John Deere PowerTech™ 2.9 L Diesel Engines Index:

• Contents
  • General Information
    • Safety
      • Handle Fluids Safely—Avoid Fires
      • Avoid Static Electricity Risk When Refueling
      • Prevent Battery Explosions
      • Prepare for Emergencies
      • Prevent Acid Burns
      • Avoid High-Pressure Fluids
      • Wear Protective Clothing
      • Service Machines Safely
      • Work In Ventilated Area
      • Work in Clean Area
      • Remove Paint Before Welding or Heating
      • Avoid Heating Near Pressurized Fluid Lines
      • Illuminate Work Area Safely
      • Use Proper Lifting Equipment
      • Practice Safe Maintenance
      • Use Proper Tools
      • Dispose of Waste Properly
      • Live With Safety
    • Engine Identification Information
      • Engine Identification
      • OEM Engine Option Code Label
      • Emission Certified Engine Label
      • Engine References
      • Basic Engine Specifications
      • Longitudinal Cut-Away
      • Transversal Cutaway
      • General Engine Description
      • Diesel Fuel
      • Diesel Fuel Additive Products
      • BioDiesel Fuel
      • Handling and Storing Diesel Fuel
      • Oil Information for Non-certified, Tier 1 or Trem 3 Engines (see application list)
      • Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I
      • Extended Diesel Engine Oil Service Intervals — Non-Emissions Certified and Certified Tier 1 and Stage I
      • Oil Information for Tier 2 Engines (see application list)
      • Diesel Engine Oil — Tier 2 and Stage II
      • Diesel Engine Oil and Filter Service Intervals
      • Oil Information for Tier 3 Engines (see application list)
      • Diesel Engine Oil — Tier 3 and Stage III
      • Diesel Engine Oil and Filter Service Intervals
      • Oil Information for Interim Tier 4 Engines (see application list)
      • Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV
      • Diesel Engine Oil and Filter Service Intervals
      • Lubricant Storage
      • Mixing of Lubricants
      • Diesel Engine Coolant (engine with wet sleeve cylinder liners)
      • Drain Intervals for Diesel Engine Coolant
      • Operating in Warm Temperature Climates
      • Metric Bolt and Screw Torque Values
      • Unified Inch Bolt and Screw Torque Values
    • Engine Mounting
      • Clean Engine
      • Engine Lifting Procedure
      • Engine Repair Stand
      • Mounting Engine on Repair Stand
    • Engine Rebuilt Guide
      • Engine Disassembly Sequence
      • Sealant Application Guidelines
      • Engine Re-Assembly Sequence
      • Engine break-in guidelines
      • Perform engine break-in
      • Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
  • Repair and Adjustments
    • Cylinder Head and Valves
      • Cylinder Head – Exploded View
      • Check Valve Lift
      • Remove Cylinder Head
      • Clean Injection Nozzle Bores
      • Valve Actuating Parts
      • Remove Valves and Valve Springs
      • Checking Cylinder Head Flatness
      • Clean Valve Guides
      • Measure Valve Guides
      • Knurl Valve Guides
      • Clean and Inspect Valve Seats
      • Lapping Valve Seats
      • Check Valve Recess
      • Remove Valve Seat Inserts
      • Valve Seat Insert Installation
      • Check Valves
      • Grind Valves
      • Check Valve Spring Compression
      • Inspect Valve Rotators
      • Install Valves
      • Install Cylinder Head
      • Torque Turn Tightening Method
      • Disassembling and Checking Rocker Arm Shaft
      • Reassembling Rocker Arm Shaft
      • Install Rocker Arm Assembly
      • Valve Clearance
      • Valve Adjustment Sequence
      • Install Rocker Arm Cover
      • Final Work
    • Cylinder Block, Liners, Pistons and Rods
      • Exploded View
      • Connecting Rods – General Information
      • Remove Pistons and Connecting Rods
      • Measure Cylinder Liner Bore
      • Remove Cylinder Liners
