John Deere Series 300 3179, 4239, 6359, 4276, 6414 Diesel Engine PDF

repair manuals John Deere Series 300 3179, 4239, 6359, 4276, 6414 Diesel Engine PDF
Type of catalogue: repair manuals
Make: John Deere
Region: WorldWide
Inclusive languages: English
Amount of disks: 547 pages
OS: Windows XP 32 bit, Windows 7 32 bit, Wnidows 7 64 bit, Windows 8/8.1 32 bit
Date:

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Product description

Repair Manual contains instructions on the body repair, wiring diagrams, service manuals, instruction manuals, instructions on diagnostics of all units of the diesel engines John Deere.
Online Repair Manual contains full information about electrical schematic, the moments of delays, the process of assembly and disassembly, management on repair, all electric components and control units.
Service Manual contains the detailed and full description of repair and diagnostics of all units engines John Deere.
Provided on the site repair documentation presented in PDF.
Workshop Manual is an important and indispensable source of information for services and service stations that are engaged in repair and service as well as their owners.


Contents:
Group 00—Safety
Group 01—General Information
Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
Metric Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
Engine Model Designation . . . . . . . . . . . . . . 01-3
Engine Serial Number Plate Information . . . . . 01-5
Engine Application Chart . . . . . . . . . . . . . . . 01-7
Group 02—Fuels, Lubricants, and Coolant
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . 02-1
Lubricity of Diesel Fuels . . . . . . . . . . . . . . . 02-1
Engine Break-In Oil . . . . . . . . . . . . . . . . . . 02-2
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . 02-3
OILSCAN® and COOLSCAN™ . . . . . . . . . . . 02-4
Alternative and Synthetic Lubricants . . . . . . . 02-4
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-5
Engine Coolant Requirements . . . . . . . . . . . 02-6
Recommended Engine Coolant . . . . . . . . . . . 02-7
Engine Coolant Specifications . . . . . . . . . . . 02-9
Replenishing Supplemental Coolant
Additives (SCA’s) . . . . . . . . . . . . . . . . . 02-11
Operating in Tropical Conditions . . . . . . . . . 02-12
Flush and Service Cooling System . . . . . . . 02-13
Disposing of Coolant . . . . . . . . . . . . . . . . 02-14
Group 03—Engine Mounting
Engine Repair Stand . . . . . . . . . . . . . . . . . 03-1
Safety Precautions . . . . . . . . . . . . . . . . . . . 03-2
Install 300 Series Adapters on Repair
Stand . . . . . . . . . . . . . . . . . . . . . . . . . . 03-3
Engine Lifting Procedure . . . . . . . . . . . . . . . 03-3
Clean Engine . . . . . . . . . . . . . . . . . . . . . . 03-4
Disconnect Turbocharger Oil Inlet Line . . . . . 03-4
Mount Engine on Repair Stand . . . . . . . . . . 03-5
Engine Mounted on Repair Stand . . . . . . . . . 03-6
Group 04—Engine Rebuild Guide
Engine Disassembly Sequence . . . . . . . . . . . 04-1
Sealant Application Guidelines . . . . . . . . . . . 04-2
Engine Assembly Sequence . . . . . . . . . . . . . 04-4
Group 05—Cylinder Head and Valves
Special or Essential Tools . . . . . . . . . . . . . . 05-1
Service Equipment and Tools . . . . . . . . . . . . 05-4
Specifications . . . . . . . . . . . . . . . . . . . . . . 05-5
Other Material . . . . . . . . . . . . . . . . . . . . . . 05-9
Check and Adjust Valve Clearance . . . . . . . 05-10
Measure Valve Lift . . . . . . . . . . . . . . . . . . 05-14
Remove Cylinder Head . . . . . . . . . . . . . . . 05-16
Disassemble and Inspect Rocker Arm
Shaft Assembly . . . . . . . . . . . . . . . . . . 05-19
Assemble Rocker Arms on Shaft . . . . . . . . 05-21
Clean and Inspect Push Rods . . . . . . . . . . 05-21
Make Preliminary Valve Checks . . . . . . . . . 05-22
Check Valve Recess in Cylinder Head . . . . . 05-23
