John Deere 6090H Engine

⚠ Valve clearance MUST BE checked and adjusted with engine COLD.

⚠ Visually inspect contact surfaces of valve tips and rocker arm wear pads; replace parts showing visible damage.

⚠ When reinstalling rocker arm cover, DO NOT reuse gasket.

Tools: JDG820 Flywheel Turning Tool and Timing Pin, bent feeler gauge, torque wrench

1. Disconnect NEGATIVE (—) battery terminal and remove rocker arm cover with vent tube.
2. Remove plastic plug from cylinder block bores and install JDG820 Flywheel Turning Tool and Timing Pin.
3. Rotate engine with the flywheel turning tool until timing pin engages timing hole in flywheel.
4. If rocker arms for No. 1 (front) cylinder are loose, engine is at No. 1 TDC-Compression; if No. 6 is loose, rotate one full revolution.
5. Push the rocker arm foot forward for easier feeler gauge access.
6. Use a bent feeler gauge to check clearance on Nos. 1, 3 and 5 exhaust valves and Nos. 1, 2 and 4 intake valves.
7. Loosen lock nut; turn adjusting screw until feeler gauge slips with a slight drag.
8. Hold adjusting screw with a screwdriver and tighten lock nut to specification.
9. Recheck clearance after tightening lock nut; readjust as necessary.
10. Rotate flywheel 360° until No. 6 piston is at TDC of its compression stroke.
11. Check and adjust clearance on Nos. 2, 4 and 6 exhaust and Nos. 3, 5 and 6 intake valves.
12. Install new rocker arm cover gasket, then install cover with vent tube.
13. Tighten cap screws in sequence shown to 35 N·m; after 10 minutes re-torque in sequence.
14. Connect main engine wiring harness.

⚠ Only remove cap when cool enough to touch with bare hands; slowly loosen cap to first stop to relieve pressure before removing completely.

⚠ If coolant level does not drop below Full Hot, there is a leak in the cooling system; engine damage may result.

1. Remove cap from top tank (de-aeration tank) of cooling system.
2. Remove EGR cooler vent plug from rear of cooler.
3. Fill high pressure coolant circuit at top tank.
4. Begin filling coolant recovery tank (if equipped).
5. When air is purged and coolant is visible coming out of the vent hole on EGR cooler, reinstall EGR cooler vent plug and tighten.
6. Complete filling coolant recovery tank (if equipped) to Full Hot mark.
7. Install top tank (de-aeration) cap; start engine and run at idle for 1 to 5 minutes.
8. Shut off and remove top tank cap; fill high pressure circuit tank and reinstall cap.
9. Start engine and warm up for 15 minutes; top off top tank until coolant loss stops.
10. Shut off engine and allow to cool; observe coolant level dropped below Full Hot in recovery tank.
11. Monitor coolant recovery tank for two days; refill recovery tank or top tank as required.

Tools: wrench

1. Use a wrench to unscrew cap; wait 30 seconds to allow oil filter housing to drain.
2. Remove cap and filter assembly.
3. While holding on to screw cap, strike filter element against a solid surface to disconnect filter from cap; discard used filter.
4. Remove o-ring seal and replace with new o-ring provided with new filter element.
5. Press new filter into cap until it snaps into place.
6. Insert cap and filter assembly into oil filter housing; screw cap in place.
7. Use wrench to tighten cap to specification.

⚠ Do not drain coolant until the coolant temperature is below operating temperature. Always loosen coolant pump drain valve and block drain valve slowly to relieve any excess pressure.

⚠ Both coolant pump drain valve and block drain valve must be opened to completely drain the engine.

⚠ Air must be expelled from cooling system when system is refilled.

Tools: heavy gauge wire

1. Remove trash that has accumulated on or near radiator.
2. Visually inspect entire cooling system and all components for leaks or damage; repair or replace as necessary.
3. Remove the foam filter from the weep hole located on the side of timing gear cover and discard filter.
4. Insert a heavy gauge wire deep into weep hole to make sure hole is open.
5. Install new foam filter flush with timing gear cover.
6. Remove and check thermostat(s).
7. Drain and flush cooling system.
8. Fill cooling system with coolant.
9. Run engine until it reaches operating temperature; check entire cooling system for leaks.
10. After engine cools, check coolant level; level should be even with bottom of radiator filler neck.
11. Check system for holding pressure.