      • Cylinder Liner Deglazing
      • Cylinder Block Cleaning
      • Check Piston Cooling Jets
      • Cam Follower Bore Measure
      • Measure Camshaft Bore
      • Remove Camshaft Bushing
      • Install Camshaft Bushing
      • Measure Crankshaft Bore
      • Replace Crankshaft Bearing Caps
      • Cylinder Block Top Desk Flatness
      • Measure Cylinder Liner Protrusion
      • Liner Packing Installation
      • Liner O-Ring Installation
      • Install Cylinder Liners
      • Measure Connecting Rod Bearing
      • Rod Bearing Clearance
      • Measure Connecting Rod Bushing
      • Replace Connecting Rod Bushing (Straight Pin-End)
      • Replace Connecting Rod Bushing (Tapered Pin-End)
      • Measure Piston Pin
      • Clean and Inspect Pistons
      • Measure Piston Pin Bore
      • Piston Top Ring Groove
      • Second and Third Piston Ring Grooves
      • Piston Head and Skirt Checking
      • Install Piston Rings
      • Piston Rings Staggering
      • Piston/Liner Set Information
      • Assemble Piston and Connecting Rod
      • Install Piston and Connecting Rod
      • Measure Piston Protrusion
      • Complete Final Assembly
    • Crankshaft, Main Bearings and Flywheel
      • Remove Crankshaft Pulley
      • Install Crankshaft Pulley
      • Check Pulley Wobble (Engine With Front PTO)
      • Remove PTO Pulley
      • Install PTO Pulley
      • Flywheel Removal
      • Flywheel Ring Gear Replacement
      • Install Ball Bearing
      • Install Flywheel
      • Remove Crankshaft Rear Oil Seal
      • Flywheel Housing Replacement
      • Install Oil Seal/Wear Sleeve
      • Crankshaft End Play Measure
      • Remove Crankshaft
      • Crankshaft Inspection
      • Crankshaft Identification
      • Check Crankshaft Journal Diameter
      • Determine Crankshaft Main Bearing Clearance Using PLASTIGAGEPLASTIGAGE is a trademark of DANA Corp.®
      • Regrind Crankshaft
      • Crankshaft Regrinding Guidelines
      • Micro-Finishing Specifications
      • Replace Crankshaft Gear
      • Install Main Bearing Inserts
      • Install 2-Piece Thrust Bearing
      • Install 6-Piece Thrust Bearing
      • Crankshaft Installation
    • Camshaft and Timing Gear Train
      • Remove Crankshaft Front Oil Seal
      • Remove Timing Gear Cover
      • Measure Timing Gear Backlash
      • Camshaft End Play Measure
      • Remove Camshaft
      • Measure Camshaft Journal
      • Measure Height of Cam Lobe
      • Replace Camshaft Gear
      • Tachometer Pick-Up Pin Removal
      • Install Camshaft
      • Check Cam Follower
      • Idler Gear End Play Measure
      • Remove Front Plate
      • Idler Gear Bushing and Shaft Measure
      • Idler Gear Bushing Replacement
      • Remove Idler Shaft
      • Install Idler Shaft Spring Pin
      • Install Idler Shafts
      • Front Plate Gasket
      • Install Front Plate
      • Install Upper Timing Gear Train
      • Install Lower Timing Gear Train
      • Install Oil Deflector
      • Timing Gear Cover Identification
      • Install Timing Gear Cover
      • Install Crankshaft Front Oil Seal
      • Install Wear Ring
      • Install Auxiliary Equipment
    • Lubrication System
      • Oil Cooler Identification
      • Remove Oil Cooler
      • Replace Oil Cooler Nipple
      • Install Oil Cooler on Standard Engine
      • Replace Oil Cooler/Filter Bracket on Engine with Auxiliary Drive
      • Replace Oil Filter Adapter on Engine with Remote Oil Filter
      • Remove Oil Pressure Regulating Valve
      • Replace Oil Pressure Regulating Valve Seat
      • Install Oil Pressure Regulating Valve
      • Replace Oil Dipstick Guide
      • Replace Oil By-Pass Valve
      • Oil Pump – Exploded View
      • Replace Oil Pump Strainer
      • Remove Oil Pump
      • Oil Pump Gear Axial Clearance
      • Oil Pump Gear Radial Clearance
      • Oil Pump Specifications
      • Oil Pump Installation
      • Install Oil Pan