Remove Valve Assembly . . . . . . . . . . . . . . 05-23
Inspect and Measure Valve Springs . . . . . . 05-24
Inspect Valve Rotators and Wear Caps . . . . 05-24
Clean Valves . . . . . . . . . . . . . . . . . . . . . . 05-25
Inspect and Measure Valves . . . . . . . . . . . 05-25
Grind Valves . . . . . . . . . . . . . . . . . . . . . . 05-26
Inspect and Clean Cylinder Head . . . . . . . . 05-27
Check Cylinder Head Flatness . . . . . . . . . . 05-27
Measure Cylinder Head Thickness . . . . . . . 05-28
Clean Injection Nozzle Bores . . . . . . . . . . . 05-28
Clean Valve Guides . . . . . . . . . . . . . . . . . 05-29
Measure Valve Guides . . . . . . . . . . . . . . . 05-29
Knurl Valve Guides . . . . . . . . . . . . . . . . . 05-30
Clean and Inspect Valve Seats . . . . . . . . . 05-30
Grind Valve Seats . . . . . . . . . . . . . . . . . . 05-31
Remove Valve Seat Inserts . . . . . . . . . . . . 05-33
Measure Valve Seat Bore in Cylinder
Head . . . . . . . . . . . . . . . . . . . . . . . . . 05-34
Install Valve Seat Inserts . . . . . . . . . . . . . . 05-35
Install Valves . . . . . . . . . . . . . . . . . . . . . . 05-35
Valve Stem Seals—General Information . . . . 05-36
Install Valve Stem O-Ring Seals . . . . . . . . . 05-36
Install Valve Stem Tower Seals . . . . . . . . . 05-37
Inspect and Clean Ventilator Outlet Hose . . . 05-38
Inspect and Clean Exhaust Manifold . . . . . . 05-39
Clean and Inspect Top Deck of Cylinder
Block . . . . . . . . . . . . . . . . . . . . . . . . . 05-39
Measure Cylinder Liner Standout (Height
Above Block) . . . . . . . . . . . . . . . . . . . . 05-40
Clean and Inspect Cylinder Head Cap
Screws . . . . . . . . . . . . . . . . . . . . . . . . 05-40
Install Cylinder Head . . . . . . . . . . . . . . . . 05-41
Install Cylinder Head Cap Screws . . . . . . . . 05-42
TORQUE-TURN Method for Proper Torque
Install Rocker Arm Assembly . . . . . . . . . . . 05-45
Install Rocker Arm Cover . . . . . . . . . . . . . 05-47
Complete Final Assembly . . . . . . . . . . . . . 05-48
Perform Engine Break-In . . . . . . . . . . . . . . 05-49
Group 10—Cylinder Block, Liners, Pistons, and Rods
Special or Essential Tools . . . . . . . . . . . . . . 10-1
Service Equipment and Tools . . . . . . . . . . . . 10-3
Other Material . . . . . . . . . . . . . . . . . . . . . . 10-3
Specifications . . . . . . . . . . . . . . . . . . . . . . 10-4
Remove Pistons and Connecting Rods . . . . . 10-8
Remove Cylinder Liners . . . . . . . . . . . . . . 10-11
Complete Disassembly of Cylinder Block (If Required)
Preliminary Liner, Piston and Rod Checks . . . 10-14
Disassemble Piston and Rod Assembly . . . . 10-15
Clean Pistons . . . . . . . . . . . . . . . . . . . . . 10-16
Visually Inspect Pistons . . . . . . . . . . . . . . . 10-17
Install Piston Pin . . . . . . . . . . . . . . . . . . . 10-18
Clean Cylinder Liners . . . . . . . . . . . . . . . . 10-19
Visually Inspect Cylinder Liners . . . . . . . . . 10-19
Check Piston Ring Groove Wear . . . . . . . . 10-20
Measure Piston Skirt . . . . . . . . . . . . . . . . 10-21
Determine Piston-to-Liner Clearance . . . . . . 10-22
Deglaze Cylinder Liners . . . . . . . . . . . . . . 10-23
Replace Piston and Liner Sets . . . . . . . . . . 10-24
Determine Piston Type . . . . . . . . . . . . . . . 10-25
Measure Piston Protrusion . . . . . . . . . . . . . 10-26
Inspect and Measure Connecting Rod
Bearings . . . . . . . . . . . . . . . . . . . . . . . 10-27
Inspect Rod and Cap . . . . . . . . . . . . . . . . 10-29
Inspect Piston Pins and Bushings . . . . . . . . 10-30
Remove Piston Pin Bushing . . . . . . . . . . . . 10-31
Clean and Inspect Connecting Rod Pin
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Install Piston Pin Bushing in Connecting
Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Inspect and Clean Cylinder Block . . . . . . . . 10-33
Clean Cylinder Liner O-Ring Bore . . . . . . . . 10-34
Measure Cylinder Block Main Bearing
