John Deere PowerTech™ 13.5L OEM Diesel Engines Base Engine Repair Index:

• Contents
  • General Information
    • Safety
      • Work In Ventilated Area
      • Recognize Safety Information
      • Work in Clean Area
      • Dispose of Waste Properly
      • Avoid Harmful Asbestos Dust
      • Handle Fuel Safely—Avoid Fires
      • Prepare for Emergencies
      • Handle Starting Fluid Safely
      • Handle Fluids Safely—Avoid Fires
      • Avoid High-Pressure Fluids
      • Use Proper Lifting Equipment
      • Illuminate Work Area Safely
      • Live With Safety
      • Service Machines Safely
      • Handle Chemical Products Safely
      • Remove Paint Before Welding or Heating
      • Stay Clear of Rotating Drivelines
      • Service Cooling System Safely
      • Follow Safety Instructions
      • Use Proper Tools
      • Construct Dealer-Made Tools Safely
      • Practice Safe Maintenance
      • Understand Signal Words
      • Prevent Battery Explosions
      • Protect Against High Pressure Spray
      • Avoid Heating Near Pressurized Fluid Lines
      • Wear Protective Clothing
      • Handle Agricultural Chemicals Safely
      • Handling Batteries Safely
      • Install Fan Guards
      • Avoid Hot Parts
    • Engine Identification and Applications
      • Engine Model Designation
      • Engine Serial Number Plate Information
      • Engine Option Code Label
    • Fuels, Lubricants and Coolant
      • Diesel Fuel
      • Biodiesel Fuel
      • Minimizing the Effect of Cold Weather on Diesel Engines
      • Handling and Storing Diesel Fuel
      • Lubricity of Diesel Fuel
      • Testing Diesel Fuel
      • Engine Oil and Filter Service Intervals
      • Diesel Engine Oil
      • Diesel Engine Break-In Oil
      • Oil Filters
      • Grease
      • Alternative and Synthetic Lubricants
      • Lubricant Storage
      • Mixing of Lubricants
      • Heavy Duty Diesel Engine Coolant
      • Supplemental Coolant Additives
      • Operating in Warm Temperature Climates
      • Additional Information About Diesel Engine Coolants and John Dee
      • Diesel Engine Coolant
      • Testing Diesel Engine Coolant
      • Drain Intervals for Diesel Engine Coolant
  • Repair and Adjustments
    • Engine Rebuild Guide, Break-In and Tune-Up
      • Engine Overhaul Guidelines
      • Engine Repair Stand
      • Safety Precautions
      • Disconnect Turbocharger Oil Inlet Line
      • Install Engine Adapter Onto Repair Stand
      • Engine Lifting Procedure
      • Mount Engine Onto Repair Stand
      • Clean Engine
      • 6135 Engine Disassembly Sequence
      • Sealant Application Guidelines
      • 6135 Engine Assembly Sequence
      • Engine Break-In Guidelines
      • Perform Engine Break-In
      • Check Crankcase Ventilation System
      • Check Air Intake System
      • Check Exhaust System
      • Check and Service Cooling System
      • Check Electrical System
    • Cylinder Head and Valves
      • Remove and Install Rocker Arm Cover
      • Clean and Inspect Crankcase Ventilation Assembly
      • Replace Rocker Arm Cover Gasket
      • Check and Adjust Valve Assembly Clearances and Injector Preload
      • Remove Rocker Arm Assembly
      • Remove Cylinder Head
      • Diagnosing Head Gasket Joint Failures
      • Head Gasket Inspection and Repair Sequence
      • Disassemble and Inspect Rocker Arms and Shaft Assembly
      • Preliminary Cylinder Head and Valve Checks
      • Assemble Rocker Arms and Shaft Assembly
      • Check Valve Height in Relation to Head Surface (Valve Recess)
      • Remove Valve Assembly
      • Inspect and Measure Valve Springs
      • Inspect Valve Rotators
      • Clean, Inspect, and Measure Valves
      • Grind Valves
      • Clean and Inspect Cylinder Head
      • Check Cylinder Head Flatness
      • Measure Cylinder Head Thickness
      • Measure Valve Guide ID
      • Replace Valve Guides
      • Clean and Inspect Valve Seats
      • Grind Valve Seats
      • Remove Valve Seat Inserts
      • Measure Valve Seat Bore in Cylinder Head
