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Remove John Deere John Deere diesel engine balance shaft (if equipped-4-cylinder John Deere John Deere John Deere diesel engine)
1. Remove the timing gear, if equipped. (Double-valve John Deere John Deere diesel engines with all VP44 or DE10 injection pumps and all four-valve John Deere John Deere diesel engines, see section 040 "Removing and Installing Camshaft Timing Gears".)
Note: The balance shaft can be installed with a fixed weight or a removable weight with one or two cap screws.
2. Remove the idler gear and oil pump gear (shown after removal).
3. On a new John Deere John Deere diesel engine equipped with a removable counterweight 1 (A), the counterweight must be removed before the balance shaft can be removed.
4. Remove the cap screws of the balance shaft thrust plate as shown.
Important: For correct installation, mark the left and right balance shaft positions. Make a permanent mark “R” (right) or “L” (left) behind the balance shaft to distinguish it. Positioning the balance shaft can cause premature wear of the balance shaft and bushing.
Note: When removing the balance shaft, be careful not to damage the balance shaft journal and bushing in the cylinder.
5. Remove the balance shaft.
Check and measure John Deere John Deere diesel engine balance shaft bushings and journals
1. Inspect, measure, and record the inside diameter of the balancer bushing (A) at all locations.
2. Measure the outer diameter of the balance shaft journal (B). The difference between the outer diameter of the balance shaft journal and the inner diameter of the bushing is the oil gap.
If the oil gap does not meet the technical specifications, install a new bushing and replace it with a new balance shaft if necessary.
Balance Shaft Bushings (New)-40.177-40.237 mm I.D. (1.5818-1.5841 inches)
Balance shaft journal-outer diameter... 40.135-40.161 mm (1.5801-1.5811 inches)
Balance shaft journal to bushing-oil gap ... 0.016-0.102 mm (0.0006-0.0040 inch)
Balance Shaft Cylinder Bore Hole-Inner Diameter. 43.262-43.288 mm (1.7032-1.7042 inches)
B-journal outside diameter
Remove and install balance shaft bushing
Important note: John Deere John Deere diesel engine is equipped with a balance shaft bushing or not.
The new John Deere John Deere diesel engine without balance shaft may use semi-finished bushings without oil holes. When replacing with a finished bushing, the bushing can be rotated to cover the oil hole in the cylinder. When replacing the balance shaft bushing, the front plate of the cylinder block must be removed.
1. Remove all fuel lines from the fuel injection pump or rotary pump.
2. Remove the front plate. (See the "Removing the Cylinder Front Plate" section later in this chapter.)
Note: The semi-finished bushing can be removed with JD249 (JD-249) balance shaft bushing remover.
3. Use JD249 (JD-249) 1 balance shaft bushing remover and JDG963 adapter to remove the bushing from the cylinder block. If the rear bushing (third) is removed, the flywheel housing must be removed.
Important note: For John Deere John Deere diesel engine equipped with balance shaft, the bushing and the oil hole of the cylinder block must be aligned so that the bushing and journal can be well lubricated. For John Deere John Deere diesel engine without balance shaft, the bushing must be turned 90 ° to cover the oil hole of the cylinder block.
4. Lubricate the bushings with clean engine oil and fit the bushings into the cylinder block using the same tools used to remove the bushings.
5. John Deere John Deere diesel engine equipped with balance shaft, check the oil gap between bush and balance shaft after installing balance shaft. If you push the balance shaft slightly with your hand, it indicates that there is sufficient oil gap between the bushing and the balance shaft. It is not necessary to sand the bushings to meet the oil gap requirements of the technical specifications. Excessive oil clearance can cause the balance shaft to jam.
Removing the front plate of the John Deere John Deere diesel engine block
The following components must be removed first, and then the John Deere John Deere diesel engine front plate.
• Timing gear cover. (See the "Removing the Timing Gear Cover" section in this chapter.)
• Timing wheels (double-valve John Deere John Deere diesel engine with all VP44 or DE10 injection pumps and all four-valve John Deere John Deere diesel engine, see Chapter 040 "Removing and Installing the Crankshaft Timing Gear" section.)
• Camshaft and gear (A). (See the "Removing the Camshaft" section of this chapter.)
