2004–2006 John Deere PowerTech / PowerTech Plus 4.5L & 6.8L Diesel Engines Base Engine Technical Manual (P/N CTM104)

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John Deere Models Covered & Key Technical Specifications

Models: John Deere PowerTech / PowerTech Plus 4.5L Diesel Engines, John Deere PowerTech / PowerTech Plus 6.8L Diesel Engines

Models & Model Codes:

PowerTech / PowerTech Plus 4.5L Diesel Engines — John Deere: 4045HZ060, CD4045DAT70, CD4045DF120, CD4045DF150, CD4045DF151, CD4045DF152, CD4045DF153, CD4045DF154, CD4045DF157, CD4045DF158, CD4045DF270, CD4045DFG70, CD4045DFM50, CD4045DFM70, CD4045DL050, CD4045DL070, CD4045DL270, CD4045DLV50, CD4045DRT50, CD4045DRT51, CD4045DTK20, CD4045HF120, CD4045HF150, CD4045HF152, CD4045HF157, CD4045HF158, CD4045HF252, CD4045HF254, CD4045HF275, CD4045HF475, CD4045HF485, CD4045HL070, CD4045HL071, CD4045HL072, CD4045HL073, CD4045HL270, CD4045HL271, CD4045HL272, CD4045HL273, CD4045HL470, CD4045HL472, CD4045HL473, CD4045HL476, CD4045HLA70, CD4045HLA71, CD4045HLA72, CD4045HLA73, CD4045HTJ75, CD4045HTJ76, CD4045HTJ77, CD4045HZ050, CD4045HZ275, CD4045TAT50, CD4045TAT70, CD4045TAT71, CD4045TBE50, CD4045TBE51, CD4045TBE52, CD4045TF120, CD4045TF150, CD4045TF151, CD4045TF152, CD4045TF154, CD4045TF155, CD4045TF157, CD4045TF158, CD4045TF161, CD4045TF162, CD4045TF220, CD4045TF250, CD4045TF251, CD4045TF252, CD4045TF253, CD4045TF254, CD4045TF257, CD4045TF258, CD4045TF270, CD4045TF271, CD4045TF273, CD4045TF275, CD4045TFM50, CD4045TFM75, CD4045TL050, CD4045TL051, CD4045TL052, CD4045TL053, CD4045TL054, CD4045TL055, CD4045TL056, CD4045TL057, CD4045TL058, CD4045TL059, CD4045TL060, CD4045TL061, CD4045TL062, CD4045TL063, CD4045TL064, CD4045TL070, CD4045TL071, CD4045TL072, CD4045TL073, CD4045TL074, CD4045TL075, CD4045TL270, CD4045TL271, CD4045TL272, CD4045TL273, CD4045TL274, CD4045TLA50, CD4045TLA51, CD4045TLV50, CD4045TRT50, CD4045TZ250, CD4045TZ270, J04045DCQ01, J04045DJ31, J04045TCQ01, J04045TCQ02, J04045TCQ03, J04045TJ31, PE4045DF120, PE4045DF150, PE4045DF151, PE4045DF152, PE4045DF153, PE4045DF154, PE4045DF157, PE4045DF158, PE4045DF270, PE4045DFM50, PE4045DKV50, PE4045DKV51, PE4045DLV50, PE4045DLV51, PE4045DP052, PE4045DP053, PE4045DP054, PE4045DT050, PE4045DT056, PE4045DT057, PE4045DT059, PE4045HDW52, PE4045HDW53, PE4045HDW63, PE4045HF120, PE4045HF150, PE4045HF152, PE4045HF157, PE4