PowerTech 6105ADW Technical Manual Download Page 197

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Cylinder Block, Liners, Pistons, and Rods

02
030
55

RG,RG34710,138

–19–30AUG02–1/1

Complete Final Assembly

NOTE: Refer to the proper group for installation of

components.

1. Coat threads of oil gallery plugs with LOCTITE



242

Thread Lock and Sealant. Install plugs and tighten
to specifications.

Specification

Oil Gallery Plug—Torque

20 N•m (15 lb-ft)

..........................................

Main Oil Gallery (Front)
Expansion Plug—Installed
Depth

Flush—1.5 mm (0.059 in.)

Below Surface

.........................................................

2. Install oil pickup tube. (See REMOVE AND

INSTALL OIL PICKUP TUBE in Group 060.) Install
oil pan. (See INSTALL ENGINE OIL PAN in Group
060.)

3. Install the cylinder head using new head gasket.

(See INSTALL CYLINDER HEAD in Group 020.)

4. Install camshaft and valve train. (See REMOVE

AND INSTALL CAMSHAFT in Group 050.) Install
timing gear cover. (See INSTALL TIMING GEAR
COVER in Group 040.)

5. Install electronic unit injectors. Refer to the

appropriate fuel system repair manual.

Delphi/Lucas ECU controlled fuel systems:

•

See REMOVE AND INSTALL ELECTRONIC
UNIT INJECTORS in CTM115, Section 02, Group
090.

John Deere Level 6 ECU controlled fuel systems:

•

See REMOVE AND INSTALL ELECTRONIC
UNIT INJECTORS in CTM188, Section 02, Group
090. (Dual rail fuel systems)

•

See REMOVE AND INSTALL ELECTRONIC
UNIT INJECTORS in CTM188, Section 02, Group
091. (Single rail fuel systems)

6. Adjust clearances, preloads, and gear backlash.

(Groups 020, 040, 050.)

7. Install remaining fuel injection system components.

(CTM115 Section 02, Group 090 or CTM188
Section 02 Group 090 and 091.)

8. Install the coolant pump and water piping. (See

INSTALL COOLANT PUMP in Group 070.)

9. Install lubrication system components. (Group 060.)

10. Install crankshaft pulley. (See INSTALL

CRANKSHAFT VIBRATION DAMPER AND
FRONT OIL SEAL in Group 040.)

11. Install the exhaust manifold. (See REMOVE,

INSPECT AND INSTALL EXHAUST MANIFOLD in
Group 080.) Install intake assembly. (See
REMOVE, INSPECT AND INSTALL INTAKE
MANIFOLD in Group 080.)

12. Install starter motor. (See REMOVE AND

INSTALL STARTER MOTOR in Group 100.)

13. Install alternator. (See REMOVE AND INSTALL

ALTERNATOR in Group 100.)

14. Install fan and fan belts. (See Machine Technical

Manual.)

15. Fill engine with clean oil. (See DIESEL ENGINE

OIL in Section 01, Group 002.) Service engine
with coolant. (See DIESEL ENGINE COOLANT
RECOMMENDATIONS in Section 01, Group 002.)

16. Perform engine break-in. (See PERFORM

ENGINE BREAK-IN in Group 010.)

LOCTITE is a registered trademark of Loctite Corp.

CTM100 (06APR04)

02-030-55

OWER

ECH

10.5 L & 12.5 L Diesel Engines

040604

PN=195

Summary of Contents for 6105ADW

Page 1: ... service information also see POWERTECH 10 5 L 12 5 L Diesel Engines Delphi Lucas Electronic Fuel Systems With Delphi Lucas EUIs CTM115 POWERTECH 10 5 L 12 5 L Diesel Engines Level 6 Electronic Fuel Systems With Delphi Lucas EUIs CTM188 OEM Engine Accessories CTM67 English Only Alternators and Starter Motors CTM77 John Deere Power Systems LITHO IN U S A ...

Page 2: ... application listing in Section 01 Group 001 identifies product model component type model relationship Information is organized in sections and groups for the various components requiring service instruction At the end of this manual are summary listings of all applicable essential tools service equipment and tools other materials needed to do the job service parts kits specifications wear tolera...

Page 3: ... 010 Engine Rebuild Added new engine front lift strap Revised engine disassembly sequence Revised engine assembly sequence SECTION 02 GROUP 020 Cylinder Head and Valves Revised procedure for adjusting valves and injector preload Revised procedure for repair of crankcase ventilation assembly Revised valve guide specifications Revised procedure for installation of rocker arm assembly SECTION 02 GROU...

Page 4: ... operation is covered in this section group NOTE Fuel system theory of operation has been moved to Section 03 Group 130 of the following manuals CTM115 Delphi Lucas Electronic Fuel Systems With Delphi Lucas EUIs CTM188 Level 6 Electronic Fuel Systems With Delphi Lucas EUIs SECTION 04 GROUP 150 Observable Diagnostics and Tests Base engine observable tests and diagnostics are covered in this section...

Page 5: ...Right Side View Early Engine RG9031 UN 21MAY98 Left Side View Early Engine RG9032 UN 21MAY98 3 4 Right Front View Early Engine RG9033 UN 21MAY98 3 4 Left Front View Early Engine POWERTECH is a registered trademark of Deere Company CTM100 06APR04 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 5 ...

Page 6: ...ht Rear View Early Engine RG11175 UN 20NOV00 3 4 Left Rear View Early Engine RG11171A UN 03NOV00 Right Side View Later Engine S N 30000 RG11172A UN 04DEC00 3 4 Right Front View Later Engine S N 30000 POWERTECH is a registered trademark of Deere Company CTM100 06APR04 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 6 ...

Page 7: ...W Engines RG8222 UN 21MAY98 Right Side View RG8221 UN 21MAY98 Left Side View RG8223 UN 21MAY98 3 4 Right Front View RG8224 UN 21MAY98 3 4 Left Front View POWERTECH is a registered trademark of Deere Company CTM100 06APR04 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 7 ...

Page 8: ... 1 POWERTECH 6105HRW and 6125HRW Engines Continued RG8220 UN 21MAY98 3 4 Right Rear View RG8219 UN 21MAY98 3 4 Left Rear View POWERTECH is a registered trademark of Deere Company CTM100 06APR04 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 8 ...

Page 9: ...ide View Early Engine RG8448 UN 21MAY98 3 4 Left Front View Early Engine RG8453 UN 21MAY98 3 4 Right Rear View Early Engine RG8451 UN 21MAY98 3 4 Left Rear View Early Engine POWERTECH is a registered trademark of Deere Company CTM100 06APR04 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 9 ...

Page 10: ...DW Engine Continued RG11171A UN 03NOV00 Right Side View Later Engines S N 30000 RG11172A UN 04DEC00 Right Front View Later Engines S N 30000 POWERTECH is a registered trademark of Deere Company CTM100 06APR04 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 10 ...

Page 11: ...3 1 1 POWERTECH 6125 Tier II 30000 RG11171A UN 03NOV00 Right Side View 30000 RG11172A UN 04DEC00 Right Front View 30000 POWERTECH is a registered trademark of Deere Company CTM100 06APR04 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 11 ...

Page 12: ...Oil Cooler E Crankshaft I Piston Rings M Valves B Oil Pump Drive Gear F Cylinder Liner J Connecting Rod N Electronic Unit Injector C Idler Gear G Cylinder Liner O Rings K Oil Spray Jet O Two Piece Rocker Arm D Camshaft Gear H Piston L Camshaft Shaft CTM100 06APR04 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 12 ...

Page 13: ...on Group 120 Base Engine Operation SECTION 04 Diagnostics Group 150 Observable Diagnostics and Tests SECTION 05 Tools and Other Materials 04 Group 170 Repair Tools and Other Materials Group 180 Diagnostic Service Tools Group 190 Dealer Fabricated Service Tools SECTION 06 Specifications Group 200 Repair and General OEM Specifications Group 210 Diagnostic Specifications 05 All information illustrati...

Page 14: ...Contents 01 02 03 04 05 06 INDX CTM100 06APR04 ii POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 2 ...

Page 15: ...Engine Oil Non Certified and Tier I Certified Engines 01 002 5 Diesel Engine Oil Tier II Engines 01 002 6 Extended Diesel Engine Oil Service Intervals 01 002 7 Alternative and Synthetic Lubricants 01 002 7 Mixing of Lubricants 01 002 8 OILSCAN and COOLSCAN 01 002 8 Grease 01 002 9 Diesel Engine Coolant 01 002 10 Supplemental Coolant Additives 01 002 11 Testing Diesel Engine Coolant 01 002 12 Reple...

Page 16: ...Contents 01 CTM100 06APR04 01 2 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 2 ...

Page 17: ... 1 1 Service Cooling System Safely TS281 UN 23AUG88 Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely DX FIRE2 19 03MAR93 1 1 Prepare for Emergencies TS291 UN 23AUG88 Be prepared if a fire starts Keep a fir...

Page 18: ... well ventilated area 2 Wearing eye protection and rubber gloves 3 Avoiding breathing fumes when electrolyte is added 4 Avoiding spilling or dripping electrolyte 5 Use proper jump start procedure If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 15 30 minutes Get medical attention immediately If acid ...

Page 19: ...Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Such information is available from Deere Company Medical Department in Moline Illinois U S A DX WEAR 19 10SEP90 1 1 Wear Protective Clothing TS206 UN 23AUG88 Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause impairment or loss of hearing Wear ...

Page 20: ...a TS220 UN 23AUG88 Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area remove the exhaust fumes from the area with an exhaust pipe extension If you do not have an exhaust pipe extension open the doors and get outside air into the area DX CLEAN 19 04JUN90 1 1 Work in Clean Area T6642EJ UN 18OCT88 Before starting a job Clean work area and machine ...

Page 21: ...stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating Do not use a chlorinated solvent in areas where welding will take place Do all work in an area that is well ventilated to carry toxic fumes and dust away Dispose of paint and solvent properly DX TORCH 19 03MAR93 1 1 Avoid Heating Near Pressurized Fluid Lines TS953 UN 15M...

Page 22: ... 23AUG88 Lifting heavy components incorrectly can cause severe injury or machine damage Follow recommended procedure for removal and installation of components in the manual DPSG OUO1004 899 19 19MAY99 1 1 Construct Dealer Made Tools Safely LX1016749 UN 01JUL97 Construct Dealer Made Tools Safely Faulty or broken tools can result in serious injury When constructing tools use proper quality material...

Page 23: ...any buildup of grease oil or debris On self propelled equipment disconnect battery ground cable before making adjustments on electrical systems or welding on machine On towed implements disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine DX REPAIR 19 17FEB99 1 1 Use Proper Tools TS779 UN 08NOV89 Use tools appropriate to the work Makeshift to...

Page 24: ...rain or into any water source Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center or from your John Deere dealer DX LIVE 1...

Page 25: ...ylinders 10 5 Liter designation H Aspiration RW User code 01 Application Code Aspiration Code A Turbocharged and air to coolant aftercooled H Turbocharged and air to air aftercooled User Code DW Davenport Construction Equipment Works F OEM Outside Equipment Manufacturers a RW Waterloo Tractor Works T Dubuque Construction Equipment Works T8 Cameco Z Zweibrucken Forage Harvester Works a OEM users ar...

Page 26: ...ry engine model designation and a 6 digit sequential number The following is an example RG6105H000000 RG Factory code producing engine 6105H Engine model designation 000000 Sequential number Factory Code Producing Engine RG Waterloo Engine Works Engine Model Designation 6105H See Engine Model Designation on previous page Sequential Number 000000 6 digit sequential number 2 Engine Application Data ...

Page 27: ...ber plate OEM engines have an engine option code label affixed to the rocker arm cover These codes indicate which of the engine options were installed on your engine at the factory When in need of parts or service furnish your authorized servicing dealer or engine distributor with these numbers CTM100 06APR04 01 001 3 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 27 ...

Page 28: ... 9620T 6125HRW18 HARVESTER COMBINES 9860 6125HH003 ZWEIBRUCKEN COMBINES FORAGE HARVESTERS 6750 6125HZ002 6125HZ006 6850 6125HZ001 6125HZ005 7300 Europe 6125HZ007 7400 Europe 6125HZ008 7500 Europe 6125HZ009 7700 Europe 6125HZ009 7300 North America 6125HZ011 7400 North America 6125HZ012 7500 North America 6125HZ013 7700 North America 6125HZ013 9880 STS Combine Europe 6125HZ004 CANE HARVESTER CAMECO ...

Page 29: ...02 2 2 Original Equipment Manufacturers OEM Applications Machine Model No Engine Model OEM 6105AF001 6105HF001 6125AF001 6125HF001 30000 6125HF070 30000 Tier II Marine 6125AFM01 6125AFM75 Tier II CTM100 06APR04 01 001 5 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 29 ...

Page 30: ...Engine Identification and Applications 01 001 6 CTM100 06APR04 01 001 6 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 30 ...

Page 31: ...00 ft Cold Filter Plugging Point CFPP below the expected low temperature OR Cloud Point at least 5 C 9 F below the expected low temperature Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE scuffing test Sulfur content Sulfur content should not exceed 0 5 Sulfur content less than 0 05 is preferred If diesel fuel with sulfur content greater than 0 5 sulfur conten...

Page 32: ...not burn completely and will cause engine failure by leaving deposits on injectors and in the combustion chamber A major environmental benefit of bio diesel fuel is its ability to biodegrade This makes proper storage and handling of bio diesel fuel especially important Areas of concern include Quality of new fuel Water content of the fuel Problems due to aging of the fuel Potential problems result...

Page 33: ... may result in leaks Use of low lubricity diesel fuels may also cause accelerated wear injection nozzle erosion or corrosion engine speed instability hard starting low power and engine smoke Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 12156 1 If fuel of low or unknown lubricity is used ...

Page 34: ...esel engine oil meeting one of the following during the first 100 hours of operation API Service Category CE API Service Category CD API Service Category CC ACEA Oil Sequence E2 ACEA Oil Sequence E1 After the break in period use John Deere PLUS 50 or other diesel engine oil as recommended in this manual IMPORTANT Do not use PLUS 50 oil or engine oils meeting any of the following during the first 1...

Page 35: ...4 API Service Classification CH 4 API Service Classification CG 4 API Service Classification CF 4 ACEA Specification E5 ACEA Specification E4 ACEA Specification E3 ACEA Specification E2 Multi viscosity diesel engine oils are preferred If diesel fuel with sulfur content greater than 0 5 5000 ppm is used reduce the service interval by 50 Extended service intervals may apply when John Deere preferred...

