Part of the John Deere Repair Manuals.
All 635 pages of this John Deere 4045 Technical Manual PDF (OEM CTM104) zero in on one job: a complete factory-level rebuild of the 4.5L and 6.8L diesel engines powering the 4700 Sprayer, 6700/6700S Sprayer, 9935 Cotton Picker, 7455 Cotton Stripper, and 9400 Combine. Open to full exploded views of every major assembly, torque tables for inch and metric fasteners, error code charts, test values for each subsystem, and piston-to-bore clearance specs you won't find in a field guide. Inside, you also get a full engine rebuild sequence: disassembly through final assembly and break-in, backed by maintenance intervals from the factory. Check the vibration damper: maximum radial run-out is 1.50 mm, replace at 4500 hours or five years, and set the belt tensioner spring tension to 18–22 N•m. Engine apart. Every wrong guess costs you another head gasket. Bookmarked by section and keyword-searchable; open it on your phone or tablet right at the machine.
What's Inside This John Deere 4.5L, 6.8L, 4045, 6068 Diesel Engines Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 17-24 | Handle Fluids Safely, Avoid Fires, Prevent Battery Explosions, Prepare for Emergencies, Prevent Acid Burns, Avoid High-Pressure Fluids, Wear Protective Clothing |
| General Information | 25-32 | Unified Inch Bolt and Cap Screw Torque Values, Metric Bolt and Cap Screw Torque Values, Engine Model Designation, Engine Serial Number Plate Information, Engine Application Charts |
| Fuels, Lubricants and Coolant | 33-48 | Diesel Fuel, Lubricity of Diesel Fuels, Engine Break-In Oil, Alternative and Synthetic Lubricants, Mixing of Lubricants, Oilscan Plus® and Coolscan Plus®, Grease |
| Engine Mounting | 49-56 | Engine Repair Stand, Safety Precautions, Install Adapters on Engine Repair Stand, Engine Lifting Procedure, Clean Engine, Mount Engine on Repair Stand |
| Engine Rebuild Guide | 57-62 | Engine Disassembly Sequence, Sealant Application Guidelines, RTV Silicone Sealant Form-In-Place Gasket, Never-Seez® Compound, Engine Assembly Sequence, Perform Engine Break-In |
| Cylinder Head and Valves | 63-118 | Essential Tools, Cylinder Head and Valves Specifications, Check and Adjust Valve Clearance, Remove Cylinder Head, Inspect and Measure Camshaft Followers, Complete Final Assembly |
| Cylinder Block, Liners, Pistons and Rods | 119-184 | Liner removal/install, Piston & Ring Service, Connecting Rods (Precision Joint), Piston Protrusion & Bore Clearances |
| Crankshaft, Main Bearings and Flywheel | 185-238 | Crankshaft Inspection & Regrind, Main Bearings, Vibration Damper Run-Out, Front & Rear Oil Seals & Wear Sleeves, Flywheel |
| Camshaft, Balancer Shafts and Timing | 239-300 | Camshaft & Followers, Balancer Shafts, Timing Gears & Backlash, Timing Gear Cover, Front Plate |
| Lubrication System | 301-330 | Oil Pump, Oil Cooler, Oil Filter Base, Dipstick Tubes, Oil Pan, Piston Cooling Orifices |
| Cooling System | 331-364 | Water Pump, Thermostats, Dual Thermostat Water Manifold, Coolant Deaeration, Automatic Belt Tensioner |
| Air Intake and Exhaust System | 365-388 | Turbocharger Service, Wastegate Actuator Adjustment, Intake & Exhaust Manifolds, Air Intake Heater |
| Fuel System | 389-470 | Rotary & In-Line Injection Pumps, Static Timing, Primary & Final Fuel Filters, Supply Pump, Aneroid, Injection Nozzles |
| Starting and Charging Systems | 471-474 | Starting & Charging Component Removal & Installation |
| Engine Tune-Up and Break-In | 475-490 | Dynamometer Test Specs, Tune-Up Procedures, Engine Break-In |
| Engine System Operation and Tests | 491-520 | Cranking-Speed Test, Crankcase Blow-By Pressure Check, System Diagnostics |
| Air Intake and Exhaust Operation and Tests | 521-542 | Turbo Boost-Pressure Specs, Oil-Seal Leak Test, Intake & Exhaust Restriction Check, Wastegate Test |
| Fuel System Operation and Tests | 543-624 | Injection-Pump Theory & Specs, Fuel Supply Quality & Air-In-Fuel & Return-Line Checks, Shut-Off Solenoid Test |
| Dealer Fabricated Tools | 625-635 | Dealer-Fabricated Service Tools |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Vibration Damper Maximum radial run-out | 1.50 mm | p. 199 |
| Vibration Damper Maximum wobble | 1.50 mm | p. 199 |
| Belt Tensioner Spring Tension | 18—22 N•m | p. 352 |
| Restricted Fuel Line Cleaning | Clean as required | p. 582 |
John Deere 4.5L, 6.8L, 4045, 6068 Diesel Engines Common Problems This Manual Covers
Poly-vee belt squealing continuously during cold starts and alternator dropping system voltage
Test the automatic belt tensioner assembly directly on the engine. Measure the internal spring tension and verify it falls strictly within the 18 to 22 N•m range as shown on page 352. Replace both the tensioner and the poly-vee belt immediately if the measured force drops below this required specification.
Manual Section: General Information p. 352Crankshaft pulley wobbling visibly at idle and excessive engine vibration at high RPM
Check the vibration damper condition while the engine is completely secured. Mount a dial indicator on the block and verify the maximum wobble does not exceed 1.50 mm as detailed on page 199. Discard the damper completely if it exceeds this strict limit or reaches the mandatory 4500 hours.
Manual Section: Engine Rebuild Guide p. 199Frequently Asked Questions
What are the torque specs for cylinder head bolts?
For cylinder head cap screws, the initial torque is 100 N•m (75 lb-ft), followed by a second torque of 150 N•m (110 lb-ft). After 5 minutes, verify the torque at 150 N•m (110 lb-ft), and then tighten each screw an additional 60° using a torque angle gauge. p. 110
How do you inspect the crankshaft vibration damper for wear?
Inspect the vibration damper closely for damage. Measure the maximum radial run-out using a dial indicator, ensuring it absolutely does not exceed 1.50 mm as specified on page 199. Replace the damper immediately without question if it has been in service for 4500 hours or five years. p. 199
Which engines and machines does this CTM104 manual cover?
The 4.5L (4045) and 6.8L (6068) PowerTech diesel engines used in the 4700 Sprayer, 6700/6700S Sprayer, 9935 Cotton Picker, 7455 Cotton Stripper and 9400 Combine (see the application charts in Group 01).
What engine systems and procedures does it cover?
A full factory rebuild — cylinder head & valves, cylinder block/liners/pistons/rods, crankshaft & main bearings, camshaft & timing, lubrication, cooling, air intake & exhaust/turbocharger, and the fuel system — plus starting/charging and operation-and-test diagnostic sections.
Does it cover injection-pump timing and turbocharger testing?
Yes — the fuel-system groups cover static timing of the rotary and in-line injection pumps and fuel-supply checks, and the air-intake/exhaust groups cover turbocharger wastegate adjustment/testing and boost-pressure specs.
What format is this John Deere 4.5L, 6.8L, 4045, 6068 Diesel Engines manual in?
This is a 635-page scanned PDF (77 MB) 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.
Can I print specific sections of this John Deere 4.5L, 6.8L, 4045, 6068 Diesel?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
Reviews
There are no reviews yet.