045HF158, PE4045HF252, PE4045HF275, PE4045HF475, PE4045HF485, PE4045HP050, PE4045HP051, PE4045HT050, PE4045HT051, PE4045HT054, PE4045HT055, PE4045TDW50, PE4045TE050, PE4045TE051, PE4045TF120, PE4045TF150, PE4045TF151, PE4045TF152, PE4045TF154, PE4045TF155, PE4045TF157, PE4045TF158, PE4045TF161, PE4045TF162, PE4045TF220, PE4045TF250, PE4045TF251, PE4045TF252, PE4045TF253, PE4045TF257, PE4045TF258, PE4045TF270, PE4045TF271, PE4045TF275, PE4045TFM50, PE4045TFM75, PE4045TKV50, PE4045TLV50, PE4045TLV51, PE4045TLV52, PE4045TLV53, PE4045TLV54, PE4045TN050, PE4045TP051, PE4045TP052, PE4045TP053, PE4045TP054, PE4045TP055, PE4045TP056, PE4045TP057, PE4045TP058, PE4045TP059, PE4045TP060, PE4045TP061, PE4045TP062, PE4045TP063, PE4045TP064, PE4045TT050, PE4045TT057, PE4045TT058, PE4045TT061, PE4045TT063, PE4045TT064, PE4045TT065, PE4045TT066, PE4045TT067, PE4045TT069, PE4045TT070, PE4045TT080, PE4045TT081, PE4045TT082, PE4045TT083, PE4045TT084, PE4045TT085, PE4045TT086, PE4045TT087, PE4045TT088, PE4045TT089, PE4045TT090, PE4045TT091, PE4045TT092, PE4045TT093, PE4045TT094, PE4045TT850, PE4045TT851, PE4045TT852, T04045DF120, T04045DF150, T04045DF151, T04045DF152, T04045DF153, T04045DF154, T04045DF157, T04045DF158, T04045DF270, T04045DFM50, T04045DT004, T04045DT006, T04045DT050, T04045DT052, T04045DT053, T04045DT055, T04045DT056, T04045DT057, T04045DT058, T04045HDW50, T04045HDW51, T04045HF120, T04045HF150, T04045HF152, T04045HF157, T04045HF158, T04045HF252, T04045HF275, T04045HF475, T04045TDW50, T04045TE050, T04045TE051, T04045TF120, T04045TF150, T04045TF151, T04045TF152, T04045TF154, T04045TF155, T04045TF157, T04045TF158, T04045TF161, T04045TF162, T04045TF220, T04045TF250, T04045TF251, T04045TF252, T04045TF253, T04045TF257, T04045TF258, T04045TF270, T04045TF271, T04045TF273, T04045TF275, T04045TFM50, T04045TN050, T04045TT005, T04045TT006, T04045TT007, T04045TT013, T04045TT014, T04045TT015, T04045TT050, T04045TT052, T04045TT053, T04045TT054, T04045TT055, T04045TT056, T04045TT057, T04045TT058, T04045TT060, T04045TT061, T04045TT062, T04045TT063, T04045TT064, T04045TT065, T04045TT066, T04045TT067, T04045TT068, T04045TT069, T04045TT070, T04045TT080, T04045TT081, T04045TT082, T04045TT083, T04045TT084, T04045TT085, T04045TT091, T04045TT801, T04045TT850. Performance-reference table entries: CD4045HL475, CD4045HZ060, CD4045TAT050, PE4045TT095.