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Measure Camshaft Follower Bore . . . . . . . . 10-35
Measure Camshaft Bearing Bore . . . . . . . . 10-35
Measure Balancer Shaft Bore—4-Cylinder
Engines . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Measure Cylinder Block Top Deck
Flatness . . . . . . . . . . . . . . . . . . . . . . . 10-37
Inspect Piston Cooling Orifices . . . . . . . . . . 10-38
Measure Liner Flange Thickness and
Block Counterbore Depth . . . . . . . . . . . . 10-38
Recheck Cylinder Liner Standout (Height
Above Block) . . . . . . . . . . . . . . . . . . . . 10-39
Install Steel Ball in Oil Passage of
Service Cylinder Block . . . . . . . . . . . . . . 10-41
Install Cylinder Liner O-Rings and
Packings . . . . . . . . . . . . . . . . . . . . . . . 10-42
Install Cylinder Liner . . . . . . . . . . . . . . . . . 10-43
Assemble Piston and Connecting Rod . . . . . 10-44
Install Piston Rings . . . . . . . . . . . . . . . . . 10-45
Install Piston and Connecting Rod
Assembly . . . . . . . . . . . . . . . . . . . . . . . 10-46
Check Engine Rotation For Excessive
Tightness . . . . . . . . . . . . . . . . . . . . . . . 10-48
Measure Piston Protrusion . . . . . . . . . . . . . 10-49
Complete Final Assembly . . . . . . . . . . . . . 10-49
Group 15—Crankshaft, Main Bearings, and
Flywheel
Special or Essential Tools . . . . . . . . . . . . . . 15-1
Service Equipment and Tools . . . . . . . . . . . . 15-4
Specifications . . . . . . . . . . . . . . . . . . . . . . 15-5
Other Material . . . . . . . . . . . . . . . . . . . . . . 15-8
Crankshaft and Main Bearing Failure
Analysis . . . . . . . . . . . . . . . . . . . . . . . . 15-9
Inspect Vibration Damper (6-Cylinder
Engine) . . . . . . . . . . . . . . . . . . . . . . . . 15-10
Remove Pulley or Vibration Damper
Pulley . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
Install Pulley or Vibration Damper Pulley . . . 15-12
Checking Vibration Damper or Pulley
(Front PTO) . . . . . . . . . . . . . . . . . . . . . 15-13
Removing Vibration Damper or Pulley
(Front PTO) . . . . . . . . . . . . . . . . . . . . . 15-14
Install Vibration Damper or Pulley (Front
PTO) . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
Replace Front Crankshaft Oil Seal
(Without Removing Cover) . . . . . . . . . . . 15-16
Check Crankshaft End Play . . . . . . . . . . . . 15-19
Inspect Flywheel . . . . . . . . . . . . . . . . . . . 15-20
Check Flywheel Housing Face Runout . . . . . 15-20
Check Flywheel Face Flatness . . . . . . . . . . 15-21
Remove Flywheel . . . . . . . . . . . . . . . . . . 15-21
Replace Flywheel Ring Gear . . . . . . . . . . . 15-22
Install Flywheel . . . . . . . . . . . . . . . . . . . . 15-23
Crankshaft Rear Oil Seal and Wear
Sleeve General Information . . . . . . . . . . . 15-24
Remove Two-Piece Crankshaft Oil Seal
and Wear Sleeve . . . . . . . . . . . . . . . . . 15-24
Remove Unitized Crankshaft Rear Oil
Seal and Wear Sleeve . . . . . . . . . . . . . . 15-27
Install Crankshaft Rear Oil Seal and
Wear Sleeve . . . . . . . . . . . . . . . . . . . . 15-28
Remove Flywheel Housing . . . . . . . . . . . . 15-30
Remove Crankshaft Main Bearings . . . . . . . 15-30
Check Main Bearing Clearance . . . . . . . . . 15-31
Remove and Install Crankshaft Gear with
Crankshaft Installed . . . . . . . . . . . . . . . . 15-32
Remove Crankshaft . . . . . . . . . . . . . . . . . 15-33
Remove Crankshaft Rear Wear Sleeve
with Crankshaft Removed . . . . . . . . . . . . 15-34
Inspect Crankshaft . . . . . . . . . . . . . . . . . . 15-35
Measure Assembled ID of Bearings and
OD of Crankshaft Journal . . . . . . . . . . . . 15-36
Measure Main Thrust Journal Width and
Thrust Bearing Width . . . . . . . . . . . . . . . 15-37
Crankshaft Grinding Guidelines . . . . . . . . . . 15-38
Crankshaft Grinding Specifications . . . . . . . 15-40
Measure Assembled ID of Main Bearing