Page 36: ...4 ACEA Specification E3 ACEA Specification E4 Multi viscosity diesel engine oils are preferred Diesel fuel quality and sulfur content must comply with all existing emissions regulations for the area in which the engine operates If diesel fuel with sulfur content greater than 0 05 500 ppm is used reduce the service interval by 100 hours If diesel fuel with sulfur content greater than 0 5 5000 ppm i...

Page 37: ...ne oil and filter at the normal service interval DX ALTER 19 15JUN00 1 1 Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual Some John Deere brand coolants and lubricants may not be available in your location Consult your John Deere dealer to obtain information and recommendations Synthetic ...

Page 38: ...rmation and recommendations DX OILSCAN 19 02DEC02 1 1 OILSCAN and COOLSCAN T6828AB UN 15JUN89 T6829AB UN 18OCT88 OILSCAN and COOLSCAN are John Deere sampling programs to help you monitor machine performance and identify potential problems before they cause serious damage Oil and coolant samples should be taken from each system prior to its recommended change interval Check with your John Deere dea...

Page 39: ... following greases are also recommended John Deere HD MOLY GREASE John Deere HD LITHIUM COMPLEX GREASE John Deere HD WATER RESISTANT GREASE John Deere GREASE GARD Other greases may be used if they meet the following NLGI Performance Classification GC LB IMPORTANT Some types of grease thickener are not compatible with others Consult your grease supplier before mixing different types of grease CTM10...

Page 40: ...ives during the drain interval Coolants requiring supplemental coolant additives Other low silicate ethylene glycol base coolants for heavy duty engines may also be used if they meet one of the following specifications ASTM D4985 ethylene glycol base prediluted 50 coolant ASTM D4985 ethylene glycol base coolant concentrate in a 40 to 60 mixture of concentrate with quality water Coolants meeting AS...

Page 41: ...t testing John Deere COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines IMPORTANT Do not add a supplemental coolant additive when the cooling system is drained and refilled with John DeereCOOL GARD If other coolants are used consult the coolant supplier and follow the manufacturer s recommendation for use of supplemental coolant additives The use of non rec...

Page 42: ...re available from your John Deere dealer These test strips provide a simple effective method to check the freeze point and additive levels of your engine coolant Compare the results to the supplemental coolant additive SCA chart to determine the amount of inhibiting additives in your coolant and whether more John Deere COOLANT CONDITIONER should be added COOLSCAN and COOLSCAN PLUS For a more thoro...

Page 43: ...ed The cooling system must be recharged with additional supplemental coolant additives available in the form of liquid coolant conditioner Maintaining the correct coolant conditioner concentration SCAs and freeze point is essential in your cooling system to protect against rust liner pitting and corrosion and freeze ups due to incorrect coolant dilution John Deere LIQUID COOLANT CONDITIONER is rec...

Page 44: ...plier and follow the manufacturer s recommendation for use of supplemental coolant additives See DIESEL ENGINE COOLANTS AND SUPPLEMENTAL ADDITIVE INFORMATION earlier in this group for proper mixing of coolant ingredients before adding to the cooling system DX COOL6 19 18MAR96 1 1 Operating in Warm Temperature Climates John Deere engines are designed to operate using glycol base engine coolants Alw...

Page 45: ... come from corrosion that occurs to some degree with in a cooling system When a coolant is saturated to the point where it can no longer hold heavy metals and other dissolved solids they settle out and act as abrasives on engine parts NOTE Refer to your operator s manual for a specific service interval Flush cooling system as described in your operator s manual Clean cooling system with clean wate...

Page 46: ...on uniformly and circulates it through the entire system After running engine check coolant level and entire cooling system for leaks Contact your engine servicing dealer if there are further questions RG 01 DT7032 19 29OCT97 1 1 Disposing of Coolant TS1133 UN 26NOV90 Improperly disposing of engine coolant can threaten the environment and ecology Use leakproof containers when draining fluids Do no...

Page 47: ...81 02 020 40 Check Electrical System 02 010 21 Replace Unit Injector Sleeve in Cylinder Preliminary Engine Testing Before Head Using JDG1184 02 020 45 Tune Up 02 010 22 Clean and Inspect Top Deck of Cylinder General Tune Up Recommendations 02 010 23 Block 02 020 55 Measure Cylinder Liner Standout Height Above Block 02 020 56 Group 020 Cylinder Head and Valves Install Cylinder Head 02 020 57 Remove...

Page 48: ...ushing 02 030 37 Inspect Thrust Bearings 02 040 27 Thrust Bearing New Part Specifications 02 040 27 Complete Disassembly of Cylinder Block If Required 02 030 38 Install Main Bearing Inserts in Block 02 040 28 Install Crankshaft 02 040 29 Inspect and Clean Cylinder Block 02 030 39 Measure Cylinder Block 02 030 41 Install Crankshaft Rear Oil Seal Housing 02 040 32 Install Crankshaft Rear Oil Seal an...

Page 49: ...move Clean and Inspect Engine Oil Engines 02 100 1 Remove and Install Starter Motor OEM Cooler 02 060 6 Install Oil Cooler Oil Filter Valve Housing Engines 02 100 2 Assembly or Oil Cooler Cover Valve Housing Assembly 02 060 8 Remove Engine Oil Pump 02 060 10 Clean and Inspect Oil Pump and Drive Gear 02 060 11 Install Engine Oil Pump 02 060 12 Remove Engine Oil Pan 02 060 13 Remove and Install Oil ...

Page 50: ...Contents 02 CTM100 06APR04 02 4 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 4 ...

Page 51: ... begins to use oil Refer to Section 04 for acceptable oil consumption The engine has high usage hours and the owner wants to take preventive measure to avoid high cost repairs and costly downtime John Deere overhaul kits have a 1500 hour or 12 month warranty whichever comes first Installation labor is covered by warranty if an authorized John Deere dealer installed the overhaul kit and the replace...

Page 52: ...re than 330 mm 13 in from the mounting hub surface of the engine stand The center of balance of an engine must be located within 51 mm 2 in of the engine stand rotating shaft Engine center of balance is generally located a few millimeters above the crankshaft To prevent possible personal injury due to engine slippage recheck to make sure engine is solidly mounted before releasing support from engi...

Page 53: ...r housing drains through the turbocharger the exhaust and intake manifolds and then into the cylinder head After starting the engine the trapped oil in the manifold and head is released into the cylinder s filling them with oil causing hydraulic lock and possible engine failure 2 Disconnect turbocharger oil inlet line at turbocharger or oil filter base RG RG34710 46 19 21AUG02 1 1 Install Engine A...

Page 54: ...1 Front Lift Strap and R128000 Rear Lift Strap or attach sling to front plate lift eye and tighten cap screws to specification Specification Engine Lift Strap Cap Screws Torque 90 N m 66 lb ft NOTE Lift spacing on sling is adjustable Position each lifting point so that engine hangs level when lifted 2 Attach the JDG23 Engine Lifting Sling D to lift straps and overhead hoist or floor crane of adequ...

Page 55: ... and R503481 OEM AT801 Applications Only or R128001 Front Lift Strap F The front plate lift eye B can be used as a lifting point instead of R503481 OEM AT801 Applications Only or R128001 Front Lift Strap Use extreme caution when lifting and NEVER permit any part of the body to be positioned under an engine being lifted or suspended Lift engine with longitudinal loading on lift sling and lifting br...

Page 56: ...ilter water separator On later engines with large single fuel filter mounted on left side of engine remove fuel filter assembly RG RG34710 48 19 13SEP02 2 3 RG8185 UN 05DEC97 Front Repair Stand Cap Screws A Cap Screws IMPORTANT DO NOT use shorter cap screws than recommended since mounting threads in block bore may be stripped when tightening to specified torque USE ONLY JDG980 METRIC BOLT KIT for ...

Page 57: ...c Bolt Kit RG RG34710 49 19 21DEC00 1 1 Clean Engine RG8188 UN 21MAY98 6125HRW Engine on Repair Stand 1 Cap or plug all openings air intake exhaust fuel coolant etc 2 Remove electrical components starter alternator etc Cover electrical components that are not removed with plastic and tape securely to prevent moisture damage 3 Thoroughly steam clean engine IMPORTANT Never steam clean or pour cold w...

Page 58: ...FUEL FILTER ELEMENT in CTM188 Section 02 Group 090 dual rail fuel systems See FUEL FILTER WATER SEPARATOR ASSEMBLY in CTM188 Section 02 Group 091 single rail fuel systems Mount engine onto recommended safety approved repair stand See MOUNT ENGINE ONTO REPAIR STAND in this group Remove fan drive belts and fan drive assembly See Group 070 Remove alternator See REMOVE AND INSTALL ALTERNATOR in Group ...

Page 59: ...in Group 060 Remove front gear train access cover and timing gear cover See REMOVE TIMING GEAR COVER in Group 040 Remove rocker arm cover See REMOVE AND INSTALL ROCKER ARM COVER in Group 020 NOTE Identify valve train components and electronic unit injectors See REMOVE ROCKER ARM ASSEMBLY in Group 020 for reassembly in same location as removed Remove front and rear rocker arm and shaft assembly and...

Page 60: ...CRANKSHAFT END PLAY in Group 040 Remove main bearing caps with bearings Perform wear checks on See REMOVE CRANKSHAFT MAIN BEARINGS in Group 040 main bearing surfaces with PLASTIGAGE See CHECK MAIN BEARING TO JOURNAL OIL CLEARANCE in Group 040 Remove crankshaft See REMOVE CRANKSHAFT in Group 040 Remove cylinder block plugs and serial number plate if block is to be See COMPLETE DISASSEMBLY OF CYLIND...

Page 61: ...el system Piston spray jets Timing gear cover gasket and camshaft gear access cover gasket on earlier engines using Fel Pro gaskets Idler gear carrier cap screws camshaft gear retainer cap screws and fuel supply pump drive coupler cap screws EUI hold down clamp cap screws LOCTITE 271 Thread Lock Sealer High Strength clear TY9371 6 mL 0 2 oz tube Oil filter adapter to base LOCTITE 277 Thread Lock S...

Page 62: ... 5 mL 0 02 oz tube EUI solenoid terminal nuts LOCTITE 17430 High Flex Form in Place Gasket T43514 50 mL 1 7 oz bottle Oil pan to cylinder block timing gear cover and rear seal housing T joints LOCTITE 7649 TY16285 Clean and Cure Primer Clean mating gasket surfaces on timing gear cover camshaft gear access cover oil pan and block sealing surfaces LOCTITE is a registered trademark of Loctite Corp NE...

Page 63: ...ns and connecting rods Rotate crankshaft by hand to See in INSTALL PISTONS AND CONNECTING RODS in Group 030 ensure correct assembly Install crankshaft rear oil seal housing See INSTALL CRANKSHAFT REAR OIL SEAL HOUSING in Group 040 Install rear oil seal and wear sleeve assembly See INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE ASSEMBLY in Group 040 Install flywheel See INSTALL FLYWHEEL in Group ...

Page 64: ...ucas ECU controlled fuel See REMOVE AND INSTALL FUEL MANIFOLD in CTM 115 Section systems 02 Group 090 Install fuel manifold assembly on John Deere ECU controlled fuel See REMOVE AND INSTALL FUEL MANIFOLD in CTM 188 Section systems 02 Group 090 dual rail fuel systems Install all remaining fuel lines identify for reassembly in correct See CTM115 Section 02 Group 090 location See CTM188 Section 02 Gr...

Page 65: ...oup 070 Mount engine into vehicle See vehicle repair manual Flush cooling system Fill engine systems with recommended fuel See FLUSH AND SERVICE COOLING SYSTEM in Section 01 lubricant and coolant Group 002 Perform engine break in and normal standard performance checks See PERFORM ENGINE BREAK IN in this group RG RG34710 1053 19 05DEC00 1 1 Engine Break In Guidelines Engine break in should be perfo...

Page 66: ...ormulated to enhance break in of John Deere diesel engines Under normal conditions do not exceed 100 hours with break in oil If John Deere Engine Break In Oil is not available use diesel engine oil meeting API Service Classification CE or ACEA Specification E1 IMPORTANT During preliminary break in periodically check engine oil pressure and coolant temperature Also check for signs of fuel oil or co...

Page 67: ...L ENGINE OIL in Group 002 Fuels Lubricants and Coolant NOTE Some increase in oil consumption may be expected when low viscosity oils are used Check oil levels more frequently If air temperature is below 10 C 14 F use an engine block heater TORQ GARD SUPREME is a registered trademark of Deere Company PLUS 50 is a registered trademark of Deere Company DPSG OUO1004 919 19 30JUN99 1 1 Check Crankcase ...

Page 68: ...t dust from entering the air intake system which could cause serious engine damage 4 If air cleaner has an automatic dust unloader valve A inspect valve for dust buildup or restrictions 5 Check air intake restriction indicator gauge B if equipped to determine if air cleaner needs to be serviced RG RG34710 1057 19 23OCT97 1 1 Check Exhaust System 1 Inspect exhaust system for leaks or restrictions C...

Page 69: ...ing system and all components for leaks or damage Repair or replace as necessary 3 Remove the foam filter from weep hole A shown removed located on the side of timing gear cover and discard filter Inspect the weep hole for any restrictions 4 Insert a heavy gauge wire deep into weep hole to make sure hole is open 5 Install new foam filter flush with bore opening Continued on next page CTM100 06APR0...

Page 70: ...ystem is refilled Loosen temperature sending unit fitting at rear of cylinder head bleed plug at top front of cylinder head or plug in thermostat housing to allow air to escape when filling system Retighten fitting or plug when all the air has been expelled 8 Fill cooling system with coolant Follow recommendations in Group 002 See DIESEL ENGINE COOLANT RECOMMENDATIONS in Group 002 9 Run engine unt...

Page 71: ...nnectors with petroleum jelly mixed with baking soda to retard corrosion 3 Test batteries If batteries are not near full charge try to find out why 4 On low maintenance batteries check level of electrolyte in each cell of each battery Level should be to bottom of filler neck If water is needed use clean mineral free water If water must be added to batteries more often than every 250 hours alternat...

Page 72: ... plug and watch for any water to seep out A few drops could be due to condensation but any more than this would indicate problems which require engine repairs rather than just a tune up 2 With engine stopped inspect engine coolant for oil film With engine running inspect coolant for air bubbles Either condition would indicate problems which require engine repairs rather than just a tune up 3 Perfo...

Page 73: ...tch internal levers and linkage if equipped Operator s Manual Replace fuel filter CTM115 or CTM188 Operator s Manual Clean crankcase vent tube This Group Operator s Manual Check air intake system Replace air cleaner elements This Group Operator s Manual Check exhaust system This Group Check and service engine cooling system This Group Operator s Manual Check and adjust fan and alternator belts Ope...