    • Cooling System
      • Water Pump — Exploded View
      • Remove Water Pump
      • Disassemble Water Pump
      • Assemble Water Pump
      • Install Water Pump
      • Inspect Thermostat
      • Cold Start Advance Switch
      • Cooling System Deaeration
      • Check Fan/Alternator Belt Tension
      • Install Fan
      • Coolant Heater
      • Radiator Exploded View (Typical Installation)
    • Air Intake and Exhaust System
      • Check Air Inlet Pipe
      • Exhaust Manifold Inspection
      • Turbocharger Failure Analysis
      • Remove Turbocharger
      • Turbocharger Cut-Away View (Borg-Warner/Schwitzer)
      • Check Radial Clearance
      • Check Axial Clearance
      • Repair Turbocharger
      • Prelube Turbocharger
      • Install Turbocharger
      • Turbocharger Break-In
      • Recommendations for Turbocharger Use
      • Remove and Install Air Heater Glow Plug
      • Air Filter Exploded View
    • Fuel System
      • Replace Fuel Filter Element (Rotary Fuel Injection Pump)
      • Replace Fuel Filter Assembly (Rotary Fuel Injection Pump)
      • Replace Fuel Filter Assembly (MICO – BOSCH in-Line Injection Pump)
      • Replace Fuel Filter Element (MICO – BOSCH in-Line Injection Pump)
      • Replace Fuel Supply Pump (Rotary Fuel Injection Pump)
      • STANADYNE Rotary Fuel Injection Pump Identification
      • Remove STANADYNE models DB2 or DB4 Fuel Injection Pump (Without Lock Shaft Timing)
      • Remove STANADYNE Model DB4 Fuel Injection Pump (with Lock Shaft Timing)
      • Inspect STANADYNE Injection Pump Drive Gear Inside Diameter and Shaft Diameter (all pumps)
      • Repair STANADYNE Fuel Injection Pump
      • Install STANADYNE DB2 or DB4 Fuel Injection Pump (Without Lock Shaft timing)
      • Install STANADYNE Model DB4 Injection Pump (with Lock Shaft Timing)
      • Remove DELPHI/LUCAS Fuel Injection Pump
      • Repairs to DELPHI/LUCAS Fuel Injection Pump
      • Install DELPHI/LUCAS Fuel Injection Pump
      • Remove Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
      • Test Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
      • Disassemble Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
      • Assemble Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
      • Install Fuel Supply Pump (MICO – BOSCH in-Line Injection Pump)
      • Service Injection Pump Overflow Valve (MICO – BOSCH in-Line Injection Pump)
      • Modification of JDG670A
      • Remove MICO – BOSCH in-Line Fuel Injection Pump
      • Repair MICO – BOSCH in-Line Fuel Injection Pump
      • Install MICO – BOSCH in-Line Fuel Injection Pump
      • Check and Adjust Rotary Injection Pump Dynamic Timing Using TIME TRACTIME TRAC is a registered trademark of Stanadyne Automotive Corp.®
      • Check and Adjust Rotary Injection Pump Dynamic Timing Using TACH-N-TIME™ (JDG10534)
      • Check and Adjust Rotary Injection Pump Dynamic Timing Using TACH-N-TIME™ (JDG11411)
      • Replace Throttle Lever (STANADYNE)
      • Aneroid Replacement (STANADYNE)
      • Aneroid Field Adjustment (STANADYNE)
      • Aneroid Workshop Adjustment (STANADYNE)
      • Fuel Injection Nozzle Identification
      • Remove Fuel Injection Nozzle (9.5mm)
      • Clean Fuel Injection Nozzle (9.5 mm)
      • Fuel Injection Nozzle Test (9.5 mm)
      • Fuel Injection Nozzle Disassembly
      • Adjust Fuel Injection Nozzle (9.5 mm)
      • Install Fuel Injection Nozzle (9.5 mm)
      • Remove Fuel Injection Nozzles (17 mm)
      • Clean Fuel Injection Nozzle Bore(17 mm)
      • Clean Fuel Injection Nozzles (17 mm)
      • Test Fuel Injection Nozzles (17 mm)
      • Install Seals on Fuel Injection Nozzle(17 mm)
      • Install Fuel Injection Nozzles (17 mm)
      • Bleed Fuel System
      • Check Engine Speed on Rotary Fuel Injection Pump
      • Check Engine Speed on MICO – BOSCH in-Line Fuel Injection Pump
  • Theory of Operation
    • Engine Tune-Up