Caps . . . . . . . . . . . . . . . . . . . . . . . . . 15-40
Inspect Piston Cooling Orifices . . . . . . . . . . 15-42
Install Main and Thrust Bearing Inserts in
Block . . . . . . . . . . . . . . . . . . . . . . . . . 15-43
Install Crankshaft . . . . . . . . . . . . . . . . . . . 15-44
Install Flywheel Housing . . . . . . . . . . . . . . 15-46
Complete Final Assembly . . . . . . . . . . . . . 15-48
Group 16—Camshaft, Balancer Shafts, and
Timing Gear Train
Special or Essential Tools . . . . . . . . . . . . . . 16-1
Service Equipment and Tools . . . . . . . . . . . . 16-3
Other Materials . . . . . . . . . . . . . . . . . . . . . 16-3
Specifications . . . . . . . . . . . . . . . . . . . . . . 16-4
Auxiliary Gear Drive Specifications . . . . . . . 16-10
Measure Valve Lift . . . . . . . . . . . . . . . . . . 16-11
Page
Remove Timing Gear Cover . . . . . . . . . . . 16-13
Remove Auxiliary Drive Gears . . . . . . . . . . 16-14
Measure Camshaft End Play . . . . . . . . . . . 16-14
Measure Balancer Shaft End
Play—4-Cylinder Engines . . . . . . . . . . . . 16-15
Measure Timing Gear Backlash . . . . . . . . . 16-16
Measure Idler Gear End Play . . . . . . . . . . . 16-17
Remove Camshaft . . . . . . . . . . . . . . . . . . 16-17
Visually Inspect Camshaft . . . . . . . . . . . . . 16-18
Measure Camshaft Thrust Plate
Clearance . . . . . . . . . . . . . . . . . . . . . . 16-19
Inspect and Measure Camshaft Bearing
Bore ID and Journal OD . . . . . . . . . . . . 16-19
Measure Camshaft Lobe Height . . . . . . . . . 16-20
Remove and Install Camshaft Gear . . . . . . . 16-20
Inspect Camshaft Followers . . . . . . . . . . . . 16-21
Replace Tachometer Drive Gear . . . . . . . . . 16-22
Remove Balancer Shafts—If Equipped
(4-Cylinder Engines) . . . . . . . . . . . . . . . 16-23
Inspect and Measure Balancer Shaft
Bushings and Journals . . . . . . . . . . . . . . 16-24
Remove and Install Balancer Shaft
Bushings in Block . . . . . . . . . . . . . . . . . 16-25
Install Oversize Balancer Shaft Bushings
in Block—4239 Engines . . . . . . . . . . . . . 16-26
Inspect Balancer Shaft Gears and Thrust
Plates . . . . . . . . . . . . . . . . . . . . . . . . . 16-27
Remove and Install Balancer Shaft Gears . . . 16-28
Remove Balancer Shaft . . . . . . . . . . . . . . 16-29
Remove Cylinder Block Front Plate . . . . . . . 16-29
Measure Idler Gear Bushing and Shaft . . . . 16-31
Remove and Install Idler Gear Bushings . . . 16-31
Remove Lower and Upper Idler Shafts . . . . 16-32
Clean and Inspect Front Plate . . . . . . . . . . 16-33
Replace Engine Front Plate . . . . . . . . . . . . 16-34
Transfer Fuel Injection Pump Timing
Mark Onto Replacement Front Plate . . . . . 16-35
Install Idler Shaft Spring Pins . . . . . . . . . . . 16-35
Install Upper Idler Shaft in Front Plate . . . . . 16-36
Install Lower Idler Shaft in Front Plate . . . . . 16-36
Install Engine Front Plate . . . . . . . . . . . . . 16-38
Install and Time Balancer Shafts—If
Equipped (4-Cylinder Engines) . . . . . . . . 16-39
Install and Time Camshaft and Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . 16-42
Clean and Inspect Timing Gear Cover . . . . . 16-44
Install Ball Bearings and Dowels . . . . . . . . . 16-44
Install Drive Gear . . . . . . . . . . . . . . . . . . . 16-45
Install Timing Gear Cover . . . . . . . . . . . . . 16-46
Install Crankshaft Front Oil Seal . . . . . . . . . 16-49
Install Idler Gear and Output Gear . . . . . . . 16-50
Complete Final Assembly . . . . . . . . . . . . . 16-51
Group 20—Lubrication System
Special or Essential Tools . . . . . . . . . . . . . . 20-1
Service Equipment and Tools . . . . . . . . . . . . 20-2
Other Material . . . . . . . . . . . . . . . . . . . . . . 20-2
Specifications . . . . . . . . . . . . . . . . . . . . . . 20-3
Engine Crankcase Oil Fill Quantities . . . . . . . 20-6
Identify Oil Cooler Type—3179, 4239,
6359 Engines . . . . . . . . . . . . . . . . . . . . 20-14