Page 74: ...Engine Rebuild Guide Break In and Tune Up 02 010 24 CTM100 06APR04 02 010 24 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 72 ...

Page 75: ...ted Do not store cover resting on gasket surface 4 Lift rocker arm cover off engine Install Rocker Arm Cover IMPORTANT Always check routing of unit injector wiring B before installing rocker arm cover Wiring should be positioned so that rocker arms never contact wire 1 Inspect rocker arm cover gasket to ensure that gasket is properly seated in groove and that contact face is clean 2 Position rocke...

Page 76: ...cover self tapping cap screws have been replaced by flange head cap screws with pre applied sealant Discard old self tapping cap screws and replace with new cap screws 2 Remove two cap screws securing ventilator assembly B to cover and remove 3 Clean ventilator assembly in solvent and dry with compressed air 4 Install ventilator assembly in reverse order of removal Replace O rings A as necessary 5...

Page 77: ... from cover and discard Clean gasket groove as needed 3 Position new gasket at two front corners of cover with double lips A of gasket facing up IMPORTANT DO NOT stretch gasket while seating in groove of cover 4 Seat gasket on front side of cover and proceed around entire cover gasket groove using a deep well socket 5 Re seat gasket again especially in corners after entire gasket is installed in g...

Page 78: ...COVER earlier in this group 2 Remove plug from cylinder block and install JDG820 Flywheel Turning Tool B 3 Remove threaded plug from timing hole below oil cooler and filter housing assembly IMPORTANT Timing pin MUST BE installed in slot of camshaft first then install second timing pin in crankshaft slot by carefully rocking flywheel back and forth 4 Rotate engine flywheel in running direction coun...

Page 79: ...ing timing pin 5 Slightly move engine flywheel back and forth with turning tool until a second JDG971 Timing Pin C can be installed in slot in crankshaft This ensures that camshaft and crankshaft are in sync properly timed If timing pin does not enter crankshaft timing slot crankshaft is not properly timed with camshaft Crankshaft MUST BE timed to camshaft See CHECK AND ADJUST CAMSHAFT TO CRANKSHA...

Page 80: ... ignition point type feeler gauge installed at the joint between the valve bridge and valve stem tip B that is near the exhaust right side of engine Loosen lock nuts set clearance with adjusting screw and tighten lock nut to specified torque while holding adjusting screw stationary Valve Stem to Bridge Clearance Engine Cold Specification Intake Valve Clearance 0 58 0 05 mm 0 023 0 002 in Exhaust V...

Page 81: ...djusting screw in an additional one half turn 180 Hold adjusting screw stationary while tightening lock nut to specified torque Tighten EUI adjusting screw lock nuts to specifications Specification Electronic Unit Injector Preload 0 00 mm in clearance plus 1 2 turn in 180 Electronic Unit Injector Adjusting Screw Lock Nuts Torque 65 N m 48 lb ft Continued on next page CTM100 06APR04 02 020 7 POWERT...

Page 82: ...and rotate engine flywheel one full revolution 360 until timing pin B enters slot in crankshaft again Engine will now be locked at No 6 TDC compression stroke 11 Check and adjust as needed valve clearance lash on intake valves Nos 3 5 and 6 and exhaust valves Nos 2 4 and 6 shaded locations Adjust preload on injectors Nos 1 2 and 4 shaded locations 12 Tighten intake and exhaust valve adjusting scre...

Page 83: ...n each bridge to verify proper seating VALVE BRIDGES THAT ARE NOT PROPERLY SEATED ON VALVE STEMS WILL RESULT IN MAJOR ENGINE VALVE TRAIN FAILURE 13 Check that all intake rocker arm adjusting screws D have approximately the same number of threads visible above lock nut Normally flush to maximum of two threads If the number of threads above lock nut at any location is visually different verify bridg...

Page 84: ...pressure This allows for a more uniform rocker arm cap screw clamp load and reduces the possibility of damage to valve train components Remove push tubes and valve bridges immediately after relieving rocker arm pressure Push tubes can fall into oil drain opening of cylinder head causing oil pan removal to retrieve tubes 4 Loosen EUI intake and exhaust valve rocker arm adjusting screw lock nut and ...

Page 85: ...ndle the rocker arm shaft assembly BE CERTAIN to verify the engine serial number then use the correct pins for that engine 8 Depress actuator ball pins and install JDG970A Rocker Arm Lifting Fixture B into rocker arm shaft cap screw holes as shown Replace pins to seat ball locks 9 Remove both front and rear rocker arm and shaft assemblies using JDG970A Rocker Arm Lifting Fixture 10 Discard rocker ...

Page 86: ...fore removing completely 1 Drain all oil and coolant 2 Remove intake manifold 6105H and 6125H engines See REMOVE INSPECT AND INSTALL INTAKE MANIFOLD in Group 080 3 Remove turbocharger A See REMOVE TURBOCHARGER in Group 080 4 Remove exhaust manifold B See REMOVE INSPECT AND INSTALL EXHAUST MANIFOLD in Group 080 5 On 6105A and 6125A engines remove aftercooler assembly See REMOVE AND INSTALL AFTERCOO...

Page 87: ...ed fuel systems See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM188 Section 02 Group 090 dual rail fuel systems See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM188 Section 02 Group 091 single rail fuel systems 9 Remove fan drive hub and camshaft gear access cover Continued on next page CTM100 06APR04 02 020 13 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 85 ...

Page 88: ...ld block C on engines with dual rail systems or disconnect fuel inlet and return lines on single rail systems Refer to the appropriate fuel system repair manual Delphi Lucas ECU controlled fuel systems See REMOVE AND INSTALL FUEL MANIFOLD in CTM115 Section 02 Group 090 John Deere Level 6 ECU controlled fuel systems See REMOVE AND INSTALL FUEL MANIFOLD in CTM188 Section 02 Group 090 12 Remove fuel ...

Page 89: ...iding out of bushings See DFRG4 CAMSHAFT LOCKING TOOL in Section 05 Group 190 for details on this dealer fabricated tool Camshaft position sensor MUST BE removed from air intake side of cylinder head when removing or installing camshaft to prevent camshaft binding on sensor 13 Remove camshaft front thrust ring Remove camshaft position sensor and remove camshaft if desired see REMOVE AND INSTALL CA...

Page 90: ...nd prybars can damage head and block gasket surfaces 15 Carefully lift cylinder head from block using an overhead hoist or floor crane Place head on a clean flat surface 16 Remove cylinder head gasket Inspect gasket for any manufacturing imperfections Inspect head gasket and check for possible oil coolant or combustion chamber leakage NOTE DO NOT rotate engine crankshaft with cylinder head removed...

Page 91: ...body The oil or coolant may leak to an adjacent coolant or oil passage or externally Follow these diagnostic procedures when a head gasket joint failure occurs or is suspected 1 Before starting or disassembling engine conduct a visual inspection of machine and note any of the following Oil or coolant in head gasket seam or on adjacent surfaces especially right rear corner of gasket joint Displacem...

Page 92: ...oss of coolant from overflow Excessive cooling system pressure Coolant overheating Low coolant flow Loss of cab heating air lock 4 Shut engine down Recheck crankcase radiator and overflow tank for any significant differences in fluid levels viscosity or appearance 5 Compare your observations from above steps with the appropriate diagnostic procedures in Section 04 Group 150 If diagnostic evaluatio...

Page 93: ...ody area burned eroded Fire ring severed displaced missing Flange sealing pattern eccentric contains voids Discoloration of flange and adjacent body areas Flange surfaces rough abraided channelled Examine gasket body B for the following Combustion gas erosion paths or soot deposits originating at combustion seals Extreme discoloration hardening embrittlement in localized areas Oil or coolant paths...

Page 94: ...linder Liner Group 030 Check liner flange flatness finish Check liner flange thickness if liner is removed Inspect flange for damage Cylinder Head Cap Screws this group Inspect condition of threads Check length 9 When inspections and measurements have been completed determine most probable causes of joint failure Make all necessary repairs to joint components cooling system and fuel injection syst...

Page 95: ...lve bridges and push tubes for contact wear 5 Clean all parts with clean solvent Dry with compressed air 6 Measure rocker arm shaft OD and rocker arm bushing ID Compare measurements with specifications below 7 Inspect rocker arm roller for uneven wear Measure roller OD and compare with specifications below Specification Rocker Arm Bushing ID 38 064 0 013 mm 1 4986 0 0005 in Rocker Arm Shaft OD 38 ...

Page 96: ...oper surface finish on cylinder head Improperly tightened cylinder head cap screws or faulty gasket installation misaligned Worn or Broken Valve Seats Misaligned valves Distorted cylinder head Carbon deposits on seats due to incomplete combustion Valve spring tension too weak Excessive heat Improper valve clearance Improper valve timing Incorrect valve or seat installed Burned Pitted Worn or Broke...

Page 97: ...ifting Fixture A onto rocker arm and shaft assembly RG RG34710 74 19 03NOV99 1 1 Check Valve Height in Relation to Head Surface Valve Recess RG8330A UN 09DEC97 Measure Valve Recess A Height Gauge B Dial Indicator 1 Thoroughly clean all gasket material from cylinder head combustion face 2 Measure and record valve recess using JDG451 English or KJD10123 Metric Height Gauge A along with D17526CI Engl...

Page 98: ...ner locks D 1 Place cylinder head on a clean flat surface with combustion face down 2 Using JDG982 Valve Spring Compressor A compress valve spring far enough to remove retainer locks as shown 3 Release spring tension remove valve rotator C and valve spring B 4 Remove valve stem seals E from valve guide tower 5 Lay cylinder head on air intake side using a 1016 x 51 x 102 mm 40 x 2 0 x 4 0 in block ...

Page 99: ... check valve spring tension Compressed height must be within specification given below Specification Intake and Exhaust Valve Springs All 1 Height at 0 N 0 lb force Free Length 67 9 72 1 mm 2 67 2 84 in Intake and Exhaust Valve Springs R116585 Height at 352 396 N 79 89 lb force Valve Closed 59 4 mm 2 34 in Intake and Exhaust Valve Springs R116585 Height at 845 935 N 190 210 lb force Valve Open 45 ...

Page 100: ...8323 UN 21MAY98 Inspecting Valve Rotator Valve rotators cannot be repaired Replace valve rotators when valves are replaced or reground Ensure that valve rotators turn freely in both directions Replace if defective CTM100 06APR04 02 020 26 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 98 ...

Page 101: ...l carbon is removed from valve head face and unplated portion of stem 3 Inspect valve face stem tip and retainer lock groove 4 Measure valve stem OD Record measurements and compare with valve guide ID See MEASURE VALVE GUIDE ID later in this group Specification Intake and Exhaust Valve Stems OD 8 999 0 013 mm 0 3543 0 0005 in 5 Using a valve inspection center determine if valves are out of round b...

Page 102: ... to specified angle A Face angle on intake and exhaust valves is as follows Specification Intake and Exhaust Valve Face Angle 29 25 0 25 IMPORTANT DO NOT nick valve head to stem radius when grinding valves A nick could cause the valve to break Break all sharp edges after grinding CTM100 06APR04 02 020 28 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 100 ...

Page 103: ...r valve seat torching Inspect all cylinder head passages for restrictions 2 Inspect around injector sleeve for evidence of fuel or coolant leakage 3 Scrape gasket material oil carbon and rust from head Use a powered brass or copper soft wire brush to clean sealing surfaces DO NOT use a steel wire brush 4 Clean valve guides using a plastic brush IMPORTANT During engine repair or overhaul cleanlines...

Page 104: ...98 Measuring Cylinder Head Flatness Check cylinder head flatness using D05012ST Precision Straightedge and feeler gauge Check lengthwise crosswise and diagonally in several places Specification Cylinder Head Maximum Acceptable Out of Flat for Entire Length of Head 0 10 mm 0 004 in Maximum Acceptable Out of Flat for Every 305 mm 12 0 in 0 025 mm 0 0009 in If out of flat exceeds specifications the c...

Page 105: ...attempt to resurface Install a new cylinder head If cylinder head thickness is greater than wear limit a MAXIMUM of 0 15 mm 0 006 in can be ground from new part dimension for a minimum overall thickness See RESURFACE CYLINDER HEAD COMBUSTION FACE later in this group Specification Cylinder Head Rocker Arm Cover to Combustion Face New Part Thickness 124 975 125 025 mm 4 9203 4 9222 in Minimum Accept...

Page 106: ... or valve face may be ground to bring within specifications NOTE If necessary to resurface cylinder head a MAXIMUM of 0 15 mm 0 006 in can be milled from minimum new part dimension Remove ONLY what is necessary to restore flatness Specification Cylinder Head Rocker Arm Cavity to Combustion Face Minimum Overall Thickness 124 840 mm 4 9150 in Cylinder Head Combustion Face Surface Finish Surface Mill...

Page 107: ...tem clearance See REPLACE VALVE GUIDES later in this group RG RG34710 85 19 16OCT00 1 2 Replace Valve Guides RG8823 UN 11DEC97 Removing Valve Guide with JDG164A A JDG164A Valve Seat Pilot Driver Remove Valve Guides 1 Position cylinder head with combustion face facing up 2 Drive valve guides from combustion face side of cylinder head using JDG164A Driver A and a press 3 Inspect valve guide bore for...

Page 108: ...until adapter bottoms on machined surface 4 Measure valve guide installed height Installed height should be as follows Specification Valve Guide Installed Height 14 5 15 5 mm 0 57 0 61 in 5 Insert a valve stem through valve guide to check for adequate clearance Valve stem should move freely in valve guide RG RG34710 86 19 30SEP97 1 1 Clean and Inspect Valve Seats 1 Use an electric hand drill with ...

Page 109: ...rind excessively Only a few seconds are required to recondition the average valve seat Dress grinding stone as necessary to maintain specified seat angle Support the weight of grinder to avoid excessive pressure on the stone Blend or radius all sharp edges 0 50 mm 0 02 in maximum corner break to eliminate burrs after grinding valve seats 1 Install appropriate pilot A in valve guide bore 2 Install ...

Page 110: ...necessary lap the valve onto its seat using a lapping tool and lapping compound Replace valves and inserts as necessary 6 Install new or refaced valve and check valve recess in cylinder head after grinding See CHECK VALVE HEIGHT IN RELATION TO HEAD SURFACE earlier in this group RG RG34710 88 19 30SEP97 1 1 Remove Valve Seat Inserts RG8314 UN 06DEC97 Removing Valve Seat Insert A JDE41296 Valve Seat...

