John-Deere 3029, 4039, 4045, 6059, 6068 Engines (Saran)-499999CD Disassembly

This article describes the disassembly of John-Deere 3029, 4039, 4045, 6059, 6068 Engines (Saran)-499999CD

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 ENGINE DISASSEMBLY SEQUENCE

The following sequence is suggested when complete

disassembly for overhaul is required. Refer to the

appropriate repair group when removing individual

engine components.

1. Drain all coolant and engine oil. Check engine oilfor metal contaminates (see Groups 25 and 30). 

 

2. Remove fan belts, fan, and alternator (seeGroup 30). 

 

3. Remove turbocharger (if equipped) and exhaust manifold (see Group 35). 

 

4. Remove rocker arm cover with vent tube. On engines having an Option Code label on rocker arm cover, be careful not to damage label (see Group 05). 

 

5. Remove water manifold with thermostats (see Group 30). 

6. Remove oil cooler piping and water pump (seeGroups 25 and 30).(Continued on next page) 

 

7. Remove dipstick, oil filter, and engine oil cooler.

Discard standard-flow oil cooler if oil contained metal

particles (see Group 25). 

 

8. Remove oil pressure regulating valve assembly(see Group 25).

 

9. Remove fuel filter, fuel transfer pump, and fuel lines (see Group 40). 

 

10. Remove injection lines, injection pump, andinjection nozzles (see Group 40). 

 

11. Remove starting motor. 

 

12. Remove rocker arm assembly and push rods.Keep rods in sequence (see Group 05). Check forbent push rods and condition of wear pad contactsurfaces on rockers. 

 

13. Remove cylinder head. Check piston protrusion.Verify piston height selection (see Groups 05 and10).

14. Remove cam followers. Keep in same sequence as removed (see Group 20).

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15. Remove oil pan (see Group 25). 

 

16. Remove flywheel and flywheel housing (see Group 15). 

 

17. Remove crankshaft pulley (see Group 15). 

 

18. Remove timing gear cover (see Group 20). 

 

19. Remove oil pump drive gear, outlet tube (and its O-ring in block) and pump body (see Group 25). 

 

20. Remove oil slinger, timing gears and camshaft.Perform wear checks (see  roup 20). 

 

21. Remove balancer shafts (4-cylinder only, if equipped), see Group 20. 

 

22. Remove engine front plate (see Group 20). 

 

23. Remove lube oil system by-pass valve (see  Group 25). 

 

24. Stamp cylinder number on rod (if required). Remove pistons and rods. Perform wear checks with  “PLASTIGAGE”. On 4 and 6-cylinder engines, remove  two at a time (see Group 10). 

 

25. Remove main bearings and crankshaft. Perform  wear checks with  PLASTIGAGE” (see Group 15). 

 

26. Remove cylinder liners and mark each one with  cylinder number from which removed (see Group 10). 

 

27. Remove piston cooling orifices (see Groups 10  and 15). 

 

28. Remove balancer shaft and camshaft bushings (if  equipped), see Group 20.

29. Remove cylinder block plugs and serial number plate (as required) when block is to be put in a “hot  tank” (see Group 10).   

30. Clean out liner bores (upper and lower areas)  with nylon brush (see Group 10).

 

31. Measure cylinder block (see Groups 10, 15, and  20)

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Perkins 2806F Engine Inlet Module (Catalyst) Remove and Install Guide

This article mainly introduces Perkins 2806F Engine Inlet Module (Catalyst) Remove and Install 

 

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WARNING:

Hot engine components can cause injury from burns. Before performing maintenance on the en-gine, allow the engine and the components to cool.


WARNING:

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particu-
late Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.


1. To remove the inlet module (Catalyst), access to

the underside of the clean emission module will be required. Refer to the Original Equipment

Manufacturer (OEM) for the correct location and the correct procedure to gain access to the

underside of the inlet module (Catalyst).







2. Remove temperature sensor (7). Refer to
Disassembly and Assembly, Temperature Sensor (DPF Inlet, Flame Detect) - Remove and Install for the correct procedure.


3. Loosen hose clamp (5) for tube assembly (6). Disconnect tube nut (3) for the tube assembly. Remove the tube assembly from inlet module catalyst (4).


4. Sufficiently loosen clamp (1) and clamp (2) to allow removal of inlet module catalyst (4).


5. Sufficiently loosen band clamp (8) to allow removal of inlet module catalyst (4).

6. Remove inlet module catalyst (4)
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Installation Procedure




1. When installing a new inlet module catalyst, a

“ Diesel Oxidation Catalyst (DOC) Reset” must be performed. Refer to Troubleshooting, Service Tool Features or your Perkins distributor for more

information.









Viewed from the inlet module catalyst assembly.

2. Install a new clamp (1). Position the clamp to

Dimension (Y) of 30° ± 5°. Refer to Illustration 183









3. Install a new clamp (8). Ensure that the clamp is correctly orientated.
4. Install inlet module catalyst (4). Ensure that the
clamp (8) and clamp (1) are correctly seated on to the inlet module catalyst. Hand tighten the clamps.
5.Apply Tooling (A) to the threads of clamp (2) along Distance (Z). Distance (Z) is 25 mm ( 1.0 inch)
above the trunnion.

6. Tighten band clamp (1) to a torque of 60 N·m

(44 lbft). Ensure that the band clamp remains in the correct position. Refer to Illustration 184 for the correct position.

Note: Do not use power tools to torque the clamp.

7. Tighten band clamp (2) to a torque of 15 N·m

( 133 lb in).

Note: Do not use power tools to torque the clamp.







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Cutaway view of band clamp (8) in position on the
assembly.
8. Torque band clamp (6) to a torque of 35 ± 2 N·m (26 ± 1 lbft).
Verify that the cup of the Ball Joint (G) does not touch the radius of the Ball (F). Position band
clamp (8) and hand tighten the band clamp. The band clamp should be in the center of the joint.
Dimension (D) and Dimension (E) should be equal
within 2.0 mm (0.08 inch). Repeat the
measurements every 90° around band clamp (8). If necessary, adjust the band clamp.


Tighten tube nut (3) to a torque of 40 N·m (30 lbft) . Ensure that tube assembly (6) is not strained as the tube nut is tightened.


9. Install temperature sensor (7). Refer to

Disassembly and Assembly, Temperature Sensor (DPF Inlet, Flame Detect) - Remove and Install for the correct procedure.

10. Connect tube assembly (6) to the elbow adapter on inlet module catalyst (4) and to the hose

assembly.

11. Hand tighten tube nut (3) for tube assembly (6).

12. Tighten hose clamp (5) to a torque of 1.4 N·m ( 12 lb in).