      • Install Valve Seat Inserts
      • Install Valves
      • Replace Unit Injector Sleeve in Cylinder Head Using JDG981
      • Replace Unit Injector Sleeve in Cylinder Head Using JDG1184
      • Remove Unit Injector Sleeve Using JDG10014
      • Clean and Inspect Top Deck of Cylinder Block
      • Measure Cylinder Liner Standout (Height Above Block)
      • Install Cylinder Head
      • Torque-Turn Cylinder Head Cap Screws
      • Install Rocker Arm Assembly
      • Complete Final Assembly for Cylinder Head Installation
    • Cylinder Block, Liners, Pistons, and Rods
      • Remove and Install Cylinder Block Front Plate
      • Preliminary Liner, Piston, and Rod Checks
      • Connecting Rods—General Information
      • Remove Piston Spray Jets
      • Remove Pistons and Connecting Rods
      • Measure Cylinder Liner Standout (Height Above Block)
      • Remove Cylinder Liners Using D01062AA or D01073AA Cylinder Liner
      • Remove Cylinder Liners Using JDG1145 Cylinder Liner Service Set
      • Visually Inspect Cylinder Liners
      • Deglaze Cylinder Liners
      • Clean Cylinder Liners
      • Cylinder Liner Manufacturing Date Code Explanation
      • Disassemble Piston/Rod Assembly and Clean Piston
      • Check Piston Oil Control Ring Groove Wear
      • Inspect Piston Pin and Pin Bore in Piston
      • Inspect Piston Pin and Pin Bore in Piston
      • Determine Piston-to-Liner Clearance
      • Measure Liner Flange Thickness
      • Inspect and Measure Connecting Rod Bearings
      • Inspect Connecting Rod and Cap
      • Inspect Piston Pins and Rod Bushings
      • Remove Piston Pin Bushing, Clean, and Inspect Bushing Bore
      • Install Piston Pin Bushing
      • Complete Disassembly of Cylinder Block (If Required)
      • Inspect and Clean Cylinder Block
      • Measure Cylinder Block
      • Recheck Cylinder Liner Standout (Height Above Block)
      • Install Cylinder Liner O-Rings and Packings
      • Install Cylinder Liners
      • Assemble Pistons and Connecting Rods
      • Install Pistons and Connecting Rods
      • Torque-Turn Connecting Rod Cap Screws
      • Check Engine Rotation for Excessive Tightness
      • Install Piston Spray Jets
      • Measure Piston Protrusion
      • Complete Final Assembly
    • Crankshaft, Main Bearings, and Flywheel
      • Crankshaft Rubber Damper Torque Sequence
      • Inspect Crankshaft Vibration Damper
      • Check Crankshaft End Play
      • Remove Crankshaft Rubber Damper and Pulley
      • Remove Viscous Damper and Front Crankshaft Oil Seal
      • Remove Timing Gear Cover
      • Check Flywheel Housing Face Runout
      • Check Flywheel Face Flatness
      • Remove Flywheel
      • Inspect and Repair Flywheel
      • Replace Flywheel Ring Gear
      • Remove and Install Flywheel Housing
      • Install Flywheel
      • Remove Rear Crankshaft Oil Seal and Housing Assembly
      • Crankshaft Unitized Rear Oil Seal — Removal
      • Crankshaft Unitized Rear Oil Seal and Housing — Installation
      • Crankshaft and Main Bearing Failure Analysis
      • Remove Crankshaft Main Bearings
      • Check Main Bearing-to-Journal Oil Clearance
      • Remove Crankshaft
      • Inspect Crankshaft
      • Measure Assembled ID of Bearings and OD of Crankshaft Journals
      • Measure Assembled ID of Main Bearing Caps (Without Bearings)
      • Replace Crankshaft Drive Gear
      • Inspect Thrust Bearings
      • Thrust Bearing New Part Specifications
      • Install Main and Thrust Bearing Inserts in Block
      • Install Crankshaft
      • Install Crankshaft Rear Oil Seal Housing
      • Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly
      • Install Timing Gear Cover
      • Install Crankshaft Rubber Damper and Front Oil Seal
      • Install Viscous Damper Assembly and Front Oil Seal
      • Complete Final Assembly
    • Camshaft and Timing Gear Train
      • Camshaft Timing Pin
      • Check and Adjust Camshaft-to-Crankshaft Timing
      • Adjust Front Timing Gear Backlash Using JDG993