Page 111: ...mm 1 9458 0 0005 in Bore Depth 11 50 mm 0 443 in Radius at Lower Bore 0 64 0 25 mm 0 025 0 001 in Standard Intake and Exhaust Valve Seat OD 49 487 49 513 mm 1 9483 1 9493 in 2 If valve seat bores are not within specification oversize seat inserts are available Have a qualified machine shop bore the valve seat to specification for installation of oversize valve seat inserts See INSTALL VALVE SEAT I...

Page 112: ...on practice is to chill valve seat inserts in a freezer before installing This chilling process allows for less interference when pressing in valve seats Once inserts heat up to room temperature original press fit is restored RG RG34710 91 19 13AUG99 1 2 Install Valves RG8306A UN 06DEC97 Installing Valve Stem Seals A Valve Stem Seals 1 Lubricate valve stems and guides with AR44402 Valve Stem Lubri...

Page 113: ...ication Valve springs must be replaced in sets of two with new rotators DO NOT intermix springs across valve bridges 4 With cylinder resting on combustion face install valve springs A and rotators B with retainer locks C 5 Compress valve springs using JDG982 Valve Spring Compressor and install retainer locks on valve stems 6 Strike end of each valve several times with a soft non metallic hammer to...

Page 114: ...ol and replace with JDG1184 2 1 Swedge Rod and 8132 Adapter 1 Remove cylinder head from engine See REMOVE CYLINDER HEAD earlier in this group 2 Remove valves from cylinder head See REMOVE VALVE ASSEMBLY earlier in this group 3 Using a 51 mm by 102 mm 2 0 in by 4 0 in block of wood B at least 914 4 mm 36 0 in long lay cylinder head on its side with air intake manifold mounting surface resting on bl...

Page 115: ...e RG12415 UN 04SEP02 A Injector Sleeve B Old Injector Sleeve C New Injector Sleeve IMPORTANT Old injector sleeve B with one O ring MUST be replaced with new injector sleeve C with two O rings IMPORTANT DO NOT use engine oil or any petroleum based product as a lubricant for the injector sleeve o rings A chemical reaction will occur leading to o ring failure Instead use a soap based solution to lubr...

Page 116: ... 6 RG8154 UN 05DEC97 Installing Injector Sleeve Guide A JDG981 1 Guide Sleeve 3 Grease polished tip of JDG981 1 Guide Sleeve A and install inside injector sleeve Continued on next page CTM100 06APR04 02 020 42 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 114 ...

Page 117: ...in cylinder head Replace cap screw as needed 4 Install JDG981 3 Guide Sleeve Holding Bar A as shown Install 220213 8 mm cap screw B finger tight 5 Install 220089 16 mm cap screw C from combustion face side of head using a phosphate washer from cylinder head mounting cap screw finger tight 6 Install JDE131 2 Driver Nut D finger tight 7 Tighten cap screws and nut in following order to specification ...

Page 118: ...solete Use only JDG1184 2 1 Swedge and 8132 Adapter 9 Assemble small end of 8132 Adapter B onto swedge arbor A 10 Assemble large end of adapter onto D01300AA 2 2 kg 5 lb Slide Hammer C 11 Position tip of swedge into guide sleeve and drive swedge through sleeve tip Withdraw swedge with slide hammer 12 Remove injector sleeve replacement tool set from cylinder head and inspect for proper installation...

Page 119: ...ved or installed on engine using JDG1184 Nozzle Sleeve Replacement Set IMPORTANT Whenever EUI is replaced sleeve in cylinder head must be replaced also CAUTION Do not drain coolant until the coolant temperature is below operating temperature Always loosen coolant drain valve A slowly to relieve any excess pressure 1 Attach a long hose to drain valve A Drain coolant into a clean container to a leve...

Page 120: ... A and place in a clean container to collect fuel Loosen fuel temperature sensor B in fuel manifold block and drain all fuel from fuel rail into a clean container 3 On single rail fuel systems loosen fuel rail inlet line C Disconnect outlet line D and drain fuel into a clean container 4 Tighten temperature sensor to specifications Specification Fuel Temperature Sensor Torque 10 N m 7 5 lb ft 5 Rec...

Page 121: ...ders 1 and 6 2 and 5 3 and 4 at the same time so crankshaft has to be rotated only three times 9 Remove electronic unit injector from injector sleeve that is to be replaced Refer to the appropriate fuel system repair manual Delphi Lucas ECU controlled fuel systems See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM115 Section 02 Group 090 John Deere Level 6 ECU controlled fuel systems See REMO...

Page 122: ...s will eliminate injector sleeve turning in swedged bore of cylinder head 11 Thoroughly clean and dry JDG1184 1 3 Protector Sleeve as needed Install protector sleeve into EUI bore until it is seated with injector sleeve DPSG OUO1004 929 19 16JUL99 5 15 RG9162A UN 21JUL99 Hold Down Cap Screw A Hold Down Cap Screw 12 Install EUI hold down clamp and cap screw A over protector sleeve Tighten cap screw...

Page 123: ...er to contain shavings and protect fuel rail in head 17 Remove cap screw and EUI hold down clamp from protector sleeve Do not remove sleeve at this time DPSG OUO1004 929 19 16JUL99 7 15 RG9164A UN 21JUL99 Adapter and Spacer RG9165 UN 21JUL99 Remove Sleeve A JDG1184 1 2 Screw Adapter B JDG1184 1 4 Spacer 18 Thread JDG1184 1 2 Screw Adapter A with JDG1184 1 4 Spacer B into threaded injector sleeve f...

Page 124: ... JDG820 Flywheel Rotation Tool A DPSG OUO1004 929 19 16JUL99 9 15 RG9162B UN 21JUL99 Install Protector Sleeve A JDG1184 1 3 Protector Sleeve B Hold Down Clamp Install Injector Sleeve 1 Install JDG1184 1 3 Protector Sleeve A into injector sleeve bore without injector sleeve 2 Install EUI hold down clamp B and cap screw over protector sleeve Tighten cap screw to 40 N m 30 lb ft 3 Thoroughly clean in...

Page 125: ...ith two O rings 6 Lubricate O rings with engine oil and install injector sleeve A into cylinder bore DPSG OUO1004 929 19 16JUL99 11 15 RG9167A UN 21JUL99 Seat Sleeve A JDG981 1 Guide Sleeve 7 Lubricate O rings with clean engine oil and position JDG981 1 Guide Sleeve A into injector sleeve and seat sleeve using a plastic or rubber hammer Be careful not to cut O rings NOTE When injector sleeve is fu...

Page 126: ...p Screw 8 Position JDG1184 2 2 Guide Sleeve Holding Bracket A over guide sleeve and tighten cap screw B finger tight DPSG OUO1004 929 19 16JUL99 13 15 RG9169A UN 21JUL99 Drive Nut A Drive Nut 9 Thread JDG1184 2 4 Drive Nut A into holding bracket but do not tighten Continued on next page CTM100 06APR04 02 020 52 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 124 ...

Page 127: ...n cap screw B finger tight IMPORTANT Use only the 10 mm cap screw B that is provided in JDG1184 Nozzle Sleeve Replacement Set Cap screws exceeding 35 mm 1 375 in can damage the camshaft bushings 11 Tighten cap screws and nut to the following specifications Guide screw holding bracket cap screw A to 40 N m 30 lb ft Bracket clamp cap screw B to 68 N m 50 lb ft Driver nut C to 115 N m 85 lb ft Contin...

Page 128: ...d refill cooling system and pressure test for leakage 16 Install electronic unit injector and wiring harness Refer to the appropriate fuel system repair manual Delphi Lucas ECU controlled fuel systems See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM115 Section 02 Group 090 John Deere Level 6 ECU controlled fuel systems See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM188 Section 02 Gr...

Page 129: ...soft wire brush DO NOT use a steel wire brush 2 Clean threaded holes in cylinder block using JDG978 Special Tap A or an equivalent M16 x 2 0 x 140 mm 5 50 in long tap 3 Use compressed air to remove debris and fluids from cap screw holes Replace block if thread damage is detected 4 Inspect and measure top deck for flatness Service as required See MEASURE CYLINDER BLOCK in Group 030 5 Clean all oily...

Page 130: ...eight A at approximately 1 5 7 and 11 o clock positions as viewed from flywheel end of engine Record all measurements by cylinder number Specification Cylinder Liner Height Above Block Standout 0 030 0 117 mm 0 0012 0 0046 in Cylinder Liner Max Height Difference at Nearest Point of Two Adjacent Liners or Within One Liner 0 051 mm 0 0020 in IMPORTANT ONE LINER SHIM ONLY may be installed under any g...

Page 131: ...t use sealant on gasket Tab A on gasket goes to left rear corner of cylinder block as viewed from flywheel end IMPORTANT If cylinder head is lowered onto cylinder block and you discover that the head is not positioned correctly on locating dowels remove cylinder head and install a new gasket DO NOT try to reposition cylinder head on the same gasket again since the fire ring will possibly be damage...

Page 132: ...same length 3 Dip new cap screws and washers in clean SAE 30 engine oil Allow excess to drain off threads 4 Initially tighten No 17 cap screw to specifications Specification Step 1 Cylinder Head No 17 Cap Screw Initial Torque 100 N m 74 lb ft This prevents head from tipping during tightening sequence 5 Use torque turn method to tighten all cylinder head cap screws to specifications See TORQUE TURN...

Page 133: ...and proceed through cap screw No 26 and tighten all cap screws to 163 N m 120 lb ft Specification Step 2 All Cap Screws Nos 1 26 Initial Torque 163 N m 120 lb ft 3 Wait 5 minutes and verify above torque Specification Step 3 Verify All Cap Screws Nos 1 26 Torque 163 N m 120 lb ft 4 Using an oil proof pen pencil or marker draw a line parallel to the crankshaft across the entire top of each cap screw...

Page 134: ...urn in one swing of the wrench TOTAL AMOUNT OF TURN FROM STEPS 5 and 6 is 180 190 Specification Step5 All Cap Screws Nos 1 26 Final Torque Turn 90 Cylinder head torque procedure summarized as follows Cylinder Head Specification Step 1 No 17 Cap Screw Initial Torque 100 N m 74 lb ft Step 2 All Cap Screws Nos 1 26 Initial Torque 163 N m 120 lb ft Step 3 Wait 5 Minutes and Verify All Cap Screws Nos 1...

Page 135: ...m Assembly Lifting Fixture A onto rocker arm and shaft assembly 3 Firmly depress buttons on two lifting arms install lifting plate with two locator pins and lifting arms positioned in holes of rocker arm shaft Release buttons so that ball actuating pins lock onto shaft and can be safely lifted IMPORTANT ALWAYS loosen all intake exhaust and EUI rocker arm adjusting screws before removal or installa...

Page 136: ...Install twelve push tubes C on top of bridges 8 Make sure intake exhaust and injector rocker arm adjusting screws are loose to eliminate binding shaft as clamps are tightened 9 Initially tighten rocker arm hold down cap screws in the end of each shaft to pull shaft down onto locking roll pins Next going from front to rear of engine tighten hold down clamp cap screws to the following specification ...

Page 137: ...il Fuel Systems 1 After applying initial torque of 30 N m 22 lb ft start at front cap screw and proceed to the rear and torque turn each cap screw 60 5 as follows Position a six point socket onto rocker arm shaft clamp cap screw With clockwise tension on socket viewed from rear of engine mark a line A on socket and another aligning mark on shaft clamp B or spacers C at each end location Continued ...

Page 138: ... Hold Down Clamp Cap Screws Dual Rail Fuel System Final Torque Turn 60 5 IMPORTANT Position electronic unit injector wiring harness so that wires DO NOT touch rocker arms 3 Install unit injector wiring harness Apply LOCTITE 222 TY24311 Thread Lock and Sealer Low Strength to harness cap screws Tighten cap screws to specifications below Specification Unit Injector Wiring Harness Bracket to Rear of H...

Page 139: ...t and carefully check each bridge for proper seating on valve stems from both sides of the engine Lift up on each bridge to verify proper seating Valve bridges that are not properly seated on valve stems will result in major engine failure Before installing rocker arm cover make sure that all EUI wires are positioned so that rocker arm will not contact wires when engine is running 5 Install rocker...

Page 140: ... cap screw 90 so ratchet handle is perpendicular C to crankshaft Remove ratchet socket from cap screw and verify line on top of cap screw is perpendicular to crankshaft NOTE If cap screw is tightened beyond aligning mark loosen cap screw and repeat procedure starting with initial torque of 30 N m 22 lb ft Repeat procedure on remaining cap screws and torque turn cap screws to the following specific...

Page 141: ... Tube IMPORTANT Thoroughly inspect intake and exhaust valve bridges A for proper seating on valve stems B from both sides of engine Also make sure that push tubes C are properly seated in top of valve bridges Use a flashlight and carefully check each bridge for proper seating on valve stems from both sides of the engine Lift up on each bridge to verify proper seating Valve bridges that are not pro...

Page 142: ...l 6 ECU controlled fuel systems See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM188 Section 02 Group 090 dual rail fuel systems See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM188 Section 02 Group 091 single rail fuel systems 5 Install fuel manifold assembly if equipped from rear of cylinder head See the appropriate fuel system repair manual Delphi Lucas ECU controlled fuel systems See REMOVE AND INST...

Page 143: ...IMING in Group 050 2 Remove timing gear cover A See REMOVE TIMING GEAR COVER in Group 040 3 Remove camshaft gear B and idler gear assembly C See CHECK AND ADJUST CAMSHAFT TO CRANKSHAFT TIMING in Group 050 4 Remove engine oil pump assembly D See REMOVE ENGINE OIL PUMP in Group 060 5 Remove auxiliary drive gear H if equipped See REMOVE AND INSTALL AUXILIARY DRIVE IDLER GEAR AND BEARING in CTM67 OEM ...

Page 144: ...pper threaded cap screw holes New service gaskets are rubberized in these locations so sealant is no longer required 7 Remove gasket G and discard Thoroughly clean gasket surfaces on cylinder block and front plate If present ensure all sealant is removed Continued on next page CTM100 06APR04 02 030 2 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 142 ...

Page 145: ... ENGINE OIL PUMP in Group 060 5 Install idler gear and camshaft gear Adjust gear backlash See CHECK AND ADJUST CAMSHAFT TO CRANKSHAFT TIMING in Group 050 6 Install auxiliary drive gear if equipped See REMOVE AND INSTALL AUXILIARY DRIVE IDLER GEAR AND BEARING in CTM67 OEM Engine Accessories Group 54 7 Install timing gear cover See INSTALL TIMING GEAR COVER in Group 040 8 Install engine oil pan See ...