PowerTech / PowerTech Plus 6.8L Diesel Engines — John Deere: CD6068DF150, CD6068DL050, CD6068DL051, CD6068DL070, CD6068DL071, CD6068HBE50, CD6068HCQ60, CD6068HCQ61, CD6068HF120, CD6068HF150, CD6068HF157, CD6068HF158, CD6068HF250, CD6068HF252, CD6068HF254, CD6068HF258, CD6068HF275, CD6068HF475, CD6068HF485, CD6068HL270, CD6068HL271, CD6068HL272, CD6068HL273, CD6068HL470, CD6068HL471, CD6068HL472, CD6068HL473, CD6068HL474, CD6068HL475, CD6068HLA70, CD6068HLA71, CD6068HLA72, CD6068HLA73, CD6068HRW01, CD6068HTJ75, CD6068HTJ76, CD6068HTJ77, CD6068HYC50, CD6068HZ050, CD6068HZ060, CD6068HZ470, CD6068HZ480, CD6068HZ481, CD6068SFM50, CD6068TBE50, CD6068TBE51, CD6068TBE52, CD6068TBE53, CD6068TCQ50, CD6068TF120, CD6068TF150, CD6068TF151, CD6068TF152, CD6068TF157, CD6068TF158, CD6068TF159, CD6068TF220, CD6068TF250, CD6068TF251, CD6068TF254, CD6068TF257, CD6068TF258, CD6068TF275, CD6068TFM50, CD6068TFM75, CD6068TFM76, CD6068TL050, CD6068TL051, CD6068TL052, CD6068TL053, CD6068TL054, CD6068TL071, CD6068TL072, CD6068TL073, CD6068TLA50, CD6068TLA51, CD6068TLA52, CD6068TLA53, CD6068TP051, CD6068TP052, CD6068TRW01, CD6068TYC50, CD6068TYC51, J06068HCQ01, J06068TCQ02, J06068TCQ03, J06068TCQ04, J06068TCQ11, J06068TCQ12, J06068TCQ14, J06068TCQ15, J06068TJ31, J06068TJ32, J06068TYC50, J06068TYC51, JO6068ACQ04, JO6068TCG04, PE6068DF150, PE6068DT850, PE6068HDW50, PE6068HDW53, PE6068HDW55, PE6068HDW56, PE6068HDW57, PE6068HDW58, PE6068HDW59, PE6068HDW60, PE6068HDW61, PE6068HDW63, PE6068HDW64, PE6068HDW65, PE6068HDW66, PE6068HDW67, PE6068HDW68, PE6068HDW69, PE6068HDW70, PE6068HF120, PE6068HF150, PE6068HF157, PE6068HF158, PE6068HF250, PE6068HF252, PE6068HF258, PE6068HF275, PE6068HF475, PE6068HF485, PE6068HH052, PE6068HH054, PE6068HH055, PE6068HH057, PE6068HH058, PE6068HN051, PE6068HN052, PE6068HRW01, PE6068HRW54, PE6068HRW59, PE6068HRW61, PE6068HRW63, PE6068HT050, PE6068HT051, PE6068HT052, PE6068HT053, PE6068HT054, PE6068HT055, PE6068HT056, PE6068HT057, PE6068HT059, PE6068HT061, PE6068HT062, PE6068HT064, PE6068HT065, PE6068HTJ54, PE6068HTJ55, PE6068SFM50, PE6068TDW50, PE6068TDW53, PE6068TDW54, PE6068TDW55, PE6068TDW57, PE6068TDW58, PE6068TE050, PE6068TE051, PE6068TF120, PE6068TF150, PE6068TF151, PE6068TF152, PE6068TF157, PE6068TF158, PE6068TF159, PE6068TF220, PE6068TF250, PE6068TF251, PE6068TF252, PE6068TF257, PE6068TF258, PE6068TF275, PE6068TFM50, PE6068TN050, PE6068TN051, PE6068TN052, PE6068TN053, PE6068TN054, PE6068TP051, PE6068TP052, PE6068TP053, PE6068TP054, PE6068TP055, PE6068TP056, PE6068TP057, PE6068TP058, PE6068TP061, PE6068TP062, PE6068TRW01, PE6068TRW50, PE6068TRW51, PE6068TRW52, PE6068TRW70, PE6068TRW72, PE6068TRW73, PE6068TT050, PE6068TT051, PE6068TT052, PE6068TT053, PE6068TT055, PE6068TT056, PE6068TT057, PE6068TT058, PE6068TT059, PE6068TT060, PE6068TT061, PE6068TT850, PE6068TT851, PE6068TTJ50, PE6068TTJ51, T06068DF150, T06068HDW50, T06068HDW52, T06068HDW53, T06068HDW55, T06068HDW58, T06068HDW70, T06068HF120, T06068HF150, T06068HF157, T06068HF158, T06068HF250, T06068HF252, T06068HF258, T06068HF275, T06068HF475, T06068HH050, T06068HH051, T06068HH052, T06068HT050, T06068HT051, T06068HT052, T06068SFM50, T06068TDW010, T06068TDW50, T06068TDW51, T06068TDW52, T06068TDW53, T06068TDW54, T06068TDW55, T06068TDW56, T06068TDW57, T06068TE050, T06068TF120, T06068TF150, T06068TF151, T06068TF152, T06068TF157, T06068TF158, T06068TF159, T06068TF220, T06068TF250, T06068TF251, T06068TF257, T06068TF258, T06068TF275, T06068TFM50, T06068TN050, T06068TN051, T06068TN053, T06068TRW50, T06068TRW51, T06068TRW52, T06068TRW53, T06068TRW54, T06068TRW70, T06068TRW72, T06068TT005, T06068TT007, T06068TT050, T06068TT051, T06068TT052, T06068TT053, T06068TT055, T06068TT056, T06068TT057. Performance-reference table entries: J06068HCQ02, J06068TCQ01, J06068TCQ13, PE6068HRW60, PE6068HT161, PE6068TRW54, T06068TDW10.