Remove, Inspect, & Install Standard-Flow
Oil Cooler (3179, 4239, 6359) . . . . . . . . . 20-14
Remove and Install High-Flow Oil Cooler
(6359 Engines) . . . . . . . . . . . . . . . . . . . 20-15
Remove Distributor Base—High-Flow
Cooler (6359) . . . . . . . . . . . . . . . . . . . . 20-16
Inspect and Repair Distributor
Base—High Flow Oil Cooler (6359) . . . . . 20-16
Install Distributor Base—High-Flow Oil
Cooler (6359) . . . . . . . . . . . . . . . . . . . . 20-17
Remove Oil Cooler (4276, 6414 Engines) . . . 20-17
Repair Oil Cooler (4276, 6414 Engines) . . . . 20-17
Install Oil Cooler (4276, 6414 Engines) . . . . 20-18
Remove and Inspect Oil Bypass Valve
(3179, 4239, 6359 Engines) . . . . . . . . . . 20-19
Measure Oil Bypass Valve Length and
Cylinder Block Bore . . . . . . . . . . . . . . . . 20-20
Install Oil Bypass Valve (3179, 4239,
6359 Engines) . . . . . . . . . . . . . . . . . . . 20-20
Remove and Install Oil Cooler/Filter
Bypass Valve (4276, 6414 Engines) . . . . . 20-21
Remove & Install Oil Pressure Regulating
Valve/Seat (3179, 4239, 6359) . . . . . . . . 20-21
Remove, Inspect and Install Oil Pressure
Regulating Valve (4276, 6414) . . . . . . . . 20-22
Repair Oil Pressure Regulating Valve
(4276, 6414 Engines) . . . . . . . . . . . . . . 20-23
Remove Oil Filter Adapter (3179, 4239,
6359 Engines) . . . . . . . . . . . . . . . . . . . 20-24
Install Oil Filter Adapter (3179, 4239,
6359 Engines) . . . . . . . . . . . . . . . . . . . 20-25
Remove, Install, and Adjust Dipstick Tube . . . 20-26
General Oil Pump Information . . . . . . . . . . 20-26
Replace Oil Pump Pick-Up Tube
Assembly . . . . . . . . . . . . . . . . . . . . . . . 20-27
Remove Standard Capacity Oil Pump . . . . . 20-27
Inspect and Measure Clearances
(Standard Capacity Oil Pump) . . . . . . . . . 20-28
Page
Complete Standard Capacity Oil Pump
Disassembly . . . . . . . . . . . . . . . . . . . . . 20-29
Assemble Standard Capacity Oil Pump . . . . 20-30
Install Standard Capacity Oil Pump . . . . . . . 20-31
Remove High Capacity Oil Pump . . . . . . . . 20-33
Inspect and Measure Clearances (High
Capacity Oil Pump) . . . . . . . . . . . . . . . . 20-34
Complete High Capacity Oil Pump
Disassembly . . . . . . . . . . . . . . . . . . . . . 20-35
Assemble High Capacity Oil Pump . . . . . . . 20-36
Install High Capacity Oil Pump . . . . . . . . . . 20-36
Install Oil Pan . . . . . . . . . . . . . . . . . . . . . 20-38
Group 25—Cooling System
Special or Essential Tools . . . . . . . . . . . . . . 25-1
Service Equipment and Tools . . . . . . . . . . . . 25-1
Other Material . . . . . . . . . . . . . . . . . . . . . . 25-2
Specifications . . . . . . . . . . . . . . . . . . . . . . 25-3
Remove, Test, and Install Thermostats . . . . 25-10
Remove and Install Thermostat
Housing/Water Manifold . . . . . . . . . . . . . 25-11
General Water Pump Information . . . . . . . . 25-13
Remove Low Flow (Standard Duty) Water
Pump . . . . . . . . . . . . . . . . . . . . . . . . . 25-14
Disassemble Low Flow (Standard Duty)
Water Pump . . . . . . . . . . . . . . . . . . . . . 25-15
Inspect and Clean Low Flow (Standard
Duty) Water Pump Parts . . . . . . . . . . . . 25-17
Assemble Low Flow (Standard Duty)
Water Pump . . . . . . . . . . . . . . . . . . . . . 25-18
Install Low Flow (Standard Duty) Water
Pump . . . . . . . . . . . . . . . . . . . . . . . . . 25-21
Remove High Flow (Heavy-Duty) Water
Pump . . . . . . . . . . . . . . . . . . . . . . . . . 25-22
Disassemble High Flow (Heavy-Duty)
Water Pump . . . . . . . . . . . . . . . . . . . . . 25-22
Inspect and Clean High Flow
(Heavy-Duty) Water Pump Parts . . . . . . . 25-26
Assemble High Flow (Heavy-Duty) Water
Pump . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
Checking Water Pump Cap Screw
Protrusion . . . . . . . . . . . . . . . . . . . . . . 25-31
Install High Flow (Heavy-Duty) Water
Pump . . . . . . . . . . . . . . . . . . . . . . . . . 25-33