      • Preliminary Engine Testing
      • General Tune-Up Recommendations
    • Engine System – Operation
      • Lubrication System
      • Cooling System
  • Diagnostics and Tests
    • Engine System – Diagnosis and Tests
      • Diagnose Engine Malfunctions
      • Check Engine Compression using JT01674A Tool (9.5 and 17 mm Injector)
      • Check Engine Compression using FKM10021 Tool (9.5 mm Injector only)
      • Check Engine Oil Pressure
      • Check for Excessive Engine Crankcase Pressure (Blow-By) (Base Pressure)
        • Crankcase Pressure (Blow-By) Diagnostic Procedure
      • Using Stanadyne “TIME-TRAC” as Tachometer
      • Using JDG10534 TACH-N-TIME as Tachometer
      • Using JDG11411 TACH-N-TIME as Tachometer
      • Inspect Thermostat and Test Opening Temperature
      • Pressure Test Cooling System and Radiator Cap
    • Air Intake System – Operation and Tests
      • Turbocharger Operation
      • Wastegate Operation
      • Test Turbocharger Wastegate
      • Check Turbocharger Boost Pressure
      • Diagnosing Turbocharger Malfunctions
    • Fuel System – Operation and Tests
      • General Operation (Rotary Fuel Injection Pump)
      • Fuel Supply Pump Operation (Rotary Fuel Injection Pump)
      • Measure Fuel Supply Pump Pressure (Rotary Fuel Injection Pump)
      • Fuel Filter Operation (Rotary Fuel Injection Pump)
      • STANADYNE Fuel Injection Pump (DB2/DB4) – Operation
      • DELPHI/LUCAS Fuel Injection Pump (DP200 shown) – Operation
      • Test Shut-Off Solenoid on DELPHI/LUCAS Injection Pump
      • Cold Start Advance System Operation
      • Check Cold Start Advance System Operation
      • Check Cold Start Switch Operation
      • Light Load Advance Operation
      • Check Light Load Advance Operation
      • General Operation (MICO – BOSCH in-Line Fuel Injection Pump)
      • Fuel Supply Pump Operation (MICO – BOSCH in-Line Fuel Injection Pump)
      • Diagnose Fuel Supply Pump Malfunctions (MICO – BOSCH in-Line Fuel Injection Pump)
      • Fuel Filter Operation (MICO – BOSCH in-Line Fuel Injection Pump)
      • MICO – BOSCH in-Line Fuel Injection Pump Operation
      • Governor Operation (MICO – BOSCH in-Line Fuel Injection Pump)
      • Diagnose MICO – BOSCH in-Line Fuel Injection Pump Malfunctions
      • Fuel Injection Nozzles Operation (9.5 mm)
      • Fuel Injection Nozzles Operation (17 mm)
      • Diagnosing Fuel System Malfunctions
      • Testing Fuel Injection Nozzles on a Running Engine
  • Special Tools
    • Essential Tools
      • Essential Tools
    • Service Equipment & Recommended Tools
      • Service Equipment & Recommended Tools
    • Self-manufactured tools
      • Template for front plate replacement
      • Modification of JDG670A
  • Specifications
    • Repair Specifications
      • Cylinder Head and Valves Specifications
      • Cylinder Block, Liners, Pistons and Rods Specifications
      • Crankshaft, Main Bearings and Flywheel Specifications
      • Camshaft and Timing Gear Train Specifications
      • Lubrication System Specifications
      • Oil Dipstick Guide Height Specifications
      • Cooling System Specifications
      • Distance from Pulley or Hub to Water Pump Housing Sealing Surface Specifications
      • Air Intake and Exhaust System Specifications
      • Fuel System Specifications
      • Fuel Injection Pump Specifications
    • Diagnostic and Test Specifications
      • Diagnostic and Test Specifications
• Page Number
  • Section 01
    • Group 000
    • Group 001
    • Group 02
    • Group 03
  • Section 02
    • Group 05
    • Group 10
    • Group 15
    • Group 20
    • Group 25
    • Group 30
    • Group 35
    • Group 40
  • Section 03
    • Group 100
    • Group 105
  • Section 04
    • Group 110
    • Group 115
    • Group 120
  • Section 05
    • Group 200
    • Group 205
    • Group 210
  • Section 06
    • Group 300
    • Group 305