John Deere PowerTech 0.9-2.0 L & Yanmar 4TNE98 Diesel Engines Workshop Repair Manual CTM119 PDF - MJODCTM119.zip

Complete Components Technical Manual Featuring Electrical Wiring Diagrams for John Deere PowerTech 0.9, 1.1, 1.2, 1.3, 1.5, 1.6 & 2.0 L and Yanmar 4TNE98 Diesel Engines, delivering every technical detail needed to maintain, troubleshoot, rebuild, and service these units the way professional technicians do.

The Components Technical Manual covering John Deere PowerTech 0.9, 1.1, 1.2, 1.3, 1.5, 1.6 & 2.0 L and Yanmar 4TNE98 Diesel Engines contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

CTM119 - John Deere PowerTech 0.9, 1.1, 1.2, 1.3, 1.5, 1.6 & 2.0 L & Yanmar 4TNE98 Diesel Engines Components Technical Manual.pdf

Total Pages: 715 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Language: English

TABLE OF CONTENTS - Expanded View

00 - Safety

Avoid Harmful Asbestos Dust

Avoid Heating Near Pressurized Fluid Lines

Avoid High-Pressure Fluids

Dispose of Waste Properly

Follow Safety Instructions

Handle Chemical Products Safely

Handle Fluids Safely-Avoid Fires

Illuminate Work Area Safely

Live With Safety

Practice Safe Maintenance

Prepare for Emergencies

Prevent Acid Burns

Prevent Battery Explosions

Protect Against Noise

Recognize Safety Information

Remove Paint Before Welding or Heating

Service Cooling System Safely

Service Machines Safely

Understand Signal Words

Use Proper Lifting Equipment

Use Proper Tools

Wear Protective Clothing

Work in Clean Area

Work in Ventilated Area

01 - General Information

Basic Engine Specifications-3009, 3011 & 3015 Engines

Basic Engine Specifications-4020D, 4020T & 4TNE98 Engines

Engine Application Chart-Industrial Applications

Engine Application Chart-OEM Applications

Engine Model Designation

Engine Serial Number Plate Information

Metric Bolt and Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

02 - Fuels, Lubricants, and Coolant

Diesel Engine Coolant Recommendations

Diesel Engine Coolant Specifications

Diesel Engine Oil

Diesel Fuel

Disposing of Coolant

Engine Break-In Oil

Grease

Lubricity of Diesel Fuels

Mixing of Lubricants

OILSCAN302256 and CoolScan342204242

Operating in Warm Temperature Climates

Testing Diesel Engine Coolant

04 - Engine Rebuid Guide

Clean Engine

Disconnect Turbocharger Oil Inlet Line-4020T Only

Engine Assembly Sequence

Engine Disassembly Sequence

Engine Lifting Procedure

Sealant Application Guidelines

05 - Cylinder Block, Pistons & Rods

Assemble Cylinder Head and Valves

Check and Adjust Valve Clearance

Cylinder Head and Valves Specifications-3009

Cylinder Head and Valves Specifications-3011

Cylinder Head and Valves Specifications-3015

Cylinder Head and Valves Specifications-4020

Cylinder Head and Valves Specifications-4TNE98

Disassemble and Assemble Rocker Arm Shaft Assembly

Disassemble Cylinder Head and Valves

Grind Valves

Inspect Cam Followers

Inspect Rocker Arm Shaft Assembly Components

Install Cylinder Head

Lap Valves

Measure Piston-to-Cylinder Head Clearance

Measure Valve Lift

Remove and Install Exhaust Manifold

Remove and Install Intake Manifold

Remove and Install Rocker Arm Cover

Remove Cylinder Head

Service Equipment and Tools

100 - Engine Tune-Up and Break-In

Check Air Intake System

Check and Service Cooling System

Check Crankcase Ventilation System

Check Electrical System

Check Exhaust System

Check Fan _ Alternator Belt

Dynamometer Test Specifications

Effects of Altitude and Temperature on Engine Performance

Engine Break-In Guidelines

General Tune-Up Recommendations

Perform Engine Break-In After Overhaul

Preliminary Engine Testing

105 - Engine System Operation and Tests