Sub-models / Variants: Non-Certified, Tier 1/Stage I, Tier 2/Stage II, Tier 3/Stage IIIA, Naturally Aspirated, Turbocharged, Turbocharged and air-to-coolant aftercooled, Turbocharged and air-to-water aftercooled, Turbocharged and air-to-seawater aftercooled, Turbocharged and air-to-air aftercooled, Two-Valve Head, Four-Valve Head. Tier 3/Stage IIIA PowerTech Plus engines feature EGR and VGT.

Transmission-Linked Applications (Base Engine Only): 7210 SYNCROPLUS (T06068TRW53); 7410 SYNCROPLUS (T06068TRW54, PE6068HRW54); 7210 POWRQUAD (T06068TRW50, PE6068TRW50); 7410 POWRQUAD (T06068TRW51, PE6068TRW51); 7510 POWRQUAD (T06068TRW70, PE6068TRW70); 7220 IVT and 7320 IVT (PE6068HRW61); European-market 6320 IVT (CD4045HLA70); North American-market 6320 IVT (CD4045HLA71, CD4045HL472, CD4045HL476); European-market 6420 IVT (CD4045HLA72); North American-market 6420 IVT (CD4045HLA72, CD4045HL473).

Engine Serial Breaks:

  • PRECISION JOINT connecting rods: Dubuque-built 4.5L engines, S.N. 793938—; Dubuque-built 6.8L engines, S.N. 794055—; Saran-built engines with RE500002 rod, S.N. 554036—, or RE500608 rod, S.N. 553937—; Torreon-built engines with RE500002 rod, S.N. 039708—, or RE500608 rod, S.N. 036628—.

  • Saran-built CD engines, coolant-gallery plug variants: steel plug, S.N. —540458; composite plug, S.N. 540459—.

  • Earlier front-plate fasteners: Dubuque-built engines, S.N. —703904; Saran-built engines, S.N. —516217. Later front-plate/timing-cover hardware: Dubuque-built engines, S.N. 703905—; Saran-built engines, S.N. 516218—; Torreon-built engines, S.N. 001000—.

  • Equipped four-cylinder engines with removable balancer-shaft weights: Dubuque-built engines, S.N. 700877—; Saran-built engines, S.N. 500212—; Torreon-built engines, S.N. 001000—.

  • Saran CD engines in 6010/6020 Series tractor applications: R136162 tube and AT21535 dipstick, S.N. —550948CD; R501178 tube and RE502740 service dipstick, S.N. 550949CD—. Some later engines retain the earlier tube with a spacer.

Machine Application Serial Ranges (Base-Engine Matching Only):

  • 310G Backhoe Loader, Alt Comp: S.N. —910007 (T04045TT080, PE4045TT080); S.N. 910057— (PE4045TT088).

  • 310SG Backhoe Loader: S.N. —910004 (T04045TT081, PE4045TT081); S.N. 910056— (PE4045TT089, PE4045HT054).

  • 315SG Backhoe Loader: S.N. —909995 (T04045TT081, PE4045TT081); S.N. 910069— (PE4045TT089).

  • 710D Backhoe Loader: S.N. —834729 (T06068TT050, PE6068TT050); S.N. 834730— (T06068TT055, PE6068TT055).

  • 450G Crawler Dozer, Direct Drive: S.N. 840528—840890 (T04045DT004, T04045TT005); S.N. 841246—879425 (T04045TT061, PE4045TT061).

  • 450G Crawler Dozer, Torque Converter: S.N. 840529— (T04045TT013).

  • 550H Crawler Dozer: S.N. —909830 (T04045TT064, PE4045TT064); S.N. 910019— (PE4045TT086, PE4045TT090).