      • Adjust Front Timing Gear Backlash Without Using JDG993
      • Remove and Install Camshaft
      • Replace Fuel Supply Pump Drive Pin
      • Visually Inspect Camshaft and Roller Followers
      • Inspect and Measure Camshaft Bushing ID and Journal OD
      • Measure Camshaft Lobe Lift Height
      • Inspect Camshaft Position Sensor Lobe
      • Replace Camshaft Bushings
      • SAE “A” (Front) and SAE “B” (Rear) Auxiliary Drive Assembly
      • SAE B Rear Auxiliary Drive — Removal and Installation
      • Align SAE “A” Front Auxiliary Drive Adapter
    • Lubrication System
      • Oil Filter and Oil Conditioning Housing Assembly
      • Remove Oil Filter and Valve Housing/Oil Cooler Cover and Valve H
      • Inspect and Replace Oil Filter Adapter
      • Remove, Inspect, and Install Oil Pressure Regulating Valve
      • Remove, Inspect, and Install Oil Cooler and Oil Filter Bypass Va
      • Remove, Inspect, and Install Oil Pressure Relief Valve
      • Remove, Clean, and Inspect Engine Oil Cooler
      • Install Oil Cooler/Oil Filter Valve Housing Assembly or Oil Cool
      • Remove Engine Oil Pump
      • Clean and Inspect Oil Pump and Drive Gear
      • Install Engine Oil Pump
      • Remove Engine Oil Pan
      • Remove and Install Oil Pickup Tube
      • Install Engine Oil Pan
    • Cooling System
      • Replace Bearings in Fan Drive Assembly
      • Inspect and Check Belt Tensioner Spring Tension
      • Replace Belt Tensioner Assembly
      • Remove Coolant Pump
      • Clean and Inspect Coolant Pump Parts
      • Install Coolant Pump
      • Remove and Install Thermostat Cover and Thermostats
      • Test Thermostat Opening Temperature
      • Remove and Install Thermostat Housing and Coolant Tubes
      • Remove and Install Coolant Heater—if Equipped
      • Bleed Air from Coolant System
    • Air Intake and Exhaust System
      • Extending Turbocharger Life
      • Remove and Install Variable Geometry Turbocharger Actuator
      • Remove and Install Actuator Linkage
      • Remove Turbocharger
      • Turbocharger Failure Analysis
      • Turbocharger Seven-Step Inspection
      • Turbocharger — Repair
      • Prelube Turbocharger
      • Install Turbocharger
      • Turbocharger Break-In
      • Remove, Inspect, and Install EGR Cooler
      • Exhaust Manifold — Remove
      • Exhaust Manifold — Install
      • Remove, Inspect, and Install Intake Manifold
      • Remove, Inspect, and Install EGR Valve (Tier 3/Stage III A)
    • Air Intake and Exhaust System — PowerTech™ E Engines
      • Exhaust Manifold — Remove
      • Exhaust Manifold — Install
      • Turbocharger — Remove
      • Turbocharger — Install
      • Air Intake Manifold — Remove
      • Air Intake Manifold — Install
    • Fuel System
      • Fuel System
    • Starting and Charging Systems
      • Remove and Install Alternator (OEM Engines)
      • Remove and Install Starter Motor (OEM Engines)
  • Theory of Operation
    • Base Engine Operation — PowerTech Plus
      • General Engine Operation
      • Lubrication System Operation
      • Cooling System Operation
      • Fuel System Theory of Operation
      • Head Gasket Joint Construction and Operation
      • Intake and Exhaust System Operation
      • Exhaust Gas Recirculator (EGR) & Variable Geometry Turbocharger
      • Turbocharger Operation
      • How the Turbocharger is Lubricated
    • Base Engine Operation — PowerTech & PowerTech E
      • General Engine Operation
      • Lubrication System Operation
      • Cooling System Operation
      • Fuel System Theory of Operation
      • Head Gasket Joint Construction and Operation
      • Intake and Exhaust System Operation
      • Turbocharger Operation
      • How the Turbocharger is Lubricated
  • Diagnostics
    • Observable Diagnostics and Tests
      • About this Section of the Manual
      • 13.5L – L1 – Excessive Oil Consumption
        • 13.5L – L1 – Excessive Oil Consumption
      • 13.5L – L2 Engine Oil Pressure High
      • 13.5L – L3 – Engine Oil Pressure Low