Air Cleaner Operation

Air Intake System Leakage Test

Alternator Regulated Amperage Test

Alternator Regulated Voltage Test

Alternator Unregulated Amperage Test

Component Location-3009

Component Location-3011, 3015, 4020 & 4TNE98

Cooling System Pressure Test

Crankcase Breather Operation

Cylinder Compression Pressure Test-3009

Cylinder Compression Pressure Test-3011, 3015, 4020 & 4TNE98

Diagnosing Air Intake Malfunctions

Diagnosing Turbocharger Malfunctions-4020T

Engine Oil Pressure Test

Engine System Diagnosis

Engine Test Specifications-3009

Engine Test Specifications-3011

Engine Test Specifications-3015

Engine Test Specifications-4020

Engine Test Specifications-4TNE98

For Pages 105-19 and 105-20, Substitue 11X17 Foldout Pages From File 34220023438A-G105B-Foldout342200235

Fuel Shutoff Solenoid Adjustment -3011 Only

Fuel Shutoff Solenoid Amperage Test-3011 Only

General Description-3009,3015,4020 & 4TNE98

General Description-3009

How the Cooling System Works

Lubrication System Operation

Oil Cooler Operation-4020T Only

Oil Filter Operation

Oil Pressure Regulating Valve Operation

Piston Cooling Nozzle Operation-4020T Only

Radiator Bubble Test

Radiator Cap Pressure Test

Special or Essential Tools_{1219}

Starter Amp Draw _ RPM Test

Starter No-Load Amp Draw _ RPM Test_{1653}

Starter Solenoid Test

Turbocharger Operation-4020T Only

10 - Cylinder Block, Pistons & Rods

Assemble Piston and Connecting Rod

Check Connecting Rod Bearing Clearance

Check Connecting Rod Side Play

Check Crankshaft End Play

Check Engine Rotation for Excessive Tightness

Check Piston Ring Groove Wear

Clean Pistons

Complete Disassembly of Cylinder Block (If Required)

Cylinder Block, Pistons, and Rods Specifications-3009

Cylinder Block, Pistons, and Rods Specifications-3011

Cylinder Block, Pistons, and Rods Specifications-3015, 4020D and 4020T

Cylinder Block, Pistons, and Rods Specifications-4TNE98

Deglaze Cylinder Bores

Disassemble Pistons and Connecting Rods

Inspect and Clean Cylinder Block

Inspect and Measure Cylinder Bore

Inspect Piston Pins and Bushings

Install Piston and Connecting Rod Assembly

Install Piston Rings

Measure Camshaft Bushing and Bores in Block

Measure Camshaft Follower Bores in Block

Measure Connecting Rod Bearings

Measure Crankshaft Connecting Rod Journals

Measure Piston Diameter

Measure Piston Pin Bore

Measure Piston Pin Bushings

Measure Piston Pins

Measure Piston Ring End Gap

Measure Piston-to-Cylinder Head Clearance_{4302}

Other Material

Preliminary Piston and Rod Checks

Rebore Cylinder Bores

Remove Pistons and Connecting Rods

Service Equipment and Tools_{4210}

Visually Inspect Pistons

110 - Fuel System Operation & Tests

Bleed Fuel System-3009

Bleed Fuel System-3011, 3015, 4020 & 4TNE98

Combustion Chamber Operation (Direct Injection)-3011, 3015, 4020 & 4TNE98

Direct Injection Nozzle Operation (Hole Type)-3011, 3015, 4020 & 4TNE98

Fast Idle Speed Adjustment

Fuel Drain Back Test

Fuel Injection Nozzle Test

Fuel Injection Pump Operation

Fuel Injection Pump Specifications

Fuel Injection Pump Static Timing Adjustment-3009

Fuel Injection Pump Static Timing Adjustment-3011, 3015, 4020 & 4TNE98

Fuel Shutoff Solenoid Adjustment -3011 Only_{2010}

Fuel Supply Pump Pressure Test

Fuel System Operation

Fuel System Specifications

Governor Operation

Indirect Injection Nozzle Operation (Pintle Type)-3009

Precombustion Chamber Operation (Indirect Injection)-3009

Slow Idle Speed Adjustment

Special or Essential Tools_{1752}

119 - Dealer Fabricated Tools

DFRG1 Extension Adapter Tip (For RHB3 Turbochargers)

DFRG2 Extension Adapter Tip (For RHB5 Turbochargers)