  • 550H LGP Crawler Dozer: S.N. —909667 (T04045TT065, PE4045TT065); S.N. 910017— (PE4045TT087, PE4045TT090).

  • 555G Crawler Loader, Direct Drive: S.N. 840461— (T04045TT063, PE4045TT063).

  • 750C Crawler Dozer: S.N. —831315 (T06068TT007); S.N. 831316— (T06068TT052, PE6068TT052).

  • 690ELC Excavator: S.N. 559603— (T06068TDW56).

  • 670CH Series II / 672CH Series II Graders: S.N. —589368 (T06068HDW58, PE6068HDW58); S.N. 589369— (PE6068HDW61).

  • 360D Timberjack Skidder: S.N. 589337— (PE6068TDW58).

  • 460D Timberjack Skidder, Direct Drive: S.N. 589337— (PE6068HDW60, PE6068HDW65).

  • 460D Timberjack Skidder, Torque Converter: S.N. —586336 (T06068TDW57, PE6068TDW57); S.N. 589337— (PE6068HDW59).

  • 540G / 548G Skidders: S.N. 558205—565684 (T06068TDW51).

  • 540G-II / 548G-II Skidders: S.N. 565685—576602 (T06068TDW54, PE6068TDW54).

  • 540G-III / 548G-III Skidders: S.N. 576603—586336 (T06068TDW54, PE6068TDW54); S.N. 586337— (PE6068HDW58).

  • 640G / 648G Skidders: S.N. 558205—565684 (T06068TDW52).

  • 640G-II / 648G-II Skidders: S.N. 565685—576602 (T06068TDW55, PE6068TDW55).

  • 640G-III / 648G-III Skidders, Direct Drive: S.N. 576603—586336 (T06068TDW55, PE6068TDW55); S.N. 589337— (PE6068HDW60).

  • 640G-III / 648G-III Skidders, Torque Converter: S.N. —586336 (T06068TDW57, PE6068TDW57); S.N. 586337— (PE6068HDW59).

Model Years: 2004–2006 (2004, 2005, 2006)

  • Engine Displacement: 4.5 Liters, 6.8 Liters

  • Intake Valve Clearance (Cold): 0.36 mm (0.014 in.)

  • Exhaust Valve Clearance (Cold): 0.46 mm (0.018 in.)

  • Rocker Arm Adjusting Screw Jam Nut Torque: 27 N•m (20 lb-ft)

  • Engine Repair Stand M12 Cap Screw Torque: 140 N•m (105 lb-ft)

  • Engine Repair Stand M14 Cap Screw Torque: 225 N•m (165 lb-ft)

  • Valve Lift (Intake, Two-Valve Head Engines, Cold, Zero Valve Clearance): 11.77–12.21 mm (0.463–0.481 in.)

  • Valve Lift (Exhaust, Two-Valve Head Engines, Cold, Zero Valve Clearance): 11.51–11.94 mm (0.453–0.470 in.)

  • Fuel Lubricity Minimum Load: 3100 grams

  • Max Fuel Sulfur Content: 10,000 ppm (1.00%)

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John Deere Manual Features & Selected Content Preview

John Deere component technical manual CTM104, dated January 27, 2006, covers 2004–2006 PowerTech and PowerTech Plus 4.5L and 6.8L diesel base engines. This edition replaces the June 30, 2005 issue and addresses non-certified engines and Tier 1/Stage I, Tier 2/Stage II, and Tier 3/Stage IIIA configurations.

  • Cylinder heads and valves: Separate procedures for two-valve and four-valve heads, including removal, valve-seat service, rocker-arm inspection, valve adjustment, and injector-sleeve replacement.

  • Internal engine repair: Cylinder liners, pistons, connecting rods, crankshafts, main bearings, flywheels, piston cooling orifices, and crankshaft oil-seal and wear-sleeve replacement.

  • Camshaft and timing gears: Camshaft inspection, timing-gear backlash checks, idler-gear service, and balancer-shaft installation and timing on equipped four-cylinder engines.

  • Lubrication and cooling: Oil-pump overhaul, oil-cooler service, pressure-regulating valves, thermostat testing, coolant-pump rebuilding, belt tensioners, and adjustable fan-drive bearings.