• Fuel injection pump drive gear (B) and fuel injection pump. See CTM217 (Mechanical Fuel System), CTM179 (Class 4 Electronic Fuel System), CTM341 (Class 12 Electronic Fuel System), CTM284 (Class 1 Electronic Fuel System) (English only) or CTM230 (Class 11 with Denso High-Voltage Common Rail) Electronic Fuel System) Part 02 Chapter 090.
• Oil pump drive gear (C) and oil pump. (See the "Removing the Oil Pump" section in Chapter 060.)
• Idler (D)
• Balance shaft (E) 1 (See “Removing the balance shaft” in this chapter.)
• Oil pressure regulator, if a vertical oil pressure regulator is installed. (See Chapter 060 "Removing and Installing the Oil Pressure Regulator".)
A-camshaft and gear
B-Fuel injection pump drive gear
C-oil pump drive gear
D-idler (upper and lower idler)
E-Balance shaft 1
1. Remove the four countersunk TORX® screws (A) from the gear and simultaneously remove the oil pump using the T-40 TORX® adapter.
Note: On the old John Deere John Deere Diesel Engine 1, replace the studs (C) with two countersunk TORXÆ screws.
The four-valve John Deere John Deere diesel engine uses a stud bolt to secure the fuel injection pump and timing gear cover. Remove if necessary.
2. Use an E-8 TORXÆ socket wrench to remove the six studs (B) and (C).
3. Remove the front plate (D).
4. Remove the oil bypass valve and spring.
Important: All surfaces must be clean and free of oil.
5. Thoroughly clean the front plate of the cylinder block.
Measure John Deere John Deere diesel engine idler bushings and idler axles
1. Measure the inner diameter of the idler bushing and the outer diameter of the idler shaft to determine the oil gap. If the oil gap exceeds the specifications, replace worn parts.
Upper idler bushing (double-valve John Deere John Deere diesel engine) (gear width 30 mm)-inner diameter ..... 69.802-69.832 mm (2.7481-2.7493 inches)
Upper idler bushing (double valve John Deere John Deere strong deer diesel engine) (gear width 22 mm)-inner diameter. 44.49-44.54 mm (1.751-1.753 inches)
Upper idler bushing (four-valve John Deere John Deere diesel engine)-92.732-92.762 mm (3.6509-3.6520 inches) inside diameter
Lower Idler Bushing-Inner Diameter... 44.489-44.539 mm (1.7515-1.7535 inches)
Upper idler axle (double valve John Deere John Deere strong deer diesel engine) (gear width 30 mm)-outer diameter ..... 69.757-69.777 mm (2.7463-2.7471 inches)
Upper idler axle (double valve John Deere John Deere strong deer diesel engine) (gear width 22 mm)-outer diameter. 44.43-44.46 mm (1.749-1.750 inches)
Upper idler axle (four-valve John Deere John Deere strong deer diesel engine)-outside diameter 92.687-92.707 mm (3.6491-3.6499 inches)
Lower idler shaft-outer diameter... 44.437-44.463 mm (1.7495-1.7505 mm)
Upper Idler Bushing to Idler Axle (Double Valve John Deere John Deere John Deere Diesel Engine)-Oil Clearance: 0.075-0.125 mm (0.0030-0.0049 inch)
Upper idler bushing to idler axle (four-valve John Deere John Deere diesel engine)-oil gap. 0.0025-0.075 mm (0.0010-0.0030 inch)
Lower Idler Bushing to Idler Shaft-Oil Clearance: 0.026-0.102 mm (0.0010-0.0040 inch)
Upper Idler-Axial Clearance... 0.070-0.170 mm (0.0027-0.0066 inch)
Lower Idler-Axial Clearance... 0.070-0.330 mm (0.0027-0.0129 inch)
2. If the idler axial clearance does not meet the technical specifications during the above measurement in this chapter, the idler shaft and thrust washer should be removed from the front plate. (See the "Removing the Upper and Lower Idler Shafts" section later in this chapter.)
3. Inspect the thrust washers for wear.
4. Measure the idler hub width and idler shaft width. Replace worn parts that do not meet technical specifications.
John Deere John Deere diesel engine camshaft, balance shaft and timing gear train
Turn the injection pump timing mark to the replacement front plate (double valve John Deere John Deere John Deere diesel engine with mechanical injection pump) Important: The front plate for replacement does not have the injection pump timing mark. It is very important to accurately transfer the original front plate timing mark to the replacement front plate and accurately correspond to the injection pump timing position.