Page 146: ... Block Liners Pistons and Rods 02 030 RG RG34710 106 19 01NOV00 4 4 Specification Crankshaft Timing Pin Plug Torque 33 N m 24 lb ft 4 CTM100 06APR04 02 030 4 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 144 ...

Page 147: ...rol Ring Improper oil Excessive blow by Contaminated oil Improper periodic service Low operating temperature Stuck Rings Improper oil classification Improper periodic service Poor operating conditions Coolant leakage into crankcase Excessive cylinder liner taper Mottled Grayish or Pitted Compression Rings Internal coolant leaks Dull Satin Finish and Fine Vertical Scratches on Rings Dirt and abrasi...

Page 148: ...NT rod and cap B To create the PRECISION JOINT the connecting rod is notched with a laser beam Then a precision mandrel in the rod bore is powered to separate the cap from the rod at the joints C Both types of rods provide a strong joint Removal and installation is similar with differences noted including different torque specifications for cap screws IMPORTANT Replace rods with the same type Do N...

Page 149: ...ston and liner sets on later 12 5 L engines are different from earlier engines Do not mix sets in engines See parts catalog for correct applications CAUTION DO NOT drain engine coolant until it cools below operating temperature Then slowly loosen block drain valve to relieve any pressure 1 Drain all coolant and engine oil 2 Remove all piston spray jets NOTE If engine is to be completely disassembl...

Page 150: ...ID x 1 3 4 in OD x 3 18 mm 1 8 in thick washers B to bolt down cylinder liners C in the seven locations as shown Tighten cap screws to specifications Specification Cylinder Liner Cap Screws For Checking Liner Standout Torque 68 N m 50 lb ft 6 Before removing pistons visually inspect condition of cylinder liners with pistons at bottom dead center BDC Liners will require replacement if The crosshatc...

Page 151: ...07277 Ridge Reamer NOTE Always follow manufacturer s directions provided with ridge reamer 7 Remove carbon ridge from liner bore with a scraper or JT07277 Ridge Reamer A Use compressed air to remove loose carbon from cylinders Continued on next page CTM100 06APR04 02 030 9 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 149 ...

Page 152: ...ill not indicate the condition of either surface 10 Measure rod bearing to journal oil clearance with PLASTIGAGE before removing piston and rod assembly Record measurements See INSPECT AND MEASURE CONNECTING ROD BEARINGS later in this group IMPORTANT Hold on to piston to prevent piston from dropping Piston will drop once piston rings have cleared cylinder liner bore If liners are to be reused be e...

Page 153: ...s to 68 N m 50 lb ft Specification Cylinder Liner Cap Screws For Checking Liner Standout Torque 68 N m 50 lb ft 2 Using JDG451 Gauge B along with D17526CI English scale or D17527CI metric scale Dial Indicator or KJD10123 Gauge C measure liner height A for all cylinders 3 Measure each liner in four places at approximately 1 5 7 and 11 o clock positions as viewed from rear of engine flywheel end Rec...

Page 154: ...er Liner Puller RG1179 UN 05DEC97 Removing Cylinder Liners A Liner B Cylinder Liner Puller C Jaw 1 Remove cap screws and washers securing liners to cylinder block 2 Number cylinder liners and mark fronts to ensure correct assembly NOTE Each cylinder liner must be reinstalled in same cylinder bore from which removed Always keep matched pistons and liners together 3 Use D01062AA or D01073AA Cylinder...

Page 155: ... A Square Packing Neoprene B Red O Ring Silicone C Black O Ring Viton D Cylinder Block E Cylinder Liner F Coolant Passage 4 Remove the cylinder liner square packing A from liner E 5 Remove red O ring B and black O ring C from cylinder block D CTM100 06APR04 02 030 13 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 153 ...

Page 156: ...er must be reinstalled in same cylinder bore from which removed Always keep matched pistons and liners together 3 Use JDG1145 Cylinder Liner Service Set A with a 2 27 kg 5 0 lb slide hammer B to remove cylinder liner IMPORTANT When using JDG1145 as shown A to remove liners make sure puller is properly assembled before attempting to remove liners Step in bottom plate of puller assembly should fit i...

Page 157: ...ng A Square Packing Neoprene B Red O Ring Silicone C Black O Ring Viton D Cylinder Block E Cylinder Liner F Coolant Passage 6 Remove the cylinder liner square packing A from liner E 7 Remove red O ring B and black O ring C from cylinder block D CTM100 06APR04 02 030 15 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 155 ...

Page 158: ...th of pits and erosion with a fine wire or needle Replace piston and liner if Pitting depth is one half liner thickness C or more Specification Cylinder Liner Wall Thickness 9 39 9 43 mm 0 370 0 371 in Erosion depth is one half packing step D or more Specification Cylinder Liner Packing Step Dimension 2 14 2 30 mm 0 084 0 090 in NOTE Liners are reusable if the depth of pits or erosion is less than...

Page 159: ...CLEAN CYLINDER BLOCK later in this group 4 Measure liner OD and compare to following specifications Cylinder Liners Specification Flange Area OD 151 565 151 615 mm 5 9671 5 9691 in Upper OD for Seating Liner OD 145 795 145 845 mm 5 7400 5 7419 in Water Jacket Area OD 144 73 144 99 mm 5 698 5 708 in Lower OD for Seating with O Rings OD 140 397 140 447 mm 5 5274 5 5294 in RG RG34710 111 19 30SEP97 1...

Page 160: ...e from OD of liners under liner flange and in O ring packing areas Make certain there are no nicks or burrs in areas where packings will seat IMPORTANT Do not use gasoline kerosene or commercial solvent to clean liners Solvents will not remove all the abrasives from liner walls 2 Thoroughly clean liner ID with a 50 percent solution of hot water and liquid detergent 3 Rinse thoroughly and wipe dry ...

Page 161: ...ed on the 15th day of October 1996 SJ96 15 S Liner Material Type J Month Liner was Manufactured 96 Year Liner was Manufactured 15 Day of Month Liner was Manufactured Liner Material Specification S Non Hardened Liner Bore H Hardened Liner Bore Month Liner was Manufactured A January B February C March D April E May F June G July H August I September J October K November L December Year Liner was Man...

Page 162: ... L RE503969 3 mm RE505901 1 If necessary check piston ring end gap prior to removing rings Specification No 1 Piston Compression Ring 4 mm Rings End Gap 0 43 0 69 mm 0 017 0 027 in No 2 Piston Compression Ring 4 mm Rings End Gap 1 01 1 27 mm 0 040 0 050 in No 1 Piston Compression Ring 3 mm Rings End Gap 0 48 0 74 mm 0 019 0 029 in No 2 Piston Compression Ring 3 mm Rings End Gap 1 35 1 65 mm 0 053 ...

Page 163: ...ORTANT When washing pistons always use a stiff bristle brush NOT A WIRE BRUSH to loosen carbon residue DO NOT bead blast ring groove areas 5 Clean pistons by any of the following methods Immersion Solvent D Part Hydra Jet Rinse Gun Hot water with liquid detergent soap If cleaning with hot water and liquid detergent soak pistons in a 50 percent solution of liquid household detergent and hot water f...

Page 164: ...ression rings Later engines with RE504343 pistons have 3 mm compression rings Piston part numbers are marked on top of pistons for identification Use the JDG1019 Ring Groove Wear Gauge on RE52836 and RE504801 pistons early engines to check wear of top two compression ring grooves Use the JDG1335 Ring Groove Wear Gauge on RE504343 pistons later engines to check wear of top two compression ring groo...

Page 165: ...the same on these pistons and only one side of the gauge is used to check both Check grooves at several locations around the circumference of piston crown The word TOP on gauge should always face top of piston Earlier RE66125 Pistons with 4 mm Rings Use the JDG1022 Ring Groove Wear Gauge A end marked G1 to check wear of top compression ring groove Use end marked G2 of JDG1022 Ring Groove Wear Gaug...

Page 166: ...mm RE505901 1 Check oil control ring to groove clearance by installing a new ring in groove 2 Measure clearance with a feeler gauge at several points Compare measurements with specifications given below Specification Oil Control Ring to Groove RE52836 RE504801 RE66125 Pistons Clearance 0 064 0 114 mm 0 0025 0 0045 in Maximum Clearance 0 165 mm 0 0065 in Oil Control Ring to Groove RE504343 RE503969...

Page 167: ...Check taper in piston pin bore by inserting pin from both sides If pin enters freely but binds in the center the bore could be tapered B 4 Insert pin in piston to check for bore alignment Pin should not click or need to be forced into bore on opposite side C 5 Measure piston pin and piston bore and compare to specifications If either are not within specification replace pin piston and liner Specif...

Page 168: ...f the piston A 2 Measure 6125 engine skirt OD at right angles to piston pin bore 35 0 mm 1 38 in from bottom of skirt 3 Record measurement and compare measurement obtained from matching liner Specification Piston Skirt 6105 OD 29 97 mm 1 180 in from Bottom of Piston 126 872 126 898 mm 4 9950 4 9960 in Piston Skirt 6125 OD 35 0 mm 1 380 in from Bottom of Skirt 126 910 126 930 mm 4 9965 4 9972 in Co...

Page 169: ...nts A B C and D to determine if liner is tapered or out of round 9 Compare liner ID with matched piston OD Specification Cylinder Liner ID 126 990 127 010 mm 4 9996 5 0004 in Max Out of Round 0 020 mm 0 0008 in Max Wear or Taper Ring Travel Area 0 030 mm 0 0012 in Piston to Liner Clearance New Part 6105 Clearance 0 092 0 138 mm 0 0036 0 0054 in Max Acceptable Wear 0 152 mm 0 0060 in Piston to Line...

Page 170: ...ss Measure cylinder liner flange thickness at several locations and compare with specification given below If liner flange is not within specification use liner shims or replace piston and liner as a set Specification Cylinder Liner Flange Thickness 9 525 9 575 mm 0 3750 0 3770 in CTM100 06APR04 02 030 28 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 168 ...

Page 171: ...l determine bearing journal clearance but will not indicate the condition of either surface 1 With crankshaft removed measure connecting rod journal OD at several points 2 Install connecting rod cap A on rod B with bearings C in correct position 3 On tongue and groove connecting rods Initially tighten blind hole cap screw then tighten open hole cap screw to the following specifications Specificati...

Page 172: ...ometer 5 Using an inside micrometer A measure assembled ID of bearing 6 Subtract OD of each crankshaft journal from ID of each respective rod bearing to obtain oil clearance 7 Compare measurements with the specifications given Specification Crankshaft Rod Journal OD 88 844 88 874 mm 3 4980 3 4990 in Connecting Rod Bearing for Crankshaft Journal Assembled ID 88 93 88 98 mm 3 501 3 502 in Connecting...

Page 173: ...ION JOINT rods to ensure proper seating Never scrape joint surfaces C with a wire brush or other tool the interlocking mating surfaces must be preserved and remain free of any debris Rod cap MUST be kept with parent rod 2 Inspect in and around cap screw holes B in cap If any defects are found replace rod and cap IMPORTANT If replacing a connecting rod use the same type of joint design DO NOT inter...

Page 174: ...g Rod Cap Screw Initial Torque 27 N m 20 lb ft Next tighten rod cap screws to the following specifications Specification Tongue and Groove Connecting Rod Cap Screw Final Torque 75 N m 55 lb ft plus 90 100 turn clockwise See TORQUE TURN CONNECTING ROD CAP SCREWS later in this group 6 On PRECISION JOINT connecting rods Initially tighten rod cap screw closest to piston end then tighten other cap scre...

Page 175: ...between the greatest and least measurement is more than 0 038 mm 0 0015 in the rod and cap are out of round Replace both connecting rod and cap RG RG34710 122 19 02AUG99 4 4 RG8420 UN 09DEC97 Measuring Rod Center to Center Bores A Rod s Piston Pin Bore to Crankshaft Bore Center to Center Dimension 9 Measure rod s piston pin bore to crankshaft bore center to center dimension A and compare with spec...

Page 176: ... A Connecting Rod B Piston Pin 1 Insert piston pin B through piston pin bushing and carefully clamp in a soft jawed vise 2 Rotate connecting rod A back and forth several times to make sure connecting rod moves freely on piston pin 3 Remove piston pin from connecting rod Continued on next page CTM100 06APR04 02 030 34 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 174 ...

Page 177: ...pecification Piston Pin OD 50 772 50 787 mm 1 9989 1 9995 in Rod Pin Bore Without Bushing ID 55 529 55 555 mm 2 1862 2 1872 in Installed Rod Pin Bushing Before Boring ID 50 729 50 781 mm 1 9972 1 9992 in Installed Rod Pin Bushing After Boring ID 50 805 50 830 mm 2 0002 2 0012 in Piston Pin Bushing Bore Out of Round 0 038 mm 0 0015 in Piston Pin to Bushing Oil Clearance 0 017 0 059 mm 0 0007 0 0023...

Page 178: ...he JDE98A Connecting Rod Bushing Service Set 2 Clean rod bushing bore using a medium grit emery cloth as burrs will distort bushing Install bushing on side opposite rod burr 3 If necessary file a slight chamfer around bushing bore to remove any sharp edges Chamfer will also aid in bushing installation 4 Measure rod bushing bore in three or more places approximately 45 apart Specification Connectin...

Page 179: ...4 Forcing Screw threads D 3 Assemble JDE98 6 Pilot F onto driver 4 Engage forcing screw heads with threads in JDE98 8 Cup A and install new bushing IMPORTANT Boring the connecting rod bushing should be done ONLY by experienced personnel on equipment capable of maintaining bushing finish specification 5 Precision bore new bushing to specification to obtain pin to bushing clearance Remove all debris...

Page 180: ...ining cooling system components See REMOVE COOLANT PUMP in Group 070 3 Remove timing gear cover See REMOVE TIMING GEAR COVER in Group 040 Remove front plate See REMOVE AND INSTALL CYLINDER BLOCK FRONT PLATE earlier in this group 4 Remove engine oil pump and all remaining lubrication system components See REMOVE ENGINE OIL PUMP in Group 060 5 Remove all components water gallery plugs oil gallery pl...

Page 181: ...g bores 2 Remove cylinder head locating dowels if not previously removed Clean out all threaded holes for cylinder head mounting cap screws in top deck of cylinder block Use JDG978 Tap or an equivalent M16 x 2 0 tap approximately 152 4 mm 6 0 in long Use compressed air to remove any debris or fluid which may be present in the cap screw hole IMPORTANT If cylinder block is cleaned in a hot tank be s...