Inspect and Install Fan Blade Assembly . . . . 25-34
Remove Coolant Heater—If Equipped . . . . . 25-34
Install Coolant Heater—If Equipped . . . . . . . 25-35
Group 30—Air Intake and Exhaust System
Other Material . . . . . . . . . . . . . . . . . . . . . . 30-1
Specifications . . . . . . . . . . . . . . . . . . . . . . 30-1
Extending Turbocharger Life . . . . . . . . . . . . 30-3
Remove Turbocharger—4239T and
6359T & A Engines . . . . . . . . . . . . . . . . . 30-5
Turbocharger Failure Analysis . . . . . . . . . . . 30-7
Turbocharger Seven-Step Inspection . . . . . . . 30-9
Perform Radial Bearing Clearance
Test—K.K.K. . . . . . . . . . . . . . . . . . . . . 30-13
Perform Axial Bearing End Play
Test—K.K.K. . . . . . . . . . . . . . . . . . . . . 30-14
Perform Radial Bearing Clearance
Test—AiResearch/Garrett . . . . . . . . . . . . 30-14
Perform Axial Bearing End Play
Test—AiResearch/Garrett . . . . . . . . . . . . 30-15
Repair Turbocharger . . . . . . . . . . . . . . . . . 30-16
Disassemble and Inspect Turbocharger . . . . 30-17
Replace Center Housing and Rotating
Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-18
Prelube Turbocharger . . . . . . . . . . . . . . . . 30-19
Install K.K.K. and AiResearch/Garrett
Turbocharger . . . . . . . . . . . . . . . . . . . . 30-19
Turbocharger Break-In . . . . . . . . . . . . . . . 30-21
Remove, Inspect, and Install Intake
Manifold . . . . . . . . . . . . . . . . . . . . . . . 30-22
Remove Cross-Over Tube Assembly—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . 30-23
Inspect and Repair Cross-Over Tube
Assembly—If Equipped . . . . . . . . . . . . . 30-23
Install Cross-Over Tube Assembly—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . 30-24
Remove Aftercooler and Intake Manifold
(6359A) . . . . . . . . . . . . . . . . . . . . . . . . 30-25
Inspect and Repair Aftercooler (6359A) . . . . 30-26
Inspect and Repair Intake Manifold
(6359A) . . . . . . . . . . . . . . . . . . . . . . . . 30-26
Install Intake Manifold and Aftercooler
(6359A) . . . . . . . . . . . . . . . . . . . . . . . . 30-27
Remove, Inspect, and Install Exhaust
Manifold . . . . . . . . . . . . . . . . . . . . . . . 30-28
Group 35—Fuel System
Special or Essential Tools . . . . . . . . . . . . . . 35-1
Service Equipment and Tools . . . . . . . . . . . . 35-3
Other Material . . . . . . . . . . . . . . . . . . . . . . 35-4
Specifications . . . . . . . . . . . . . . . . . . . . . . 35-5
Relieve Fuel System Pressure . . . . . . . . . . . 35-8
Replace Fuel Filter . . . . . . . . . . . . . . . . . . . 35-9
Remove Fuel Supply Pump . . . . . . . . . . . . 35-10
Bench Test Fuel Supply Pump . . . . . . . . . . 35-11
Page
Repair Sofabex and AC Fuel Supply
Pumps . . . . . . . . . . . . . . . . . . . . . . . . 35-13
Repair Corona Fuel Supply Pump . . . . . . . . 35-13
Install Fuel Supply Pump . . . . . . . . . . . . . . 35-15
Fuel Injection Pump Timing . . . . . . . . . . . . 35-15
Fuel Injection Pump—General Information . . . 35-16
Remove Roto Diesel/Lucas CAV Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . 35-17
Repair Roto Diesel/Lucas CAV Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . 35-20
Install Roto Diesel/Lucas CAV Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . 35-21
Timing Roto Diesel/Lucas CAV Injection
Pump (Front Plate Installed) . . . . . . . . . . 35-24
Remove Stanadyne Pump—Model JDB &
DB2 (Non-Retained Drive Shaft) . . . . . . . 35-27
Remove Stanadyne Model JDB & DB2
Pump with Non-Retained Drive Shaft . . . . 35-28
Repair Stanadyne Model JDB and DB2
Fuel Injection Pump . . . . . . . . . . . . . . . . 35-30
Install Non-Retained Drive Shaft in
Stanadyne Model JDB & DB2 Pump . . . . 35-30
Install Stanadyne Model JDB & DB2
Pump with Non-Retained Drive Shaft . . . . 35-31
Remove Stanadyne Model DB2 (Retained
Drive Shaft) & DB4 Injection Pump . . . . . 35-34
Inspect Injection Pump Drive Gear I.D.
