John Deere Series 500, 6619 Diesel Engines Repair Manual (CTM9)

Table of Content
All safety information has been updated in Group 00. All persons using this manual should read and understand this information.
• Essential and Special Tools listings have been updated throughout the manual.
• Specifications listed at the beginning of each group have been updated.
• Basic engine specifications have been deleted from Group 01. Specifications are covered in detail in their respective groups. All specifications lists have been updated.
• Engine break-in oil information has been added.
Engine coolant requirements and recommendations have been updated. (Group 02.)
• Methods for properly lifting of engines have been updated. (Group 03.)
• Information on recommended sealants, thread lock compounds, anti-seize compounds, gasket materials and adhesives has been updated. Generic material recommendations have been updated to provide more specific information. Also, Sealant Applications Guidelines that provide ordering information for these materials as well as helpful “where used” information. (Group 04.)
• Valve clearance checking and adjustment procedure updated to show that these procedures MUST BE done with engine COLD. Cylinder head removal, inspection, and installation procedures have been updated. (Group 05.)
• Cylinder head cap screw and tightening information have been updated. (Group 05.)
• Crankshaft gear removal and installation procedures, crankshaft grinding guidelindes and specifications chart have been updated. (Group 15.)
• Procedures for the removal, repair and installation of the fuel injection pumps have been updated. (Group 35.)
• Engine break-in procedures have been updated. (Group 100.)
• Most component identification illustrations and general system descriptions have been moved to Group 105, Engine System Operation and Tests.
• Dealer Fabricated Tools have been removed from the individual groups and consolidated in Group 199
Essential tools required in performing certain service work are identified in this manual and are
recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
Essential tools required in performing certain service work are identified in this manual and are
recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
necessary instructions to repair the component.
Operation and tests sections help you identify the majority of routine failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
Component Technical Manuals are concise service guides for specific components. Component technical manuals are written as stand-alone manuals covering multiple machine applications.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.