Page 182: ...pping compound to remove burrs 5 Measure liner flange counterbore depth A in block B and flange thickness on liner Compare with specification given below Specification Cylinder Liner Flange Counterbore Depth in Block 9 461 9 512 mm 0 3725 0 3745 in Cylinder Liner Flange Thickness 9 525 9 575 mm 0 3750 0 3770 in 6 Carefully inspect block for cracks or any other physical damage If a cracked block is...

Page 183: ...507 in Overall Thrust Bearing Cap Width 43 25 43 75 mm 1 703 1 722 in If any main or thrust bearing cap assembled ID is not within specification blank generic bearing caps are available and must be line bored to specification by a qualified machine shop See MEASURE ASSEMBLED ID OF MAIN BEARING CAPS in Group 040 2 Measure cylinder block top deck flatness using D05012ST Precision Straightedge and fe...

Page 184: ...block 3 Measure cylinder liner bores in block and compare to the following specifications Cylinder Block Bore for Seating Liner Specification Liner Flange Counterbore ID 153 57 153 77 mm 6 046 6 054 in Upper Block Bore for Seating Liner ID 145 845 145 895 mm 5 7419 5 7439 in Lower Block Bore for Seating Liner ID 140 465 140 515 mm 5 5301 5 5321 in CTM100 06APR04 02 030 42 POWERTECH 10 5 L 12 5 L D...

Page 185: ...he engine Rotate 90 if pits or erosion exceed limits outlined during liner inspection 2 Measure liner standout See MEASURE CYLINDER LINER STANDOUT earlier in this group Specification Cylinder Liner Standout Height Above Block 0 030 0 117 mm 0 0012 0 0046 in If liner standout is above specification recheck liner support flange C for possible remaining burrs or incorrect counterbore depth A in block...

Page 186: ... packings and O rings in soap before installation Do not leave packings or O rings in soap to soak 3 Install the black viton O ring A in the lower O ring groove of the cylinder block C 4 Install the red silicone O ring B in the upper O ring groove of the cylinder block RG RG34710 130 19 01NOV00 2 2 RG3827 UN 04DEC97 Install Square Packing on Liner A Neoprene Square Packing B Cylinder Liner 5 Turn ...

Page 187: ... their removed position Rotate the pitted section of the liner toward either the front or rear of the engine If liners are not pitted or eroded rotation will not be necessary Install liners with the identifying mark stamped on flange toward the front of the engine 1 Carefully place the cylinder liner with packing installed into the cylinder block bore NOTE A resistance will be felt when cylinder l...

Page 188: ... in lower figure Using either method apply only enough force as necessary to seat liners IMPORTANT If you suspect that a packing may have sheared or displaced during liner installation remove liner and packing assembly If no damage is found check packing and O rings for proper position Resoap packings and reinstall liner assembly 4 Hold liners in place with large flat washers and cap screws Turn c...

Page 189: ...d liner assembly is to be installed DO NOT remove piston from liner Push piston out of liner bottom only far enough to install piston pin 1 On 6125 engines assemble piston crown A and skirt B so that connecting rod pin bushings are aligned 2 Lubricate piston pin and bushings with clean engine oil NOTE Pistons are symmetrical new pistons can be installed either way If pistons are being reused align...

Page 190: ...E505901 5 Use the JDG967 Ring Expander to install compression rings D and oil control ring with expander ring E RG RG34710 133 19 26AUG02 1 6 Install Pistons and Connecting Rods RG10300 UN 27AUG99 Connecting Rods A Tongue and Groove Rod Early Engines B PRECISION JOINT Rod Later Engines IMPORTANT Replace rods with the same type Do Not mix tongue and groove with PRECISION JOINT rods in the same engi...

Page 191: ...19 26AUG02 3 6 RG8404 UN 09DEC97 Compressing Piston Rings G JDG1017 Ring Compressor 2 Coat pistons liners and inside of JDG1017 Piston Ring Compressor G with clean engine oil 3 Lay piston rod assembly on piston s top and compress rings with compressor Squeeze handles together and install pin to full depth to secure 4 Lubricate rod bearing half and install onto rod with notches on bearing seated wi...

Page 192: ...B Bearing Inserts 7 Apply clean engine oil to bearing inserts B and crankshaft rod journals A IMPORTANT On PRECISION JOINT rods make sure bearings are properly centered in the cap and rod Make sure cap is properly aligned on rod with interlocking surfaces sealing tightly and edges aligned DO NOT reverse cap on rod Match pads on side of rod and cap When installing caps make sure stamped numbers on ...

Page 193: ...cting Rod Cap Screw Initial Torque 27 N m 20 lb ft Second tighten all cap screws to the following specifications then torque turn all cap screws 90 100 Specification Tongue and Groove Connecting Rod Cap Screw Final Torque 75 N m 55 lb ft plus 90 100 turn clockwise See TORQUE TURN CONNECTING ROD CAP SCREWS next in this group 11 On PRECISION JOINT connecting rods Initially tighten cap screw closest ...

Page 194: ...lues mark connecting rod cap and socket 2 Position handle of wrench parallel to centerline of engine crankshaft axis A 3 Tighten 1 4 turn 90 100 clockwise until handle of wrench is perpendicular to centerline of engine crankshaft axis B as shown RG RG34710 134 19 03AUG99 2 2 RG5698 UN 05DEC97 JT05993 Torque Angle Gauge Using JT05993 Torque Angle Gauge to Torque Turn Connecting Rod Cap Screws After...

Page 195: ...op of cylinder block so dial indicator can be set to zero 0 000 with top of block 3 Position gauge across top of piston While pressing gauge downward rotate crankshaft until piston is at TDC 4 Measure and record piston height at several positions around top OD of piston 5 Piston protrusion must be within the following specification to prevent piston to exhaust valve contact Specification Piston Ea...

Page 196: ...iston Spray Jets B O Ring 1 Remove piston spray jets 2 Coat O ring B with JDT405 High Temperature Grease 3 Install piston spray jets A at each of the six locations on right side of block 4 Tighten cap screws to specifications Specification Piston Spray Jet Cap Screws Torque 15 N m 11 lb ft CTM100 06APR04 02 030 54 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 194 ...

Page 197: ...88 Section 02 Group 090 Dual rail fuel systems See REMOVE AND INSTALL ELECTRONIC UNIT INJECTORS in CTM188 Section 02 Group 091 Single rail fuel systems 6 Adjust clearances preloads and gear backlash Groups 020 040 050 7 Install remaining fuel injection system components CTM115 Section 02 Group 090 or CTM188 Section 02 Group 090 and 091 8 Install the coolant pump and water piping See INSTALL COOLAN...

Page 198: ...Cylinder Block Liners Pistons and Rods 02 030 56 CTM100 06APR04 02 030 56 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 196 ...

Page 199: ...ings and Flywheel 02 040 1 DPSG OUO1004 940 19 26JUL99 1 1 Crankshaft Vibration Damper Torque Sequence RG10247 UN 30JUL99 Vibration Damper Torque Sequence CTM100 06APR04 02 040 1 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 197 ...

Page 200: ...ce damper when a short block complete block or remanufactured basic engine is installed 2 Carefully inspect vibration damper for torn or split rubber protruding from front and back of assembly 3 Grasp vibration damper with both hands and attempt to turn it in both directions If rotation is felt damper is defective and should be replaced 4 Check vibration damper radial runout by positioning a dial ...

Page 201: ...possible 3 Zero the dial indicator IMPORTANT Do not apply too much pressure with bar as this could damage thrust bearings 4 Using a bar gently pry the crankshaft as far forward as possible and record end play Specification Crankshaft End Play 0 038 0 380 mm 0 0015 0 0150 in NOTE If end play is not within specifications new thrust bearings will usually restore proper end play CTM100 06APR04 02 040 ...

Page 202: ... etc Doing so can damage the rubber portion of the assembly Never apply thrust on outer ring of damper The damper is sensitive to impact damage from being dropped or struck with a hammer NOTE Remove front bolt on pulley from vibration damper assembly for access to front nose of crankshaft if equipped 1 Remove six cap screws and large washer A from front nose of crankshaft 2 Install JDG973 1 Remove...

Page 203: ... from crankshaft flange Remover installer hub will support damper after it is removed from crankshaft flange 7 Remove hub from front nose of crankshaft RG RG34710 152 19 30SEP97 1 1 Remove Crankshaft Front Oil Seal RG8119 UN 21MAY98 Removing Crankshaft Front Oil Seal 1 Remove vibration damper and pulley See REMOVE CRANKSHAFT VIBRATION DAMPER AND PULLEY earlier in this group 2 Remove eight cap scre...

Page 204: ... drive assembly the fan drive housing is cast into the camshaft gear access cover 4 Remove fan drive assembly C See REPLACE BEARINGS IN FAN DRIVE ASSEMBLY in Group 070 NOTE Mark location of cap screws to aid in reassembly 5 Remove camshaft gear access cover D from timing gear cover Mark location of cap screws to aid in reassembly 6 Remove remaining cap screws and remove timing gear cover Mark loca...

Page 205: ...heel housing face runout 2 Rotate flywheel by turning crankshaft Read total dial indicator movement and compare to specifications 3 Remount set pointer to contact flywheel housing inner bore B 4 Rotate flywheel by turning crankshaft Read total dial indicator movement and compare to specifications Specification SAE 1 Flywheel Housing Maximum Face Deviation A 0 30 mm 0 012 in Maximum Bore Eccentrici...

Page 206: ... 009 in Maximum Variation per 25 mm 1 0 in of Travel 0 013 mm 0 0005 in RG RG34710 156 19 27JUL99 1 1 Remove Flywheel RG8134A UN 05DEC97 Removing Flywheel A Cap Screws B Threaded Guide Pins CAUTION Flywheel is heavy Use proper lifting procedures to avoid personal injury NOTE SAE 1 flywheel housing must be removed before flywheel can be removed from engine See REMOVE AND INSTALL FLYWHEEL HOUSING la...

Page 207: ...overheating or cracks 2 Resurface clutch contact face as necessary to restore flatness for proper clutch contact 3 Replace a defective flywheel 4 Examine ring gear for worn or broken teeth If ring gear is damaged replace gear See REPLACE FLYWHEEL RING GEAR later in this group CTM100 06APR04 02 040 9 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 205 ...

Page 208: ... off with a brass drift and hammer IMPORTANT If flame heat is used be sure gear is heated uniformly around circumference DO NOT OVERHEAT above 232 C 450 F SEE CAUTION Overheating may also destroy original heat treatment of gear 3 Heat new ring gear sufficiently to allow gear to fit flywheel hub without interference but do not heat above 232 C 450 F maximum using either heated oil or oven heat 4 Tu...

Page 209: ...d 2 Install flywheel housing on cylinder block NOTE ALWAYS use new cap screws when installing flywheel housing 3 Dip threads of cap screw in engine oil before installing Install and tighten cap screws to specifications Specification Flywheel Housing to Cylinder Block Cap Screws SAE 1 With Rear PTO Torque 325 N m 240 lb ft Flywheel Housing to Cylinder Block Cap Screws SAE 0 1 and 2 Without Rear PTO...

Page 210: ... new cap screws when installing flywheel 1 Install two pilot studs in crankshaft to aid in assembly Position flywheel over pilot studs 2 Install flywheel attaching cap screws Remove pilot studs and install remaining two cap screws 3 Tighten flywheel attaching cap screws in the sequence shown to the following specifications Specification Flywheel to Crankshaft Cap Screws Torque 130 N m 96 lb ft 4 A...

Page 211: ...oil pan if not previously removed See REMOVE ENGINE OIL PAN in Group 060 Remove flywheel if not previously removed See REMOVE FLYWHEEL earlier in this group 2 Remove eight cap screws A securing rear seal to housing RG RG34710 161 19 13AUG99 2 4 RG8293 UN 21MAY98 Separating Rear Seal From Housing 3 Separate seal from housing using a small flat screwdriver and heel type prybar as shown Continued on ...

Page 212: ...l housing Wear sleeve portion of seal assembly should remain on crankshaft flange 8 Remove three remaining cap screws securing seal housing to block and remove housing with gasket RG RG34710 161 19 13AUG99 4 4 RG8295 UN 06DEC97 Prying Rear Wear Sleeve RG8345 UN 09DEC97 Removing Rear Wear Sleeve Using JDG1020 A Seal Assembly B JDG1020 Remover 9 If necessary push wear sleeve portion of seal assembly...

Page 213: ...ner seal failure or leaking coolant pump seal with plugged hole Insufficient bearing oil clearance Parts not lubricated prior to engine operation Wrong bearing size Inconsistent Wear Pattern Misaligned or bent connecting rod Warped or bowed crankshaft Distorted cylinder block Broken Main Bearing Caps Improper installation Dirt between bearing and crankshaft journal Low oil pressure Oil pump failur...

Page 214: ...on with corresponding crankshaft journal to check surface wear NOTE When removing main bearings and caps for crankshaft removal leave No 1 and 7 main bearing caps installed until all connecting rod caps have been removed 1 Remove engine oil pan and pick up tube See REMOVE ENGINE OIL PAN in Group 060 2 Remove front timing gear cover See REMOVE TIMING GEAR COVER in this group 3 Remove rear oil seal ...

Page 215: ...h D01300AA Slide Hammer A to cross block tighten nut securely 9 Remove main bearing cap by sliding up on hammer weight 10 Use PLASTIGAGE to measure journal to bearing oil clearance on each main bearing as they are removed See CHECK MAIN BEARING TO JOURNAL OIL CLEARANCE later in this group PLASTIGAGE is a registered trademark of DANA Corp CTM100 06APR04 02 040 17 POWERTECH 10 5 L 12 5 L Diesel Engi...

Page 216: ... of the width of the bearing 2 Use clean SAE 30 engine oil on PLASTIGAGE to prevent sticking 3 Install cap and tighten cap screws to specification Specification Crankshaft Main Bearing Cap Screws Final Torque 320 N m 236 lb ft 4 Remove cap and compare width of PLASTIGAGE with specifications below to determine clearance Specification Crankshaft Main Bearings Main Bearing to Journal Clearance 0 046 ...

Page 217: ... ASSEMBLY earlier in this group 5 Remove all six piston spray jets to avoid damage See REMOVE AND INSTALL PISTON SPRAY JETS in Group 030 6 Remove main bearings 2 through 6 See REMOVE CRANKSHAFT MAIN BEARINGS earlier in this group 7 Rotate crankshaft using the JDG820 Flywheel Turning Tool until connecting rod caps can be removed easily You will be able to remove two rod caps at each position 8 Remo...

