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 |
John Deere 4024, 5030, PowerTech 2.4L, PowerTech 3.0L Common Problems This Manual Covers
John Deere 4024 diesel cranks strong but won't fire, no smoke, started fine yesterday
Check fuel supply first: verify the tank pickup screen and fuel filter are not plugged, then bleed air from the suction side. Test compression while cranking; healthy cylinders read 2379-2792 kPa (345-405 psi), per the spec on page 287. Confirm the fuel shut-off solenoid pulls in with the key on before condemning the injection pump.
Manual Section: Group 151 - Fuel System Observable Diagnostics and Tests (E1) p. 312Engine loses power under load, bogs down on hills, runs fine at idle
Check the tank pickup screen and fuel filter for debris, then bleed air from the suction side and drain any water from the system. Inspect the air filter and exhaust for restriction. A healthy unit pump delivers up to 100 mm3/stroke at pressures up to 1200 bar (17,400 psi), described on page 265. Inspect the turbocharger if boost feels low.
Manual Section: Group 151 - Fuel System Observable Diagnostics and Tests (E3) p. 316Low oil pressure warning at operating temperature, knocking noise from the bottom end
Shut the engine down immediately and check the oil level and condition. Verify pressure with a mechanical gauge: minimum is 345 kPa at rated speed under full load and 105 kPa at low idle, both listed on page 396. If pressure stays low, drop the pan and inspect the oil pick-up tube and pressure regulating valve before pulling bearing caps.
Manual Section: Group 150 - Base Engine Observable Diagnostics and Tests (L2) p. 280Engine overheating in hot weather, coolant pushing out of the overflow after heavy work
Check the coolant level cold and inspect every hose and clamp for leaks. Test the thermostat in heated water; an 82°C (180°F) rated unit should start opening at 80-84°C (175-182°F), with full-open specs on page 295. Clean chaff and debris from the radiator fins and verify belt tension before condemning the coolant pump.
Manual Section: Group 150 - Base Engine Observable Diagnostics and Tests (C1) p. 283Starter turns the engine over slowly in cold weather, sometimes clicks once then nothing
Clean and tighten the battery terminals, then load-test the battery before touching the starter. Never crank longer than 15 seconds at a time or you will overheat the starter, per the warning on page 306. Test the solenoid hold coil resistance; spec is 14 Ohms on page 341. Replace the solenoid if the coil reads open or out of spec.
Manual Section: Group 151 - Fuel System Observable Diagnostics and Tests (E6) p. 324Frequently Asked Questions
What are the torque specifications for the injection nozzle hold-down clamp cap screw?
The torque specification for the injection nozzle hold-down clamp cap screw is 27 N•m (20 lb-ft). p. 216
How do I bleed the fuel system on a John Deere 2.4L or 3.0L engine?
To bleed the fuel system, open the air bleed vent screw on the fuel filter two full turns by hand. Pump the hand primer on the filter mounting base or supply pump until fuel and air flow from the vent, then close the screw. Repeat this process until resistance is felt in the hand primer. p. 335
What is the initial torque specification for the cylinder head cap screws on a 4-cylinder engine?
The initial torque specification for the cylinder head cap screws on a 4-cylinder engine is 110 N•m (81 ft-lb). p. 80
What is the oil capacity for a 5030 engine?
The crankcase oil capacity for a 5030 engine is 10 L (11 qt). p. 398
What is the minimum positive fuel pressure for the fuel supply pump at 2400 rpm?
The fuel supply pump should maintain a minimum positive pressure of 69 kPa (0.69 bar) (10 psi) at 2400 rpm. p. 337
What exactly do I receive with this John Deere 4024 Technical Manual?
This is a 420-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Are there any print restrictions on this John Deere 4024 manual?
Zero restrictions. The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
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