and Shaft O.D. . . . . . . . . . . . . . . . . . . . 35-38
Repair Stanadyne Fuel Injection Pump . . . . 35-38
Install Stanadyne Model DB2 (Retained
Drive Shaft) and DB4 Pump . . . . . . . . . . 35-39
Remove Stanadyne Model DM4 Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . 35-42
Repair Stanadyne Fuel Injection Pump . . . . 35-43
Install Stanadyne Model DM4 Fuel
Injection Pump . . . . . . . . . . . . . . . . . . . 35-44
Replace Engine Front Plate . . . . . . . . . . . . 35-46
Transfer Fuel Injection Pump Timing
Mark onto Replacement Front Plate . . . . . 35-47
Aneroid Replacement . . . . . . . . . . . . . . . . 35-48
Aneroid Field Adjustment . . . . . . . . . . . . . . 35-48
Aneroid Workshop Adjustment . . . . . . . . . . 35-49
Remove Fuel Injection Nozzles . . . . . . . . . 35-50
Clean Fuel Injection Nozzle Bore . . . . . . . . 35-51
Clean Injection Nozzles . . . . . . . . . . . . . . . 35-52
Diagnose Injection Nozzle Malfunction . . . . . 35-53
Test Injection Nozzles . . . . . . . . . . . . . . . . 35-55
Disassemble Injection Nozzles . . . . . . . . . . 35-58
Inspect and Clean Nozzle Body . . . . . . . . . 35-59
Inspect and Clean Valve and Valve Seat . . . 35-60
Inspect Valve Adjusting Mechanism . . . . . . . 35-62
Assemble Injection Nozzles . . . . . . . . . . . . 35-63
Adjust Fuel Injection Nozzles . . . . . . . . . . . 35-63
Install Seals on Injection Nozzle . . . . . . . . . 35-66
Install Injection Nozzles . . . . . . . . . . . . . . . 35-66
Repair Leak-Off Line Assembly . . . . . . . . . 35-67
Group 100—Engine Tune-Up and Break-In
Special or Essential Tools . . . . . . . . . . . . . 100-1
Effects of Altitude and Temperature on
Engine Performance . . . . . . . . . . . . . . . 100-1
Preliminary Engine Testing . . . . . . . . . . . . 100-2
General Tune-Up Recommendations . . . . . . 100-3
Dynamometer Test . . . . . . . . . . . . . . . . . . 100-4
Dynamometer Test Specifications . . . . . . . . 100-5
Engine Break-In Guidelines . . . . . . . . . . . . 100-9
Perform Engine Break-In . . . . . . . . . . . . . 100-10
Check Crankcase Ventilation System . . . . . 100-11
Check Air Intake System . . . . . . . . . . . . . 100-11
Check Exhaust System . . . . . . . . . . . . . . 100-11
Check and Service Cooling System . . . . . . 100-12
Check Electrical System . . . . . . . . . . . . . 100-13
Group 105—Engine System Operation and Tests
Special or Essential Tools . . . . . . . . . . . . . 105-1
Engine Test Specifications . . . . . . . . . . . . . 105-3
Engine—Sectional View . . . . . . . . . . . . . . 105-4
General Engine Description . . . . . . . . . . . . 105-5
How the Lubrication System
Works—4239T Shown . . . . . . . . . . . . . . 105-6
Oil Cooler Operation—4276 and 6414
Engines . . . . . . . . . . . . . . . . . . . . . . . . 105-8
How the Cooling System
Works—Standard Flow Oil Cooler . . . . . . 105-9
How the Cooling System
Works—High-Flow Oil Cooler . . . . . . . . 105-10
How the Crankshaft Gear-Drive Auxiliary
Drive Works . . . . . . . . . . . . . . . . . . . . 105-11
Head Gasket Joint Construction and
Operation . . . . . . . . . . . . . . . . . . . . . 105-13
Diagnosing Head Gasket Joint Failures . . . 105-14
Head Gasket Inspection and Repair
Sequence . . . . . . . . . . . . . . . . . . . . . 105-17
Diagnosing Engine Malfunctions . . . . . . . . 105-19
Test Engine Compression Pressure . . . . . . 105-22
Check Engine Oil Pressure . . . . . . . . . . . 105-23
Measure Engine Crankcase Pressure
(Blow-By) . . . . . . . . . . . . . . . . . . . . . . 105-24
Page
Pressure Test Cooling System and
Radiator Cap . . . . . . . . . . . . . . . . . . . 105-25
Inspect Thermostat and Test Opening
Temperature . . . . . . . . . . . . . . . . . . . 105-26
Group 110—Air Intake System Operation and
Tests
Special or Essential Tools . . . . . . . . . . . . . 110-1
Service Equipment and Tools . . . . . . . . . . . 110-1
