John Deere PowerTech 4.5L & 6.8L Diesel Engines (Base Engine) Repair Technical Manual (CTM104)

Table of Content

Section 01—General Information
Group 000—Safety
Group 001—Engine Identification
Group 002—Fuels, Lubricants, and Coolant
Section 02A—Repair and Adjustments (4 Cylinder Engine)
Group 010—Engine Rebuild (4045)
Group 020—Cylinder Head and Valve Repair and Adjustment (4045) (Two-Valve Head Engines)
Group 021—Cylinder Head and Valve Repair and Adjustment (4045) (Four-Valve Head Engines)
Group 030—Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment (4045)
Group 040—Crankshaft, Main Bearings, and Flywheel Repair and Adjustment (4045)
Group 050—Camshaft, Balancing Shaft and Timing
Gear Train Repair and Adjustment (4045)
Group 060—Lubrication System Repair and Adjustment (4045)
Group 070—Cooling System Repair and Adjustment (4045)
Group 080—Air Intake and Exhaust System Repair and Adjustment (4045)
Group 081—Air Intake and Exhaust System Repair and Adjustment (Marine 4045)
Group 090—Electronic Fuel System Repair and Adjustment (4045)
Group 100—OEM Starting and Charging Systems Repair and Adjustment (4045)
Section 02B—Repair and Adjustments (6 Cylinder Engine)
Group 010—Engine Rebuild (6068)
Group 020—Cylinder Head and Valve Repair and Adjustment (6068) (Two-Valve Head Engines)
Group 021—Cylinder Head and Valve Repair and Adjustment (6068) (Four-Valve Head Engines)
Group 030—Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment (6068)
Group 040—Crankshaft, Main Bearings, and Flywheel Repair and Adjustment (6068)
Group 050—Camshaft and Timing Gear Train Repair and Adjustment (6068)
Group 060—Lubrication System Repair and Adjustment (6068)
Group 070—Cooling System Repair and Adjustment (6068)
Group 080—Air Intake and Exhaust System Repair and Adjustment (6068)
Group 081—Air Intake and Exhaust System Repair and Adjustment (Marine 6068)
Group 090—Electronic Fuel System Repair and Adjustment (6068)
Group 100—OEM Starting and Charging Systems Repair and Adjustment (6068)
Section 03—Base Engine Theory of Operation
Group 120—Base Engine Operation
Group 123—Cooling System
Group 126—Lubrication System
Group 130—Electronic Fuel System
Group 135—Air Intake and Exhaust System
Section 04—Diagnostics
Group 150—Observable Diagnostics and Tests
Section 05—Tools and Other Materials
Group 170—Special Tools
Group 180—Lubricants, Sealants, and Other Materials
Section 06—Specifications
Group 200—Repair and General OEM Specifications

This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
This manual covers the base engine for PowerTech 4.5L and 6.8L engines including PowerTech “Plus”, PowerTech “E”, and PowerTech “M” engine models. It is one of eight volumes on 4.5L and 6.8L engines. The following seven companion manuals cover fuel system and electronics repair, operation, and diagnostics:
• CTM207 — Mechanical Fuel System
• CTM284 — Level 1 Electronic Fuel System
• CTM170 — Level 4 Electronic Fuel System
• CTM220 — Level 11 Electronic Fuel System
• CTM331 — Level 12 Electronic Fuel System
• CTM320 — Level 14 Electronic Fuel System
• CTM502 — Level 16 Electronic Fuel System

Section of the Manual

Section 02a covers the repair and adjustment procedures for 4.5L engines.
Section 02b covers the repair and adjustment procedures for 6.8L engines.
Section 03 explains the theory of operation of each system.
Section 04 is the diagnostics section that provides troubleshooting procedures to find problems.
Section 05 covers other materials needed to do the job.
Section 06 summarizes all specifications, wear tolerances, and torque values.