  • Turbocharger and EGR: Turbocharger failure analysis, bearing-clearance checks, wastegate adjustment, variable-geometry actuator service, and EGR cooler and valve removal and installation.

  • Engine diagnosis: Compression, cranking-speed, dynamometer, oil-pressure, blow-by, cooling-system, and intake/exhaust tests, supported by symptom charts and application-specific specifications.

Written for experienced technicians, this manual assumes access to the lifting equipment, engine stands, service tools, and measuring instruments specified for the work.

Base Engine Rebuild and Valve Train

The rebuild section defines disassembly and assembly sequences, sealant applications, and post-overhaul break-in checks. Cylinder-head procedures distinguish conventional valve-tip adjustment from the valve bridges and injector sleeves used with four-valve heads.

Internal repair coverage includes cylinder liner standout measurement and shimming, piston-to-liner inspection, connecting-rod bore checks, crankshaft journal inspection, and torque-turn tightening. Head-bolt tightening diagrams and wear-limit tables support reassembly; Loctite application charts identify the sealants and retaining compounds used at specific joints.

Timing-gear instructions distinguish head designs and gear part numbers. Tool references include the JDG451 height gauge for liner measurements and JT05993 torque-angle gauge for torque-turn fasteners.

The manual flags hydraulic-lock damage from trapped turbocharger oil when an engine is rotated on a rollover stand. It also warns that abrasive cleaning of PRECISION JOINT connecting-rod mating faces can destroy the interlocking surfaces needed for correct cap seating.

Lubrication, Cooling, and Fault Isolation

Oil-system procedures cover pump clearances, bypass and regulating valves, and oil-cooler inspection. Cooling instructions distinguish single, high-flow, and dual thermostat arrangements, plus standard-flow and high-flow coolant-pump impellers.

Illustrations include Lubrication System—Two Valve Cylinder Head Shown, Coolant Pump Assembly, and Engine Coolant Flow with EGR Cooler. These show component relationships and flow paths alongside the repair procedures.

The excessive-oil-consumption charts connect oil-condition checks, crankcase-pressure tests, turbocharger checks, and piston/liner inspection. This helps a technician narrow the cause before committing to an internal teardown. Separate charts address high or low oil pressure, abnormal coolant temperature, and oil/coolant contamination.

Turbocharger, EGR, and Service Boundaries

Turbocharger Failure Analysis links observed damage to possible causes, while Intake and Exhaust Gas Flow in EGR System explains the Tier 3 arrangement. Actuator and linkage procedures accompany references to the required Service ADVISOR/DST turbo learn reset and EGR-valve recalibration.

Turbocharger service centers on inspection, adjustment, and assembly replacement; the manual specifies complete remanufactured units rather than individual internal repair parts.

Fuel systems and electronics: Repair and diagnostics for the mechanical and electronic fuel systems are provided in separate companion manuals, which are not included. Starter and alternator removal and installation are covered, but their repair and testing are assigned to CTM77. Engine removal from the machine, access procedures, and air-to-air aftercooler service require the applicable machine technical manual.

Before disassembly, follow the manual’s precautions for heavy engine components, electrical isolation, and residual pressure in fuel and cooling systems.

A Selection of Liner Measurements and EGR Test Data

The following examples represent a small part of the manual’s inspection and test specifications.

For both head designs, cylinder-liner height above the block is specified at 0.030–0.100 mm (0.001–0.004 in.). The maximum height difference within one liner, or at the nearest points of adjacent liners, is 0.05 mm (0.002 in.).

For the Tier 3 EGR cooler, the air-leak test specifies 248 kPa (2.5 bar/36 psi). That value belongs to the cooler test, rather than the radiator-cap or complete cooling-system test.

Searchable Text and Procedure Bookmarks

Search and navigation: Searchable PDF text and embedded bookmarks provide access to sections, individual procedures, and numbered pages. Labeled flow diagrams, component views, and diagnostic charts accompany the text.

The download contains one printable, English-language 742-page PDF. The title page, introductory material, contents, index, and blank divider pages are already included in that total.

Technical Safety Notice
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Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

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2004–2006 John Deere PowerTech / PowerTech Plus 4.5L & 6.8L Diesel Engines Base Engine Technical Manual (P/N CTM104) $14.65