Test Specifications . . . . . . . . . . . . . . . . . . 110-2
Diagnosing Air Intake Malfunctions . . . . . . . 110-3
How the Air Intake and Exhaust System
Works . . . . . . . . . . . . . . . . . . . . . . . . . 110-4
Air Cleaner Operation . . . . . . . . . . . . . . . . 110-5
Diagnosing Turbocharger Malfunctions . . . . . 110-6
How the Turbocharger is Lubricated . . . . . . 110-7
Turbocharger Operation . . . . . . . . . . . . . . 110-7
How the Aftercooler Works . . . . . . . . . . . . 110-8
Check Intake Manifold Pressure (Turbo
Boost) . . . . . . . . . . . . . . . . . . . . . . . . . 110-9
Air Filter Restriction Indicator Switch Test . . 110-10
Group 115—Fuel System Operation and Tests
Special or Essential Tools . . . . . . . . . . . . . 115-1
Service Equipment and Tools . . . . . . . . . . . 115-2
Fuel System Test Specifications . . . . . . . . . 115-3
Saran Fuel Injection Pump Specifications . . . 115-4
Dubuque Fuel Injection Pump
Specifications . . . . . . . . . . . . . . . . . . . . 115-7
Fuel Injection Pump Timing . . . . . . . . . . . . 115-9
Check and Adjust Injection Pump
Dynamic Timing . . . . . . . . . . . . . . . . . . 115-9
Check Roto Diesel/Lucas CAV Injection
Pump Static Timing . . . . . . . . . . . . . . . 115-17
Check Stanadyne DB2 Pump Static
Timing . . . . . . . . . . . . . . . . . . . . . . . . 115-20
Check Stanadyne JDB Injection Pump
Static Timing . . . . . . . . . . . . . . . . . . . 115-21
Check Stanadyne DM4 Injection Pump
Static Timing . . . . . . . . . . . . . . . . . . . 115-22
Fuel System Operation . . . . . . . . . . . . . . 115-24
Diagnose Fuel System Malfunctions . . . . . 115-25
Fuel Supply Pump Operation—If
Equipped . . . . . . . . . . . . . . . . . . . . . . 115-29
Diagnose Supply Pump Malfunction . . . . . 115-30
Measure Fuel Supply Pump Pressure—If
Equipped . . . . . . . . . . . . . . . . . . . . . . 115-31
Rectangular Final Fuel Filter Operation . . . 115-32
Bleed the Fuel System . . . . . . . . . . . . . . 115-33
Roto Diesel/Lucas CAV Fuel Injection Pump
Operation . . . . . . . . . . . . . . . . . . . . . 115-36
Stanadyne DM4 Fuel Injection Pump
Operation . . . . . . . . . . . . . . . . . . . . . 115-38
Stanadyne DB2/DB4 Fuel Injection Pump
Operation . . . . . . . . . . . . . . . . . . . . . 115-40
Diagnose Fuel Injection Pump
Malfunctions . . . . . . . . . . . . . . . . . . . . 115-42
Check and Adjust Engine Speeds on
Lucas CAV Pump . . . . . . . . . . . . . . . . 115-43
Adjust Variable Speed on Generator Set
Engines (Lucas CAV) . . . . . . . . . . . . . 115-44
Check and Adjust Engine Speeds on
Stanadyne Pump . . . . . . . . . . . . . . . . 115-45
Adjust Variable Speed on Generator Set
Engines—Stanadyne . . . . . . . . . . . . . . 115-46
Changing Gen Set Engine Rated
Speed—Stanadyne . . . . . . . . . . . . . . . 115-47
Fuel Injection Nozzles—General
Information/Operation . . . . . . . . . . . . . . 115-49
Diagnose Malfunction—Fuel Injection
Nozzle . . . . . . . . . . . . . . . . . . . . . . . 115-50
Test Fuel Injection Nozzles (Engine
Running) . . . . . . . . . . . . . . . . . . . . . . 115-51
Fuel Drain Back Test Procedure . . . . . . . . 115-51
Group 199—Dealer Fabricated Tools
How to Make Tools . . . . . . . . . . . . . . . . . 199-1
DFRG2—Injection Pump Front Plate
Timing Mark Transfer Tool . . . . . . . . . . . 199-1
DFRG3—Cylinder Liner Holding Fixture . . . . 199-2

The electronic product "John Deere Series 300 3179, 4239, 6359, 4276, 6414 Diesel Engine PDF" is dealer's software which contains full detailed information.

We have the catalog "John Deere Series 300 3179, 4239, 6359, 4276, 6414 Diesel Engine PDF" in stock and it is possible to order and buy it now. After you receive the software, we will send all instructions needed to install and provide the after-sale support.


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