How To Make Tools

Valve Guide Tool for 4TNE98 Engine

15 - Crankshaft, Main Bearings, and Flywheel

Check Crankshaft End Play_{4925}

Check Crankshaft Main Bearing Clearance

Check Flywheel Face Flatness

Crankshaft and Main Bearing Failure Analysis

Crankshaft, Main Bearings, and Flywheel Specifications-3009

Crankshaft, Main Bearings, and Flywheel Specifications-3011

Crankshaft, Main Bearings, and Flywheel Specifications-3015

Crankshaft, Main Bearings, and Flywheel Specifications-4020

Crankshaft, Main Bearings, and Flywheel Specifications-4TNE98

Inspect Crankshaft and Main Bearings

Inspect Flywheel

Install Crankshaft and Main Bearing

Other Material_{4817}

Remove and Install Crankcase Extension Housing

Remove and Install Flywheel Housing

Remove and Install Flywheel

Remove and Install Flywheel Plate

Remove Crankshaft and Main Bearings

Replace Crankshaft Front Oil Seal

Replace Crankshaft Rear Oil Seal

16 - Camshaft and Timing Gear Train

Camshaft and Timing Gear Train Specification-4020

Camshaft and Timing Gear Train Specifications-3009

Camshaft and Timing Gear Train Specifications-3011

Camshaft and Timing Gear Train Specifications-3015

Camshaft and Timing Gear Train Specifications-4TNE98

Check Camshaft End Play

Check Timing Gear Backlash

Inspect Camshaft

Inspect Idler Gear-3009

Inspect Idler Gear-3011, 3015, 4020 & 4TNE98

Install Camshaft

Measure Valve Lift_{5209}

Other Material_{5117}

Remove and Install Idler Gear

Remove and Install Timing Gear Cover Mounting Plate-3011, 3015 & 4020

Remove and Install Timing Gear Cover

Remove and Install Timing Gear Housing-3009

Remove and Install Timing Gear Housing-4TNE98

Remove Camshaft

Service Equipment and Tools_{5108}

20 - Lubrication System

Disassemble, Inspect and Assemble Oil Pump

Lubrication System Specifications-3009

Lubrication System Specifications-3011

Lubrication System Specifications-3015

Lubrication System Specifications-4020

Lubrication System Specifications-4TNE98

Materials Required

Remove and Install Engine Oil Pump

Remove and Install Oil Pan and Strainer

Remove and Install Oil Pressure Regulating Valve

Remove, Inspect and Install Oil Cooler-4020T Only

Replace Piston Cooling Nozzles- 4020T Only

25 - Cooling System

Assemble Water Pump-3009, 3011, 3015 & 4020

Cooling System Specifications-3009

Cooling System Specifications-3011

Cooling System Specifications-3015

Cooling System Specifications-4020

Cooling System Specifications-4TNE98

Diagnosing Cooling System Malfunctions

Disassemble Water Pump-3009, 3011, 3015 & 4020

Other Material_{5556}

Remove and Inspect Radiator

Remove and Install Coolant Temperature Sensor or Switch

Remove and Install Cooling Fan

Remove and Install Thermostat-3009, 3011, 3015 & 4020

Remove and Install Thermostat and Housing-4TNE98

Remove, Inspect and Install Water Pump-3009, 3011, 3015 & 4020

Remove, Inspect and Install Water Pump-4TNE98

Replace and Adjust Fan _ Alternator Belt

Service Equipment and Tools_{5547}

Test Coolant Temperature Sensor _ Switch

Test Thermostat Opening

302256 3009DF001 Base Engine

30 - Air Intake and Exhaust System

Assemble Turbocharger

Check Turbocharger Rotor Shaft Axial Play

Check Turbocharger Rotor Shaft Radial Play

Check Turbocharger Waste Gate Valve-4020T With RHB5 Turbo

Disassemble Turbocharger-4020T Only

Extending Turbocharger Life-4020T Only

Inspect Air Cleaner-3009

Inspect Air Cleaner-3011

Inspect Air Cleaner-3015, 4020D & 4020T

Inspect Turbocharger

Install Turbocharger-4020T Only

Other Material_{5851}

Remove and Install Muffler-3009, 3011 & 3015

Remove and Install Muffler-4020T

Remove Turbocharger-4020T Only

Special or Essential Tools

Turbocharger Failure Analysis-4020T Only