John Deere PowerTech 9.0 Engine Disassembly Sequence for Overhaul

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John Deere PowerTech 9.0 Engine Disassembly Sequence for Overhaul.The following sequence is suggested when complete disassembly for overhaul is required.

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Instructions:
1. Drain all coolant and engine oil. Check engine oil for metal contaminates.
2. Remove turbocharger oil inlet line and oil return line.
Remove turbocharger and air pipe to EGR cooler assembly.
3. Remove fan pulley and thermostat housing assembly.
4. Remove coolant pump assembly from timing gear cover.
NOTE: DO NOT damage option code label (if equipped),when removing rocker arm cover.
NOTE: The vent hose should be disconnected from the vent elbow. The vent elbow should not be removed from the rocker arm cover unless the intent is to replace the elbow assembly.
5. Remove breather hose from rocker arm cover.
Remove rocker arm cover.
6. Remove electronic injector wiring harness.
7. Remove rocker arm assembly and push rods. Identify parts for reassembly.
8. Remove front crankshaft pulley and damper assembly.
9. Remove fuel injection lines, fuel connectors, and injection nozzles.
10. Remove engine oil filter, filter base, and valve housing
11. Remove fuel filter and mounting base. Remove high pressure fuel pump gear cover and remove injection pump.
12. Remove high pressure common rail.
13. Remove engine oil cooler assembly
14. Remove front and rear exhaust manifolds and EGR cooler and valve assembly.
15. Remove air intake manifold.
NOTE: ALWAYS bolt down liners when rotating engine flywheel with cylinder head removed.
16. Remove cylinder head with assembly. Remove head gasket.
17. Revolve engine on repair stand and remove engine oil pump assembly.
18. Remove front timing gear cover.
19. Revolve engine to vertical position. Remove pistons and connecting rods. Identify for reassembly. Perform bearing-to-journal wear checks with PLASTIGAGE®.
20. On SAE No. 3 flywheel housings, remove flywheel housing and then remove flywheel.
21. On SAE No. 1 and 2 flywheel housings, remove flywheel and then remove flywheel housing.
22. Remove main bearing caps and remove crankshaft.Perform bearing-to-journal wear checks with PLASTIGAGE®.
23. Remove camshaft and cam followers. Identify for reassembly.
24. Revolve engine to horizontal position, remove liners, O-rings, and packings. Mark liners for reassembly in same bore from which removed.
25. Remove piston cooling orifices from cylinder block.
26. Remove any sensors/gauges, cylinder block plugs and engine serial number plate, if block is to be put in a “hot tank