Part of the John Deere Operator Manuals.
Rebuilding a PowerTech 2.4L or 3.0L diesel? This 420-page John Deere 4024 technical manual PDF (OEM CTM301) is the factory shop reference for 4024 and 5030 engines, cylinder head to flywheel. You get the complete rebuild sequence: cylinder head and valves, block, pistons and rods, crankshaft and main bearings, camshaft and timing gear train, plus lubrication, cooling, and fuel system repair. A full diagnostics section walks you through base engine, fuel system, and electronic controller tests, backed by theory of operation chapters so you understand what you're measuring. Torque the final cylinder head cap screws No. 1-8 to 70 N·m (52 ft-lb) plus 150° (No. 9-10 get 120°); the unit pump runs 1200 bar with fuel delivery up to 100 mm3/stroke. Head bolts stretch, and guesses cost engines. Fully bookmarked and keyword searchable; download it and prop your tablet right on the engine stand. Your download includes both documents sold with this listing: the CTM301 component technical manual and the OMRG34851 operator's manual for the 4024 and 5030 OEM engines.
What's Inside This John Deere 4024, 5030, PowerTech 2.4L, PowerTech 3.0L Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 9-44 | Safety |
| Engine Rebuild | 45-58 | Engine Overhaul Guidelines, Engine Repair Stand, Engine Disassembly Sequence, Engine Assembly Sequence, Engine Break-In |
| Cylinder Head and Valves | 59-90 | Cylinder Head Removal, Valve Assembly, Valve Springs, Valve Seats, Cylinder Head Flatness |
| Cylinder Block, Pistons, and Rods | 91-122 | Connecting Rods, Piston Removal, Piston Ring Groove Wear, Cylinder Bore Deglazing, Cylinder Block Top Deck Flatness |
| Crankshaft, Main Bearings and Flywheel | 123-152 | Crankshaft Failure Analysis, Vibration Damper, Crankshaft Pulley, Crankshaft End Play, Flywheel Housing |
| Camshaft, Balancer Shafts and Timing Gear Train | 153-172 | Timing Gear Cover, Balancer Shafts, Camshaft Bushings, Camshaft Lobe Height, Governor Assembly |
| Lubrication System | 173-182 | Oil Pump, Oil Cooler, Oil Pressure Regulating Valve, Oil Pick-Up Tube, Oil Dipstick Tube |
| Cooling System | 183-196 | Thermostat, Fan and Alternator Belt, Belt Tensioner, Coolant Pump, Fan Bearing |
| Air Intake, Exhaust System, and Fuel System | 197-248 | Turbocharger Life, Turbocharger Inspection, Fuel Supply Pump, Injection Nozzles, Fuel Control Rack Travel |
| Theory of Operation | 249-272 | Base Engine Operation, Lubrication System Operation, Coolant System Operation, Air Intake and Exhaust System Operation, Fuel/Governor System Operation |
| Diagnostics | 273-368 | Base Engine Observable Diagnostics and Tests, Fuel System Observable Diagnostics and Tests, Electronic Controller Diagnostics and Tests |
| Tools and Other Materials | 369-392 | Repair Tools and Other Materials, Diagnostic Service Tools, Dealer Fabricated Service Tools |
| Specifications | 393-420 | Repair and General OEM Specifications, Diagnostic Specifications |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Final Cylinder Head Cap Screws No.1 - No.10 Torque | 70 N·m (52 ft-lb) plus 150° +10°/-0° | p. 81 |
| Final Cylinder Head Cap Screws No.11 - No.12 Torque | 70 N·m (52 ft-lb) plus 120° +10°/-0° | p. 81 |
| Oil Pick-up Tube Support Bracket Cap Screws—Torque | 28 N•m (21 lb-ft) | p. 178 |
| Oil Pick-up Tube Hold Down Clamp Cap Screw—Torque | 16.5 N•m (12 lb-ft) | p. 180 |
| Unit pump maximum fuel delivery | 100 mm3/stroke | p. 265 |
| Unit pump maximum pressure | 1200 bar | p. 265 |
| Thermostat Initial Opening (Range) for 71°C (160°F) rating | 69—72°C (156—162°F) | p. 295 |
| Thermostat Full Open (Nominal) for 71°C (160°F) rating | 84°C (182°F) | p. 295 |
| Maximum starter operation time | 15 seconds | p. 306 |
| Hold Coil Resistance | 14 Ohms | p. 341 |
| Unit Pump Clamp | 50 N•m (37 lb-ft) | p. 403 |
| Nozzle Clamp Cap Screw | 27 N•m (20 lb-ft) | p. 413 |