Page 218: ...tches on journals Also check each journal for evidence of excessive overheating or discoloration If either condition exists replace crankshaft since heat treatment has probably been destroyed 3 Inspect front crankshaft gear and timing wheel for cracks chipped teeth or excess wear Inspect keyway and index pin for damage and proper indexing on flange Replace gear s as required See REPLACE CRANKSHAFT...

Page 219: ... as the Fluorescent Magnetic Particle method This method magnetizes the crank employing magnetic particles which are fluorescent and glow under black light The crankshaft must be de magnetized after the test 7 Carefully check the crankshaft for cracks in the area of rod journal oil holes A and at journal fillets B Replace crankshaft if any cracks are found CTM100 06APR04 02 040 21 POWERTECH 10 5 L...

Page 220: ...are measurements with connecting rod journal OD on crankshaft See INSPECT AND MEASURE CONNECTING ROD BEARINGS in Group 030 4 Measure OD of all respective crankshaft journals at several points around journal Specification Crankshaft Main Bearing Journal OD 124 983 125 017 mm 4 9206 4 9219 in NOTE If engine has previously had a major overhaul and undersized bearing inserts were used above listed ID ...

Page 221: ...individual bearing caps as needed Specification Main Bearing Cap Bore Specifications ID Without Bearings 133 097 133 123 mm 5 2400 5 2411 in Max Bore Diameter Variation 0 013 mm 0 0005 in Max Bore Diameter Taper 0 005 mm 0 0002 in Max Straightness Any Bore to Adjacent Bore 0 038 mm 0 0015 in Max Straightness 5 Center Bores to Adjacent Bore 0 076 mm 0 0030 in Centerline of Bore to Top Deck 429 92 4...

Page 222: ...ches The fillet must blend smoothly into the journal and crank cheek Check the radius with a fillet gauge IMPORTANT Care must be taken to avoid localized heating which often produces grinding cracks 4 Cool the crankshaft while grinding by using coolant generously DO NOT crowd the grinding wheel into the work IMPORTANT Grind crankshaft with journals turning clockwise as viewed from the front end of...

Page 223: ...urnal Surface Finish Lap 0 25 Um 9 8 AA Thrust Journal and Fillet Radii Surface Finish Lap 0 4 Um 16 AA Rod Journal Fillet Radius 4 49 4 85 mm 0 177 0 191 in Main and Thrust Journal Fillet Radius 3 94 4 44 mm 0 155 0 175 in Thrust Journal Width 48 97 49 07 mm 1 928 1 932 in Bearing Size Crankshaft Main Journal OD Crankshaft Rod Journal OD Standard 124 983 125 017 mm 88 844 88 874 mm 4 9206 4 9219 ...

Page 224: ...Do not allow a heating element to be in direct contact with the oil Heat the oil in a well ventilated area Plan a safe handling procedure to avoid burns IMPORTANT Crankshaft gear must be installed on crankshaft before crankshaft is installed in engine otherwise damage to thrust bearings could occur 6 Heat crankshaft gear to 182 C 360 F maximum using either heated oil or oven heat 7 Install new rol...

Page 225: ...0 007 in NOTE Thrust bearing must be installed with slots facing crankshaft flange Two halves A and C go on cap side not block RG RG34710 174 19 13AUG99 1 1 Thrust Bearing New Part Specifications RG5269 UN 20NOV97 Thrust Bearing Clearance A Thrust Washer Clearance Base Circle B Thrust Surface Width C Relief Angle D Bearing Cap Overall Width IMPORTANT Install thrust bearing in cylinder block and ti...

Page 226: ...ides of main bearing inserts thrust bearing inserts and thrust washers Entire OD of crankshaft main bearing journals 1 Install six main bearing inserts in block except No 5 thrust bearing insert Be sure locating tabs on inserts are properly positioned with slot in block web IMPORTANT Thrust washers A and C go on both sides of block web only with the slots facing the crankshaft 2 Install No 5 main ...

Page 227: ... bearing caps have been rebored make sure bearing caps have numbers stamped on them 3 Install each bearing cap and bearings with the recesses and tabs aligned in matching order using JDG996 Main Bearing Cap Puller Installer A and D01300AA Slide Hammer B Make sure bearing tabs also match up before tightening cap screws NOTE Main bearing caps may also be installed by evenly tightening both main bear...

Page 228: ...crews to the following specification Specification Crankshaft Main Bearing Cap Screws Initial Torque 68 N m 50 lb ft 8 Tighten all main bearing cap screws including No 5 to the following specification Specification Crankshaft Main Bearing Cap Screws Final Torque 320 N m 236 lb ft 9 Turn crankshaft by hand If it does not turn easily disassemble parts and determine the cause Continued on next page C...

Page 229: ...AFT REAR OIL SEAL AND HOUSING later in this group 12 Install rear oil seal and wear sleeve See INSTALL CRANKSHAFT REAR OIL SEAL AND WEAR SLEEVE ASSEMBLY later in this group 13 Install flywheel See INSTALL FLYWHEEL earlier in this group 14 Install flywheel housing See REMOVE AND INSTALL FLYWHEEL HOUSING earlier in this group 15 Install six piston spray jets See REMOVE AND INSTALL PISTON SPRAY JETS ...

Page 230: ...ery cloth and clean surfaces thoroughly 1 Install JDG977 Pan Rail Aligner A onto rear pan rail as shown using two cap screws provided Tighten cap screws securely 2 Install rear seal housing B using a new gasket bottom edge of gasket should extend through opening in alignment plate Tighten housing cap screws finger tight 3 Install larger end of JDG975 Timing Gear Cover Rear Seal Housing Aligner C o...

Page 231: ... 680 TY15969 Retaining Compound around OD of rear crankshaft flange 4 Position rear seal assembly B and JDG974A Seal Installer C onto rear crankshaft flange and forcing screw NOTE Align mounting holes in seal casing with holes in rear seal housing as seal assembly is installed 5 Lubricate forcing screw threads and both sides of friction washer Install washer and nut tighten nut until installer bot...

Page 232: ... cap screws provided Tighten cap screws securely NOTE If necessary guide pins may be used to ensure correct gasket B earlier engines and timing gear cover C alignment with mounting holes IMPORTANT On earlier engines where sealant was applied clean front plate and timing gear cover surfaces with TY16285 Clean and Cure Primer prior to assembly Follow instructions on label 4 On earlier engines with F...

Page 233: ...s in place gaskets require only a final torque 9 Center cover with crankshaft flange and initially tighten cap screws on earlier engines to specifications following sequence in lower illustration Tighten two longest cap screws located next to crankshaft center line Then go to bottom cap screws alternating from side to side and tighten remaining cap screws to specifications Specification Timing Gea...

Page 234: ...IMPORTANT On earlier engines where sealant was applied clean timing gear cover and camshaft gear access cover gasket surfaces with TY16285 Clean and Cure Primer prior to assembly Follow directions on label 11 On earlier engines with Fel Pro gaskets only soak both sides of new camshaft gear access cover gasket A with LOCTITE 242 Thread Lock and Sealant and let dry for 15 minutes or until dry to the...

Page 235: ...quence Later engines with press in place gaskets require only a final torque 15 Initially tighten cap screws and stud nut to specification following sequence in lower drawing Specification Camshaft Gear Access Cover Cap Screws Early Engines Only 1 Initial Torque 50 N m 37 lb ft Finish tightening camshaft gear access cover cap screws following sequence in lower drawing to the following specificatio...

Page 236: ... timing wheel This applies even if the sensor was not removed from timing gear cover 19 Install crankshaft position sensor if removed or check sensor to crankshaft timing wheel dimension See REMOVE AND INSTALL CRANKSHAFT POSITION SENSOR in the appropriate fuel systems manual Delphi Lucas ECU controlled fuel systems See REMOVE AND INSTALL CRANKSHAFT POSITION SENSOR in CTM 115 Section 02 Group 110 J...

Page 237: ...plete block or reman basic engine is installed Front crankshaft oil seal A must be installed onto vibration damper before installing damper onto engine Install Front Seal onto Vibration Damper 1 Apply LOCTITE 680 TY15969 Retaining Compound around OD of crankshaft flange Position front oil seal assembly on flange with rubber seal ring facing up as shown NOTE Lubricate threads of forcing screw with ...

Page 238: ...0MAY98 Front Seal Installed on Damper A JDG974 1 Seal Installer 4 Install JDG974 1 Seal Installer A with friction washer and nut 5 Tighten nut until installer bottoms on rear face of damper 6 Remove tools and clean any sealant from tools Continued on next page CTM100 06APR04 02 040 40 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 236 ...

Page 239: ... vibration damper and seal B on forcing screw hub as shown 4 Install JDG973 2 Cross Block C onto forcing screw Secure cross block with two cap screws finger tight NOTE Lubricate forcing screw and both sides of friction washer with multi purpose grease prior to each use 5 Install friction washer and nut against cross block NOTE Cut outs in seal casing should be at 3 o clock and 9 o clock position f...

Page 240: ...screws in sequence shown to specifications Specification Damper Hub Cap Screws Torque 125 N m 92 lb ft 8 If required install pulley on damper and tighten cap screws to specifications Specification Pulley to Damper Cap Screws Torque 125 N m 92 lb ft 9 Install front seal to timing gear cover cap screws and tighten to specifications following sequence in lower illustration Specification Front Oil Sea...

Page 241: ...Y in Group 070 2 Install oil pan and service engine with clean engine oil See INSTALL ENGINE OIL PAN in Group 060 3 Fill cooling system with proper coolant See DIESEL ENGINE COOLANT RECOMMENDATIONS in Section 01 Group 002 4 Perform engine break in See ENGINE BREAK IN GUIDELINES in Group 010 CTM100 06APR04 02 040 43 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 239 ...

Page 242: ...Crankshaft Main Bearings and Flywheel 02 040 44 CTM100 06APR04 02 040 44 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 240 ...

Page 243: ... Gear Train 02 050 1 RG RG34710 188 19 30SEP97 1 1 Camshaft Gear Access Cover Torque Sequence RG8811 UN 20MAY98 Camshaft Gear Access Cover Torque Sequence CTM100 06APR04 02 050 1 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 241 ...

Page 244: ...ming slot A first before attempting to install second timing pin into crankshaft timing slot C 3 Rotate engine flywheel in running direction counterclockwise as viewed from rear until JDG971 Timing Pin A engages single timing slot D in camshaft The proper timing slot can be found by viewing camshaft timing lobe through camshaft timing pin bore while rotating engine The double timing slot E will be...

Page 245: ...ar Retainer Cap Screws RG8227D UN 05DEC97 JDG971 Timing Pin in Crankshaft A Camshaft Gear Retainer Cap Screws B JDG820 Flywheel Turning Tool C JDG971 Timing Pin Adjust Camshaft to Crankshaft Timing 1 Leave JDG971 Timing Pin in camshaft timing slot and remove camshaft gear access cover shown removed from timing gear cover See REMOVE TIMING GEAR COVER in Group 040 2 Loosen camshaft gear retainer cap...

Page 246: ... camshaft The proper timing slot can be found by viewing camshaft timing lobe through camshaft timing pin bore while rotating engine The double timing slot E will be at approximately 11 o clock viewed from rear of engine when pin is installed in slot D This ensures that engine is locked at TDC of No 1 cylinder s compression stoke Intake and exhaust rocker arms on No 1 cylinder should be loose IMPO...

Page 247: ...p Screws C Lower Cap Screws 5 Loosen all six camshaft gear retainer cap screws 6 Loosen three upper idler gear bearing carrier cap screws B so that carrier can be moved by hand Do not loosen more than required for ease of assembly NOTE Upper hole on template is larger and fits over upper cap screw This ensures proper placement of template when installed 7 Remove two lower cap screws C from upper i...

Page 248: ...o tab on backlash template as shown Also shim must be installed between gear teeth that are meshing deepest in the root 0 13 mm 0 005 in shim A for idler gear to camshaft gear backlash 0 25 mm 0 010 in shim B for idler gear to oil pump gear backlash Specification Camshaft Gear to Upper Idler Gear Backlash 0 13 mm 0 005 in Oil Pump Gear to Upper Idler Gear Backlash 0 25 mm 0 010 in Continued on nex...

Page 249: ...cannot be removed from gear teeth 10 Remove three idler gear carrier cap screws C one at a time and apply LOCTITE 242 Thread Lock and Sealer Re install and tighten to specifications Specification Upper Idler Gear Thrust Plate Cap Screws Initial Torque 35 N m 26 lb ft Both shims MUST BE tight between gear teeth 11 Retorque idler gear carrier cap screws to specifications Specification Upper Idler Ge...

Page 250: ...mshaft Gear Retainer Plate to Camshaft Second Torque 150 N m 110 lb ft 14 Finally retorque cap screws to the following specification in sequence shown Specification Camshaft Gear Retainer Plate to Camshaft Final Retorque 150 N m 110 lb ft 15 Remove two lower idler gear thrust plate cap screws and backlash template and rotate engine flywheel to remove shims Apply LOCTITE 242 Thread Lock and Sealer ...

Page 251: ...mbly See REMOVE ROCKER ARM ASSEMBLY in Group 020 NOTE See DFRG4 CAMSHAFT LOCKING TOOL in Section 05 Group 190 for instructions on how to fabricate tool 2 Secure camshaft in bushings with DFRG4 Camshaft Locking Tool A Tighten cap screw and secure locking tool to head RG RG34710 191 19 25OCT00 2 14 RG8288 UN 21MAY98 Removing Camshaft Position Sensor 3 Remove camshaft position sensor from cylinder he...

Page 252: ...move six cap screws securing camshaft gear retainer washer A and remove camshaft gear B NOTE Gently bump camshaft forward to remove thrust ring C 6 Remove camshaft thrust ring C RG RG34710 191 19 25OCT00 4 14 RG10243 UN 30JUL99 Installing JDG969A Camshaft Holder A Camshaft Holder 7 Install JDG969A Camshaft Holder A onto front face of camshaft using two camshaft gear retainer cap screws Tighten cap...

Page 253: ...rear of cylinder head 9 Remove supply pump drive coupler B from drive pin in rear of camshaft RG RG34710 191 19 25OCT00 6 14 RG8289A UN 06DEC97 Installing JDG972 Camshaft Pilot A Camshaft Pilot 10 Install JDG972 Camshaft Pilot A onto rear face of camshaft Tighten two set screws securely Lubricate pilot with clean engine oil or multipurpose grease Continued on next page CTM100 06APR04 02 050 11 POW...

Page 254: ...ort camshaft holder with a hoist Ensure that engine repair stand is level to ease removal of camshaft 12 Slowly remove camshaft from cylinder head Traverse hoist if possible as camshaft is removed to avoid binding in bushing bores Continued on next page CTM100 06APR04 02 050 12 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 252 ...

