Part of the John Deere Repair Manuals.
CTM20 takes the John Deere 6101 diesel engine down to a bare block and walks it back up, 421 pages of Series 500 factory rebuild work that covers this engine on the stand. Disassembly and assembly sequences anchor the book, and roughly half of it is hands-on procedure: valve guide measurement, seat grinding, liner and piston removal, crankshaft and main bearing work, camshaft and timing gear train. Fuel system operation and tests run long, covering injection pump, nozzles, aneroid and supply pump checks. Torque the cylinder head cap screws to 200 N·m (150 lb-ft), then turn them an additional 90 to 100 degrees; oil pressure at rated speed should read 280 to 380 kPa (40 to 55 psi). A guessed clearance costs you a second teardown and a scrap crankshaft. Bookmarks and searchable text put you on the specification page you want before your coffee cools.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 6-13 | Fluid Safety, Battery Safety, Emergency Preparedness, Acid Burn Prevention, High-Pressure Fluid Safety, Protective Clothing |
| General Information | 14-19 | Unified Inch Bolt and Cap Screw Torque Values, Metric Bolt and Cap Screw Torque Values, Engine Model Designation, Engine Nameplate Information, Engine Application Chart |
| Fuels, Lubricants, and Coolant | 20-33 | Diesel Fuel, Lubricity of Diesel Fuels, Engine Break-In Oil, Diesel Engine Oil, Oilscan and Coolscan, Alternative and Synthetic Lubricants, Grease, Engine Coolant Requirements |
| Engine Mounting | 34-39 | Engine Repair Stand, Safety Precautions, Install 500 Series Adapters on Repair Stand, Engine Lifting Procedure, Clean Engine, Mount Engine on Repair Stand |
| Engine Rebuild Guide | 40-45 | Engine Disassembly Sequence, Sealant Application Guidelines, Engine Assembly Sequence |
| Cylinder Head and Valves | 46-85 | Special or Essential Tools, Service Equipment and Tools, Other Material, Specifications, Torques, Disconnect Turbocharger Oil Inlet Line, Check and Adjust Valve Clearance |
| Cylinder Block, Liners, Pistons and Rods | 86-127 | Special or Essential Tools, Specifications, Remove Pistons and Connecting Rods |
| Crankshaft, Main Bearings and Flywheel | 128-177 | Special or Essential Tools, Specifications, Crankshaft Front Oil Seal, Remove Crankshaft Main Bearings, Oil Pump Drive Gear |
| Camshaft and Timing Gear Train | 178-203 | Special or Essential Tools, Specifications, Check Camshaft End Play, Camshaft Drive Gear-to-Crankshaft Gear Backlash, Remove Camshaft, Camshaft Bushings |
| Lubrication System | 204-223 | Specifications, Oil Bypass Valve Housing and Oil Cooler Assembly, Oil Pressure Reg. Valve |
| Cooling System | 224-249 | Special or Essential Tools, Specifications, Remove Water Pump, Assemble Water Pump, Coolant Filter Conditioner, Check and Adjust V-Belt Tension |
| Air Intake and Exhaust System | 250-281 | Special or Essential Tools, Specifications, Diagnosing Turbocharger Malfunctions, Axial End Play Bearing Test |
| Fuel System | 282-331 | Special or Essential Tools, Specifications, Disassemble Fuel Supply Pump, Remove Fuel Injection Pump |
| Engine Tune-Up and Break-In | 332-341 | Altitude Performance, Preliminary Engine Testing, Tune-Up Recommendations, Dynamometer Testing, Engine Break-In Guidelines, Engine Break-In Instructions |
| Engine System Operation and Tests | 342-363 | Engine Test Specifications, Engine Sectional View, Lubrication System, Head Gasket Joint, Engine Compression Pressure, Cooling System |
| Air Intake System Operation and Tests | 364-373 | Manifold Pressure, Air Filter Restriction, Turbocharger, Aftercooler, Intake Manifold, Exhaust System |
| Fuel System Operation and Tests | 374-405 | Fuel Supply Pump, Fuel Injection Pump, Injection Nozzles, Aneroid, Hydraulic Aneroid Activator, Fuel Filter |
| Dealer Fabricated Tools | 406-407 | Cylinder Liner Holding Fixture |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Battery charging temperature | 16°C (60°F) | p. 6 |
| Cylinder Head Cap Screws | Initial 200 N·m (150 lb-ft), Final Tighten additional 90°—100° | p. 51 |
| Cylinder Head Cap Screw Torque | Initially 200 N·m (150 lb-ft), then 200 N·m (150 lb-ft), finally 90-100 degrees | p. 81 |
| Engine Oil Pressure @ Rated Speed | 280—380 kPa (40—55 psi) | p. 204 |
| Coolant conditioner filter base cap screw torque | 47 N·m (35 lb-ft) | p. 245 |
| Coolant heater flange nut torque | 68 N·m (50 lb-ft) | p. 249 |
| Fan Belt Tension (New Belts) | 422—463 N (95—104 lb) | p. 226 |
| Fan Belt Tension (Belts in Service) | 378—418 N (85—94 lb) | p. 226 |
| Thermostat Opening Temperature | 80—84°C (175—182°F) | p. 226 |
| Thermostat Initial Opening Range (71°C Rating) | 69—72°C (156—162°F) | p. 363 |
| Minimum No Load Oil Pressure at 800 rpm | 103 kPa (1.03 bar) (15 psi) | p. 360 |
| Cylinder Head Cap Screws Initial Torque | 200 N·m (150 lb-ft) | p. 51 |