1. Place the DFRG5 aluminum template (B) on the original front plate (C) as shown. (For detailed manufacturing instructions, see Chapter 05, Chapter 190, "Dealer's Manufacturing Tools.") Install and tighten three 3 / 8-16 cap screws.
2. Use a ruler and a fine-tipped marker to transfer the original front-plate fuel injection pump timing mark (A) to the template. Remove the template from the replaced front panel.
3. Place the template (with timing marks) on the newly replaced front plate and secure it with cap screws.
4. Engage the timing mark on the template to the new front plate with a stylus. The line should be deep enough to make the mark a permanent reference.
5. Remove the template from the front panel and install the front panel. (See the "Installing the Cylinder Front Plate" section later in this chapter.)
Installation and timing of John Deere John Deere diesel engine balance shaft (if equipped-4-cylinder John Deere John Deere diesel engine)
1. Use JDE81-1 or JDE83 flywheel rotation tool and JDG1571 or JDE81-4 timing pin to lock No. 1 piston at the top dead center of the cylinder compression stroke.
2. Lubricate the balance bush and journal with clean engine oil.
Note: The rear of the balance shaft can be printed with letters to identify the balance shaft.
"R" or "RH" represents the right axis.
"L" or "LH" stands for the left axis.
3. As shown in the figure, mark the left and right balance shafts according to the gear timing marks.
A-right shaft (camshaft side)
B-left shaft (injection pump side)
Important Note: The balance shaft must be installed in the original removed position. Reversing the balance shaft position can cause excessive wear on the balance shaft bushing and balance shaft. If the shaft is suspected of being improperly installed, reinstall the balance shaft and bushing.
4. Install balance shaft and thrust plate. Tighten the thrust plate cap screws according to the technical specifications.
Balance Shaft Thrust Plate Cap Screws-Torque ... 40 Newton meters (29.5 lb-ft)
Important: Make sure the counterweight is on the side of the balance shaft opposite the key (C).
5. The balance shaft of the new John Deere John Deere diesel engine 1 is equipped with a removable counterweight. Install the balance shaft counterweight on the balance shaft with new cap screws and nuts. Tighten it as required by the technical specifications.
Removable Counterweight (Single Bolt Counterweight)-Torque ... 58 Nm (43 lb-ft)
Removable Counterweight (Double Bolt Counterweight)-Torque ... 40 Nm (30 lb-ft)
B-Bolts (1 or 2 used)
6. Turn the right (camshaft side) balance shaft so that the timing mark on the gear is aligned with the JD254A (JD-254A) 1 timing tool (A). When the timing is correct, the timing mark on the balance shaft gear must be aligned with the crankshaft centerline.
Note: When the John Deere John Deere diesel engine is locked at the top dead center of the compression stroke of the No. 1 cylinder piston, the keyway (B) on the balance shaft gear must be at 12 o'clock.
7. Use TY6333 high temperature grease to coat the inside diameter of the idler bushing and the outside diameter of the gear shaft. Install the lower idler without turning the balance shaft.
Important: Do not secure the idler with zinc-coated hardware. If cap screws are zinc coated, replace them with new silicate-coated screws. For the corresponding part numbers, see the parts catalog.
Note: Install the thrust washer with the "X" mark facing away from the gear.
8. Install thrust washers on the lower idler (C) and shaft.
9. Lubricate the cap screws and install them on the threaded bracket of the oil pump casing through the idler shaft. Only tighten by hand.
10. Turn the left (injection pump side) balance shaft so that the timing mark on the gear is aligned with the JD254A (JD-254A) 1 timing tool (A).
11. Install the oil pump gear. Tighten the gear lock nut by hand.
12. Recheck the gear timing position of the two balance shafts
13. Tighten the oil pump drive gear lock nut according to the technical specifications. Secure the nut to the shaft from three positions (B). (For the installation method of the oil pump, refer to Chapter 060 "Installing the John Deere John Deere Diesel Engine Oil Pump".)
Oil Pump Drive Gear Lock Nuts-Torque ... 50 Nm (37 lb-ft)
14. Tighten the lubricated lower idler cap screws according to the technical specifications.
Lower Idler Cap Screws (Thread Lubricated)-Torque ... 70 Nm (53 lb-ft)