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 -37˚C
01 (-34˚F). 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 -37˚C (-34˚F). 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

CTM3274 (01JUL99) 01-8 Saran Liter Engines

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

N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m 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

CTM3274 (01JUL99) 01-9 Saran Liter Engines

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

N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m lb-ft N·m 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

CTM3274 (01JUL99) 01-10 Saran Liter Engines

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

CTM3274 (01JUL99) 02-1 Saran Liter Engines

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

CTM3274 (01JUL99) 02-2 Saran Liter Engines

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

CTM3274 (01JUL99) 02-3 Saran Liter Engines

060799
PN=30
 Engine mounting/Disconnect turbocharger oil line

02
4

CTM3274 (01JUL99) 02-4 Saran Liter Engines

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

CTM3274 (01JUL99) 03-1 Saran Liter Engines

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

CTM3274 (01JUL99) 03-2 Saran Liter Engines

060799
PN=33