John Deere 9.0 L OEM Diesel Engines Remove Pistons and Connecting Rod Assemblies
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2025 John Deere Service Advisor 5.3
AUTION: Do not drain engine coolant until it cools below operating temperature. Thenslowly loosen coolant pump cover drain valve (A) and block drain valve (B) to relieve any pressure. Drain coolant and engine oil.
IMPORTANT: Both drain valves must be opened to completely drain engine block.
1. Drain all engine coolant and engine oil.
NOTE: If engine is to be completely disassembled, see ENGINE DISASSEMBLY SEQUENCE in Group 010.
2. Remove cylinder head. See REMOVE CYLINDER HEAD in Group 020.
3. Remove oil pan and oil pump. See REMOVE ENGINE OIL PUMP in Group 060.
IMPORTANT: Do not rotate crankshaft with cylinder head removed unless liners are bolted down.
Bolt liners down before removing piston.Cap screws and washers must be tightened to the following specifications to achieve an accurate reading when measuring liner standout (height above block). See MEASURE CYLINDER LINER STANDOUT (HEIGHT ABOVE BLOCK), later in this group.
4. Use 9/16-18 cap screws, approximately 51 mm (2.0 in.) long and 5/8 in. I.D. 1-3/4 in. O.D. x 3.18 mm (1/8 in.) thick washers to bolt down cylinder liners in the locations as shown. Tighten cap screws to
specifications.
Specification
Cylinder Liner Cap
Screws (For Checking
Standout)—Torque......................................................... 68 N·m (50 lb-ft)
As the cylinder liner wears, a ridge is formed at the top of piston ring travel zone. If this ridge gets too high,pistons and rings can be damaged when they are removed. Remove any ridges from liner bores with a scraper or ridge reamer before removing pistons.
5. Before removing pistons, visually inspect condition of cylinder liners with pistons at bottom dead center “BDC”. Liners will require replacement if:
• The crosshatch honing pattern is not visible immediately below the top ring turn around area.
• Liners are pitted or contain deep vertical scratches that can be detected by the fingernail.
No further inspection is required if any one of the above conditions are found.
NOTE: Connecting rod bearing-to-journal oil clearance should be measured before removing piston/rod assembly.
Use PLASTIGAGE® as directed by the manufactured. Remember, the use of
PLASTIGAGE® will determine bearing-to-journal oil clearance, but will not indicate the condition of either surface.
6. Rod bearing-to-journal oil clearance can be checked with PLASTIGAGE® if rod is connected to crankshaft.
If rod is out of engine, measure I.D. of assembled connecting rod bearings and compare with O.D. of crankshaft journal.
IMPORTANT: DO NOT use pneumatic wrenches to tighten or loosen rod cap screws. Using pneumatic wrenches may cause thread damage.
Keep bearing inserts with their respective rods and caps. Mark rods, pistons, and caps to insure correct assembly in same location as removed.
7. Remove rod cap screws and rod caps (A) with bearings (B).
Crankshaft is shown removed, but piston and rod assembly can be removed with crankshaft installed.
IMPORTANT: Be careful not to let rod nick crankshaft bearing surface as piston and rod assembly is removed.
Be extremely careful to not damage piston spray orifice. 6090 pistons are direct oil cooled, so
correct orientation of orifice is critical.
If liners are to be reused, be extremely careful not to let connecting rod hit liner bore when removing piston and rod assembly.
Piston and liners are selectively fitted to maintain piston-to-liners clearance. Always keep matched pistons and liners together as a set and each set MUST BE installed in the same cylinder as removed.
8. Gently tap piston (A) through top of cylinder block from the bottom. Once piston rings have cleared cylinder liner bore, hold on to piston to prevent piston from dropping.
