . . . . . . . . 20-29 Check valve lift . . . . . . . . . . . . . . . . . . . . 05-7
Upper timing gear installation . . . . . . . . . 20-27 Valve recess
Backlash measure . . . . . . . . . . . . . . . . . . 20-9 Check valve recess . . . . . . . . . . . . . . . . 05-13
Specifications . . . . . . . . . . . . . . . . . . . . . 20-4 Valve rotators
Torque values . . . . . . . . . . . . . . . . . . . . 20-8 Inspect . . . . . . . . . . . . . . . . . . . . . . . . 05-17
Torque values Valve seats
Air intake system . . . . . . . . . . . . . . . . . . 35-6 Clean valve seats . . . . . . . . . . . . . . . . . 05-11
Balancer shafts . . . . . . . . . . . . . . . . . . . . 20-8 Installation . . . . . . . . . . . . . . . . . . . . . . 05-15
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . 20-8 Lapping . . . . . . . . . . . . . . . . . . . . . . . . 05-12
Connecting rods . . . . . . . . . . . . . . . . . . . 10-8 Valve springs
Cooling system . . . . . . . . . . . . . . . . . . . 30-10 Check tension . . . . . . . . . . . . . . . . . . . 05-16
Cylinder block . . . . . . . . . . . . . . . . . . . . 10-8 Valves
Cylinder head and valves . . . . . . . . . . . . . 05-6 Grind face angle . . . . . . . . . . . . . . . . . . 05-16
Cylinder liners . . . . . . . . . . . . . . . . . . . . 10-8 Installation . . . . . . . . . . . . . . . . . . . . . . 05-17
Exhaust system . . . . . . . . . . . . . . . . . . . 35-6 Valves and valve springs removal . . . . . . . . 05-10
Vibration damper
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . 15-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . 15-7
Flywheel housing . . . . . . . . . . . . . . . . . . 15-6
Fuel system . . . . . . . . . . . . . . . . . . . . . 40-23
Inch . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
Lubrication system . . . . . . . . . . . . . . . . 25-14 W
Main bearings . . . . . . . . . . . . . . . . . . . . 15-6 Water pump
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9 Bearing shaft installation . . . . . . . . . . . . 30-14
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Identification . . . . . . . . . . . . . . . . . . . . . 30-11
Timing gear train . . . . . . . . . . . . . . . . . . 20-8 Impeller installation . . . . . . . . . . . . . . . . 30-15
Turbocharger Installation . . . . . . . . . . . . . . . . . . . . . . 30-16
Axial end play check . . . . . . . . . . . . . . . . 35-9 Removal . . . . . . . . . . . . . . . . . . . . . . . 30-12
Break-in . . . . . . . . . . . . . . . . . . . . . . . 35-15 Seal installation . . . . . . . . . . . . . . . . . . 30-14
Index-5 060799
PN=376
Index
Page
Water pump (standard model)

Disassemble . . . . . . . . . . . . . . . . . . . . 30-13
Install pulley or hub . . . . . . . . . . . . . . . . 30-15
Wear ring
Installation . . . . . . . . . . . . . . . . . . . . . . 20-35
INDX
6
Index-6 060799
PN=377
1
0
1
2
3
4
5
6
7
8
9
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3029

John Deere Usine de Saran

CTM3274 (01JUL99) Saran Liter Engines

ENGINE IDENTIFICATION VIEWS

CTM3274 (01JUL99) Saran Liter Engines

ENGINE IDENTIFICATION VIEWS (CONTD)

CTM3274 (01JUL99) Saran Liter Engines

3000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER

3100 . . . . . . . . . . . . . . . . . . . . . . . . CD3029DRT65 (189846 - )

4000-SERIES TELESCOPIC ENGINE MODEL SERIAL NUMBER

4400 . . . . . . . . . . . . . . . . . . . . . . . . CD4039TF005 (237697 - )

5000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER

5300/5300N . . . . . . . . . . . . . . . . . . . . CD3029DAT01 (315424 - )

5000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER

5000-SERIES TRACTORS ENGINE MODEL SERIAL NUMBER

5300 . . . . . . . . . . . . . . . . . . . . . . . . CD3029DPY01 (383283 - )

(Continued on next page) CD,3274,G00,24 -19-04JAN99

CTM3274 (01JUL99) Saran Liter Engines

ENGINE APPLICATION CHART (CONT)

6100 (Direct fan drive) . . . . . . . . . . . . CD4045DL001 (101582 - )

6200 (Direct fan drive) . . . . . . . . . . . . CD4039TL001 (101625 - )

6300 (Direct fan drive) . . . . . . . . . . . . CD4039TL003 (101649 - )

6400 (Direct fan drive) . . . . . . . . . . . . CD4045TL001 (101682 - )

6506 (Viscous fan drive) . . . . . . . . . . . CD6068DL001 (214852 - )

6600 (Viscous fan drive) . . . . . . . . . . . CD6059TL001 (128886 - )

6800 (Viscous fan drive) . . . . . . . . . . . CD6068TL001 (124505 - )

6900 (Viscous fan drive) . . . . . . . . . . . CD6068TL002 (186326 - )

WATERLOO TRACTORS ENGINE MODEL SERIAL NUMBER

ZWEIBRCKEN COMBINES ENGINE MODEL SERIAL NUMBER

2054 . . . . . . . . . . . . . . . . . . . . . . . . 6068HZ001 (116452 - )

ENGINES FOR CHINESE COMBINES SERIAL NUMBER

ENGINES FOR GOLDONI TRACTORS SERIAL NUMBER

(Continued on next page) CD,3274,G00,25 -19-04JAN99

CTM3274 (01JUL99) Saran Liter Engines

ENGINE APPLICATION CHART (CONT)

(Continued on next page) CD,3274,G00,29 -19-04JAN99

CTM3274 (01JUL99) Saran Liter Engines

ENGINE APPLICATION CHART (CONT)

CTM3274 (01JUL99) Saran Liter Engines

HANDLE FLUIDS SAFELYAVOID FIRES

When you work around fuel, do not smoke or work near 00

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn

PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and open flame away

Do not charge a frozen battery; it may explode. Warm

PREPARE FOR EMERGENCIES

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

CTM3274 (01JUL99) 00-1 Saran Liter Engines

PREVENT ACID BURNS

Avoid the hazard by:

If you spill acid on yourself:

CTM3274 (01JUL99) 00-2 Saran Liter Engines

AVOID HIGH-PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the skin 00

Search for leaks with a piece of cardboard. Protect

If an accident occurs, see a doctor immediately. Any

WEAR PROTECTIVE CLOTHING