PowWeRTECH? 8.1 L Diesel Engines Base Engine TECHNICAL MANUAL POWERTECH’ 8.1 L Diesel Engines — Base Engine CTM86 15JUL05 (ENGLISH) For complete service information also see: PowerTeC+* 8.4 L Diesel Engines—Mechanical Fuel Systems ...... eTw243, POWERTEC-” 8.8 L & 8.1 L Diesel Enginas—Level 3 Electronic Fual Systems with Bosch In-Line Pump . : Pum Electronic Fuel Injection Systems . OEM Engine Accessories : Alternators and Starting Motors.......... John Deere Power SystemsCylinder Head and Valves Repair and Adjustment SN. (200,000— ) Install Cylinder Head and Cap Screws - Serial Number (200,000— ) IMPORTANT: ALWAYS thoroughly inspect new cylinder head gasket for possible E manufacturing imperfections. Return any gasket that does not pass inspection. Be sure cylinder head and block gasket surfaces are clean, dry, and free of any il. Insteling Cyincer Head 1. Put a new head gasket an cylinder block Do not use sealant on gasket; install dry. IMPORTANT: If cylinder head is lowered onto eylinder block and the head is not positioned correctly on locating dowels, remove cylinder head and install 2 new gasket. DO NOT try to reposition cylinder head ‘on the same gasket again since the fire ring may possibly be damaged. 2. Lower cylinder head evenly to correct position on block using aporoprate lifting equipment. Make sure that head is positioned correctly aver dowels and sits lat (on cylinder block top deck. Contract on nent gage otvanoseoms siez0Econ2 GTMB6 (15JULO5) 02-021-36 Powertecir 8.1 | Diese! Engines — Base Engine PutasCylinder Head and Valves Repair and Adjustment $. N. (200,000— ) IMPORTANT: Only ASTM Grade 180 Flanged-Head cap screws marked “SPECIAL” (upper illustration) are recommended for use ‘on 6081 engines. ALWAYS use NEW cap screws when installing cylinder head. Cap screws may be used only ‘one time. DO NOT use multi-viscosity oils to lubricate cap serews, SAE3O is recommended. Roriar 3. Dip entire cap screw in clean SAE30 engine oil. Alow Special Cap Screw for Cnces ae excess oil to drip off 4. Install correct length cap screws marked “SPECIAL” in proper locations shown and tighten using the QoQ TORQUE-TO-YIELD tightening procedure, described ext in this group. See TORQUE-TO-YIELD FLANGE-HEAD CAP SCREWS—GRADE 180 z MARKED "SPECIAL" SERIAL NUMBER (200,000) x 5 in this group. 5 ‘Arrow (A) points toward front of engine 5 rower E yiindor Head Cap Screws oad Cap Serow Locatons Longin Location n Gyindor Head A-Fiont or gine air mm (asin) Za45a7 1e3Tmn 64) 23.25.17, 21,18 175 mn @9in) 115,14, 13 1211 10.8 203 nm @0in) 16 20,22, 18,25. 26 © (CTMB6 (15JUL05) 02-021-37 Powertecr 8.1 | Diesel Engines — Base Engine PNASCylinder Head and Valves Repair and Adjustment SN. (200,000— ) Torque-to-Yield Flanged-Head Cap Screws— Grade 180 Marked “SPECIAL” - Serial Number (200,000—) Arrow (A) points toward front of engine. IMPORTANT: DO NOT use multi-viscosity oils to lubricate cap screws. 1. Lubricate cap serews with clean SAEIO engine oil and install in their proper locations as outlined previously. 2. Tighten cap screw No. 17 to 80 Nem (60 lb-ft) then sequentially start at cap screw No. 1 and proceed ‘through cap screw No. 25, tightening all cap screws to specifications. Speciticaton Ovinder Hose Flengoc-Head “SPECIAL” Cap Serews (No vwiasnere)—inita! Torqus ce 80.Nem (60 Dn) 3. Using an oll-proof pen, pencil, or marker, draw a line parallel to the crankshaft across the entire top of each cap screw head. This line wll be used as a reference mark Tightoring Hoad Cap Screws ‘A—Fromt of Engine Contract on nent gage ost enosccne Roun GTMa6 (15JUL05) 02-021-38 Powertecir 8.1L Diese! Engines — Base Engine PNASCylinder Head and Valves Repair and Adjustment $. N. (200,000— ) IMPORTANT: Ifa cap screw Is accidentally tightened ‘more than 90° in any one sequence, DO NOT loosen cap screw but make adjustments in the next tightening sequence. 4, Sequentially (start at cap screw No. 1 and proceed through cap screw No. 26) turn each cap screw 90° Line on top of cap screw will be perpendicular to crankshaft. 5. Again, sequentially (start at cap screw No. 1 and proceed through cap screw No. 26) turn each cap Screw 90°. Line an top of cap serew will now be parallel to crankshaft 6. Finally, sequentially (start at cap screw No. 1 and proceed through cap screw No. 26). Turn each cap screw 902, SO THAT LINE ON TOP OF GAP SCREW IS AS GLOSE AS POSSIBLE TO BEING PERPENDICULAR TO THE CRANKSHAFT. Itis not necessary to obtain the final turn in one swing of the wrench. TOTAL AOUNT OF TURN FROM STEPS 4, 5, AND 6 IS 270° = 6 Torqusto-VoldTightanng of Head Cap Scrove IMPORTANT: Cap screws MUST NOT be tightened more than a total of 270° = 5°. A—Font of Engine (CTMB6 (15JUL05) 02-021-39 Powertecr 8.1 | Diesel Engines — Base Engine PNT