      • 13.5L – L4 – Fuel in Oil
      • 13.5L – C1 – Engine Coolant Temperature Above Normal
      • 13.5L – C2 – Engine Coolant Temperature Below Normal
      • 13.5L Engines – C3 – Coolant in Oil or Oil in Coolant
      • Dynamometer Test
      • Check Cylinder Compression
      • Engine Oil Consumption
      • Check Engine Oil Pressure
      • Check for Excessive Engine Crankcase Pressure (Blow-By)
      • Check for Turbocharger Oil Seal Leak
      • Inspect Thermostat and Test Opening Temperature
      • Pressure Test Cooling System and Radiator Cap
      • Check for Head Gasket Failures
      • Check Intake Manifold Pressure (Turbo Boost)
      • Check for Intake and Exhaust Restrictions
      • Check for Intake Air Leaks
      • Check for Exhaust Air Leaks
      • Check Camshaft-to-Crankshaft Timing
      • Check Crankshaft Position Sensor Depth
      • Check Engine Cranking Speed
  • Tools and Other Materials
    • Repair Tools and Other Materials
      • Engine Rebuild Guide, Break-In and Tune-Up (Group 010) Other Mat
      • Cylinder Head and Valves (Group 020) Essential Tools
      • Cylinder Head and Valves (Group 020) Service Equipment and Tools
      • Cylinder Head and Valves (Group 020) Other Material
      • Cylinder Block, Liners, Pistons, and Rods (Group 030) Essential
      • Cylinder Block, Liners, Pistons, and Rods (Group 030) Service Eq
      • Cylinder Block, Liners, Pistons, and Rods (Group 030) Other Mate
      • Crankshaft, Main Bearings and Flywheel (Group 040) Essential Too
      • Crankshaft, Main Bearings and Flywheel (Group 040) Service Equip
      • Crankshaft, Main Bearings and Flywheel (Group 040) Other Materia
      • Camshaft and Timing Gear Train (Group 050) Essential Tools
      • Camshaft and Timing Gear Train (Group 050) Service Equipment and
      • Camshaft and Timing Gear Train (Group 050) Other Material
      • Lubrication System (Group 060) Essential Tools
      • Lubrication System (Group 060) Other Material
      • Cooling System (Group 070) Essential Tools
      • Cooling System (Group 070) Other Material
      • Air Intake and Exhaust System (Group 080) Essential Tools
      • Air Intake and Exhaust System (Group 080) Other Material
      • Starting and Charging Systems (Group 100) Essential Tools
    • Diagnostic Service Tools
      • Observable Diagnostics and Tests Essential Tools
    • Dealer Fabricated Service Tools
      • How to Make Tools
      • DFRG4—Camshaft Locking Tool
      • DFRG3—Cylinder Liner Holding Fixture
  • Specifications
    • Repair and General OEM Specifications
      • General OEM Engine Specifications
      • Unified Inch Bolt and Screw Torque Values
      • Metric Bolt and Screw Torque Values
      • Engine Rebuild Guide, Break-In and Tune-Up (Group 010) Specifica
      • Cylinder Head and Valves (Group 020) Specifications
      • Cylinder Block, Liners, Pistons and Rods (Group 030) Specificati
      • Crankshaft, Main Bearings and Flywheel (Group 040) Specification
      • Camshaft and Timing Gear Train (Group 050) Specifications
      • Lubrication System (Group 060) Specifications
      • Cooling System (Group 070) Specifications
      • Air Intake and Exhaust System (Group 080) Specifications — Varia
      • Air Intake and Exhaust System (Group 081) Specifications — Fixed
      • Starting and Charging Systems (Group 100) Specifications
    • Diagnostic Specifications
      • Observable Diagnostics and Test Specifications
      • Dynamometer Test Specifications (OEM Engines)
      • Intake Manifold Pressure (Turbocharger Boost) Specifications
• Page Number
  • Section 01
    • Group 000
    • Group 001
    • Group 002
  • Section 02
    • Group 010
    • Group 020
    • Group 030
    • Group 040
    • Group 050
    • Group 060
    • Group 070
    • Group 080
    • Group 081
    • Group 090
    • Group 100
  • Section 03
    • Group 120
    • Group 121
  • Section 04
    • Group 150
  • Section 05
    • Group 170
    • Group 180
    • Group 190
  • Section 06
    • Group 200
    • Group 210