Tools: SW10015JD Fuel Injector Flush Kit

1. Change engine primary and secondary fuel filters.
2. Prime fuel system and start engine; run until normal operating temperature.
3. Disconnect fuel supply to primary filter; connect red supply hose to SW10015JD kit reservoir.
4. Disconnect fuel return-to-tank; connect black return hose through kit filter to reservoir.
5. Fill reservoir with TY26688 Diesel Fuel System Clean-Up solution; open valve.
6. Key-on engine to check for leaks and verify return fuel flow.
7. Start engine and run at 1100 rpm for 20-40 minutes; do not let engine run out of fuel.
8. Remove and inspect kit return filter element (SW10967P1) for debris; repeat if badly contaminated.
9. Close reservoir valve; disconnect hoses; reconnect fuel supply and return lines.
10. Start engine and run 10-15 minutes to purge cleaner solution.

⚠ DO NOT use John Deere PLUS-50 oil or engine oils meeting API CG4, API CF4, ACEA E3 or ACEA E2 during break-in of a major overhauled engine.

⚠ Do not add makeup oil until the oil level is BELOW the add mark. Do not fill above the crosshatch pattern or FULL mark.

Tools: dynamometer (preferred load control)

1. Fill engine crankcase to proper level with John Deere ENGINE BREAK-IN OIL.
2. Start engine, 1 minute no load at 850 rpm.
3. 2 minutes no load at fast idle.
4. 15 minutes at 1/2—3/4 load, 2000 rpm to rated speed.
5. 10 minutes at full load, rated speed.
6. After preliminary break-in, run engine 1—2 minutes at 1500 rpm with no load before shut-down.
7. Check and readjust valve clearance as necessary; cylinder head retorque is not required.
8. During the first 20 hours, avoid prolonged idling or sustained maximum load; if engine will idle longer than 5 minutes, stop engine.
9. Operate the engine at heavy loads with minimal idling during the break-in period.
10. After 250 hours maximum, drain break-in oil and change oil filter.
11. Fill crankcase with John Deere TORQ-GARD SUPREME or PLUS-50 or other heavy-duty diesel engine oil.

⚠ DO NOT spin the rotor assembly with compressed air; damage to bearings can occur.

1. Fill oil return (drain) port with clean engine oil.
2. Spin rotating assembly by hand to properly lubricate bearings.
3. If turbocharger is to be stored for an extended period of time, lubricate internally and install protective covers on all openings.

⚠ Escaping diesel fuel under pressure can penetrate skin causing serious injury

⚠ High-pressure fuel is dangerous

1. Stop engine and wait minimum 15 minutes (5 minutes minimum specified for rail) before disconnecting high-pressure lines.
2. Open first high-pressure line slowly to verify pressure has been relieved.

⚠ Do not pre-fill filter with fuel; may introduce debris

1. Clean filter header and surrounding area.
2. Connect drain line to drain valve; drain all fuel from canister.
3. Disconnect water-in-fuel sensor connector.
4. Turn canister counter-clockwise to remove.
5. Pull filter element down to remove from header.
6. Inspect sealing surfaces; clean as required.
7. Place new packing on canister; coat with thin film of fuel.
8. Place filter element in canister with tangs down.
9. Install filter onto header until snug.
10. Turn filter additional 3/4 turn after seal contact.
11. Connect water-in-fuel sensor connector.

⚠ Do not pre-fill filter with fuel

1. Clean filter header and surrounding area.
2. Connect drain line to drain valve; drain fuel.
3. Turn filter counter-clockwise to remove.
4. Inspect header sealing surface; clean as required.
5. Install new filter drain valve and tighten to specification.
6. Place new packing on filter; coat with thin film of fuel.
7. Install filter onto header until snug.
8. Turn filter additional 3/4 turn after seal contact.
9. Prime fuel system by turning ignition ON for 60 seconds before starting.

⚠ Do not drain coolant until coolant temperature is below operating temperature. Always loosen cooling system filler cap, radiator cap or drain valve slowly to relieve pressure.

Tools: thermostat test equipment

1. Visually inspect the area around the coolant manifold for leaks; partially drain coolant from the cooling system.
2. Remove thermostat cover with gasket.
3. Remove thermostats.
4. Inspect thermostats for debris or damage.
5. Test each thermostat using an approved testing procedure; they should start to open within specification.
6. If either thermostat fails to open within this range, replace both thermostats as a set.

⚠ The only recommended method for lifting the 6090 engine is with JDG23 Engine Lifting Sling and safety approved JDG10040 and JDG10059 lift straps.

⚠ NEVER permit any part of the body to be positioned under an engine being lifted or suspended.

⚠ Angular loading greatly reduces lifting capacity of sling and brackets.

Tools: JDG23 Engine Lifting Sling, JDG10040 Right Front Lift Strap, JDG10059 Left Rear Lift Strap

1. Attach JDG23 Engine Lifting Sling to engine JDG10040 (front) and JDG10059 (rear) lifting straps and to overhead hoist or floor crane.
2. Carefully lift engine to desired location with longitudinal loading on lift sling and lifting brackets only.