Page 255: ...EPLACE FUEL SUPPLY PUMP DRIVE PIN later in this group NOTE Engine repair stand must be level during camshaft installation Traverse hoist during installation so that camshaft bearings do not bind in bushing 2 Attach JDG969A Camshaft Holder A to front face of camshaft B Attach JDG972 Camshaft Pilot C to rear face of camshaft Securely tighten all mounting hardware 3 Coat camshaft lobes and bearings w...

Page 256: ... UN 21MAY98 Removing JDG972 Pilot from Camshaft 6 Push camshaft toward rear of engine until pilot set screws can be removed from rear face Remove pilot from rear face of camshaft Continued on next page CTM100 06APR04 02 050 14 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 254 ...

Page 257: ...Pump Drive Coupler Set Screw Torque 4 N m 3 lb ft 8 Install fuel supply pump Refer to the appropriate fuel system repair manual Delphi Lucas ECU controlled fuel systems See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM115 Section 02 Group 090 John Deere Level 6 ECU controlled fuel systems See REMOVE AND INSTALL FUEL SUPPLY PUMP in CTM188 Section 02 Group 090 dual rail fuel systems See REMOVE AND INST...

Page 258: ...G34710 191 19 25OCT00 12 14 RG8286A UN 06DEC97 Installing Camshaft Thrust Ring A Camshaft Thrust Ring 10 Install a new thrust ring gasket Lubricate O ring with clean engine oil and install camshaft thrust ring A and tighten cap screws to specifications Specification Camshaft Thrust Ring to Head Torque 35 N m 26 lb ft Continued on next page CTM100 06APR04 02 050 16 POWERTECH 10 5 L 12 5 L Diesel En...

Page 259: ...mshaft position sensor and tighten to specifications Specification Camshaft Position Sensor Torque 14 N m 10 lb ft RG RG34710 191 19 25OCT00 14 14 RG8251B UN 06DEC97 Installing Camshaft Gear A Camshaft Gear B Retainer Washer 14 Install camshaft gear A and retainer washer B Install retainer cap screws finger tight Adjust timing gear backlash See ADJUST FRONT TIMING GEAR BACKLASH earlier in this gro...

Page 260: ...earlier in this group RG RG34710 192 19 30SEP97 1 1 Visually Inspect Camshaft and Roller Followers RG8385B UN 09DEC97 Inspecting Camshaft Lobes RG8388 UN 21MAY98 Inspecting Roller Followers A Intake Lobe B Exhaust Lobe C Unit Injector Lobe D Bushing Journal 1 Clean camshaft in solvent Dry with compressed air IMPORTANT Very light score marks may be found on eccentric lobes but are acceptable if val...

Page 261: ... not within specification 2 Measure camshaft bushing ID and compare with specifications below Replace camshaft bushings if not within specification and if surface wear or scratching is detected Specification Camshaft Journal OD 101 987 102 013 mm 4 0152 4 0162 in Camshaft Bushing ID 102 091 102 167 mm 4 0193 4 0223 in Camshaft Journal to Bushing Oil Clearance 0 078 0 180 mm 0 0031 0 0071 in Camsha...

Page 262: ...e camshaft Camshaft Lobe Specification Intake Lobe Lift 8 73 8 99 mm 0 343 0 353 in Exhaust Lobe Lift 7 93 8 19 mm 0 312 0 322 in EUI Lobe 10 5 L Engines and 12 5 L Engines 29999 Lift 14 16 14 42 mm 0 557 0 567 in EUI Lobe 12 5 L Engine S N 30000 Lift 16 09 16 35 mm 0 633 0 643 in RG RG34710 195 19 30SEP97 1 1 Inspect Camshaft Position Sensor Lobe RG8385A UN 09DEC97 Inspecting Camshaft Sensor and ...

Page 263: ...ubricate 313793 Forcing Screw B and inset through remover with double nut and washer towards front of engine 5 Install JDG968 3 Guide C in rear side of No 2 tower with forcing screw through driver Secure assembly with nut and washer 6 Remove bushing from bore using a 1 2 in drive ratchet wrench with deep well socket on double nut and a combination wrench to hold single nut Protect cylinder head wi...

Page 264: ...linder head and inspect for damage Clean lubricating oil holes as needed RG RG34710 196 19 25OCT00 3 7 RG8334 UN 09DEC97 Positioning Replacement Bushing on Installer A Notch Alignment B Alignment Sleeve C Bushing Installer Install Camshaft Bushings IMPORTANT ALWAYS install bushings from front side of cylinder head bushing bore and drive toward rear 1 No 1 Bushing Apply a light coat of TY6333 or TY...

Page 265: ...d of JDG968 5 Alignment Pin C into oil hole spring pin removed until pin engages groove in alignment sleeve 7 Once pin engages groove rotate sleeve toward valves until you feel a positive stop This ensures that the oil holes in bushing and cylinder head will be properly aligned after installation RG RG34710 196 19 25OCT00 5 7 RG8337 UN 09DEC97 Bushing Installation Alignment Pin A Alignment Pin 8 S...

Page 266: ... Install JDG968 2 Bushing Installer and JDG968 4 Alignment Sleeve with bushing in front of tower No 3 and JDG968 3 Guide in rear of tower No 5 12 Install 313793 Forcing Screw with double nut toward front of engine 13 Use a 304 8 mm 12 0 in extension with ratchet to reach double nut 14 No 4 Bushing NOTE Install bushing No 4 before installing bushing No 3 Adjust double nut position on forcing screw ...

Page 267: ...ore installing bushing No 3 Install JDG968 2 Bushing Installer and JDG968 4 Alignment Sleeve with bushing in front of tower No 5 and JDG968 3 Guide in rear of No 6 tower 19 Install 313793 Forcing Screw with double nut toward rear of engine 20 Use a 152 4 mm 6 0 in extension with ratchet to reach double nut 21 Install a new spring pin in towers 3 and 5 bushing locations 2 and 3 CTM100 06APR04 02 05...

Page 268: ...Splined Gear N Cover Plate G O Ring K O Ring NOTE Refer to CTM67 OEM Engine Accessories for repair of auxiliary drive assembly Torque specifications for adapter housing F and support bushing C are as follows Specification SAE A Front Auxiliary Drive Adapter Housing Nuts Torque 50 N m 37 lb ft SAE A Front Auxiliary Drive Idler Gear Support Bushing Torque 220 N m 162 lb ft 1 A shim may be used with ...

Page 269: ...bearing 5 Thoroughly clean and inspect gear and housing Assemble Rear Auxiliary Drive Assembly 1 Assemble bearing onto gear shaft Press bearing flush with shoulder on gear 2 Determine correct size snap ring C and shim D if required to achieve 0 11 mm 0 004 in maximum clearance between bearing cone and snap ring See parts catalog for snap ring and shim sizes 3 Support back side of adapter housing P...

Page 270: ...operly aligned adapter may damage bearing assembly 1 Install SAE B rear auxiliary drive adapter and tighten to specification Specification SAE B Rear Auxiliary Drive Adapter Torque 110 N m 81 lb ft 2 Install SAE A front adapter and tighten four mounting stud nuts B finger tight 3 Install JDG1144 Alignment Tool C onto gear flange and into adapter bore to properly center adapter with gear spline 4 T...

Page 271: ...ications N 1 1 4 in ID Elbow To T Filter Adapter Assembly G Gasket Remote Oil Filter Inlet U Port to Turbocharger Oil C Oil Cooler Cover Valve H Oil Cooler Housing O 1 in ID Elbow To Remote Inlet Housing Remote Filter I Gasket Oil Filter Outlet V Pressure Regulating Valve Applications J Oil Cooler P 1 1 4 ID Adapter Remote Assembly D Port to Remote Oil Filter K Oil Filter Bypass Valve Oil Filter A...

Page 272: ...ilter B counterclockwise using filter wrench and remove filter from housing 3 Remove eight cap screws securing oil filter and valve housing to cylinder block and remove housing Remove and discard gasket 4 Remove valves and thoroughly clean all bores and passages in housing RG RG34710 208 19 30SEP97 1 1 Inspect and Replace Oil Filter Adapter RG8433 UN 19MAY98 Oil Filter Adapter A Oil Filter Housing...

Page 273: ...regulating valve assembly C from oil filter housing G Discard O ring 2 Inspect valve and valve bore for damage Replace if necessary 3 Clean all parts with a brass or copper wire brush and solvent Dry with compressed air 4 Check spring for proper compression Specification New Oil Pressure Regulating Valve Spring Free Length 86 4 mm 3 40 in Working Load at 76 84 N 17 19 lb force 42 0 mm 1 65 in 5 Di...

Page 274: ...D from oil filter housing G Discard O rings 2 Clean all parts with a brass or copper wire brush and solvent Dry with compressed air 3 Inspect bypass valves and valve bores for damage Replace if necessary 4 Check bypass valve springs for proper compression Replace if not within specification Specification New Oil Cooler Bypass Valve Spring Free Length 44 0 mm 1 73 in Working Load 64 78 N 14 18 lb f...

Page 275: ...pplications 1 Remove oil pressure relief valve assembly B from oil filter housing G 2 Clean all parts with a brass or copper wire brush and solvent Dry with compressed air 3 Inspect valve and valve bore for damage Replace if necessary 4 Check valve spring for proper compression Replace if not within specification Specification Oil Pressure Relief Valve Spring Free Length 79 0 mm 3 11 in Working Lo...

Page 276: ... may be used as an aid for removing and installing oil filter housing 1 Remove oil filter and valve housing shown removed See REMOVE OIL FILTER AND VALVE HOUSING OIL COOLER COVER AND VALVE HOUSING earlier in this group 2 Install two guide pins A as shown if desired Remove two hex socket head cap screws B and remove oil cooler housing C with oil cooler D 3 Remove and discard oil cooler to cylinder ...

Page 277: ...1 4 1 7 bar 20 25 psi IMPORTANT When installing oil cooler into housing ensure that face of both mounting nuts is square to threads for proper torque 7 Apply TY9473 LOCTITE 242 Thread Lock and Sealer to oil cooler hex nuts 8 Install oil cooler in housing using a new gasket and two new O rings Tighten two large hex nuts to specifications Specification Oil Cooler to Housing Nuts Torque 50 N m 37 lb ...

Page 278: ...B Hex Socket Head Cap Screws NOTE Standard filter valve housing assembly shown Procedure for remote filter applications is similar 1 Remove all gasket material from cylinder block oil cooler housing and oil filter valve housing All sealing surfaces must be clean and free of oil NOTE Use guide pins as an assembly aid if desired 2 Install oil cooler and housing assembly A using a new gasket Position...

Page 279: ...il cooler housing hose clamps securely 7 Coat oil filter gasket with clean engine oil Install filter to housing until gasket contacts base then tighten an additional 1 2 3 4 turn 8 If equipped with a remote filter Connect hose or line ends to oil cooler cover valve housing and tighten hose or line ends to specification Specification Remote Filter Inlet Hose or Line Torque 190 N m 140 lb ft Remote ...

Page 280: ...aft 3 Remove drive gear from shaft and oil pump housing RG RG34710 214 19 25OCT00 2 3 RG8257 UN 06DEC97 Removing Oil Pump A Hex Socket Head Cap Screws B Oil Pump Assembly 4 Remove three hex socket head cap screws A securing oil pump assembly B to cylinder block and remove oil pump IMPORTANT DO NOT disassemble oil pump since no repair parts are available Replace oil pump as a complete assembly as n...

Page 281: ...g input shaft by hand to clean any debris from housing and gears 2 Using a good light source look through rear cavities of pump to inspect all gear teeth for abnormal wear Replace pump if excess wear is noticed 3 Inspect back side of oil pump cover through cavities for evidence of gear contact with cover Replace pump if gear contact is noticed 4 Inspect oil pump drive gear teeth for wear Inspect a...

Page 282: ...t align to ensure proper lubrication for oil pump to gear bushing NOTE 101 6 mm 4 0 in long guide pins may be used to aid oil pump cap screw hole alignment if desired Cap screw holes will be aligned only when oil pump is correctly installed 3 Install oil pump on cylinder block Apply LOCTITE 242 TY9473 Thread Lock and Sealer to oil pump to cylinder block cap screw threads and tighten to initial tor...

Page 283: ...put shaft 9 Check oil pump drive gear to idler gear backlash Specification Oil Pump Drive Gear to Idler Gear Backlash 0 25 mm 0 010 in 10 Install timing gear train cover and complete final assembly See INSTALL TIMING GEAR COVER in Group 040 RG RG34710 217 19 30SEP97 1 1 Remove Engine Oil Pan RG8819 UN 20MAY98 Removing Oil Pan 1 Disconnect turbocharger oil inlet line Remove oil pan drain plug and d...

Page 284: ...nder block and remove tube assembly with gasket 3 Clean pickup tube and screen completely with solvent Dry with compressed air 4 Inspect pickup screen for damage or holes Inspect tube for weld breaks bends or any other damage Replace as necessary 5 Install pickup tube assembly to cylinder block using a new gasket Tighten cap screws to specifications Specification Oil Pickup Tube to Block Cap Screw...

Page 285: ...r and rear seal housing MUST BE free of gasket material and oil Surface must be dry 1 Apply LOCTITE 7649 Solventless Primer to two front T joint areas A At close to 5 minutes apply a 3 mm 1 8 in bead of LOCTITE 17430 High Flex Form In Place Gasket 2 Apply a 3 mm 1 8 in bead of LOCTITE 17430 High Flex Form In Place Gasket to two rear T joint areas C and on inside edge of both cap screw holes for re...

Page 286: ... housing and oil pan to timing gear cover cap screws to specification Specification Oil Pan to Rear Oil Seal Housing Cap Screws Torque 25 N m 18 5 lb ft plus 90 Turn Clockwise Oil Pan to Timing Gear Cover Cap Screws Torque 25 N m 18 5 lb ft plus 90 Turn Clockwise 7 Install oil pan drain plug using a new O ring and tighten to specifications Specification Oil Pan Drain Plug 1 1 4 in Hex Plug Torque ...

Page 287: ...e assembly from engine NOTE Early adjustable bearing housings G will use threaded type pipe plug H Fixed bearing housings F and later adjustable bearing housings G will use press in type plug I 4 Remove pipe plug H or plug I grease seal B and snap ring C Discard seal and snap ring 5 Remove shaft with bearings D by lightly tapping end of shaft through pipe plug opening with a hammer and brass drift...

Page 288: ...5 mm 2 8346 2 8356 in Shaft OD 35 001 35 017 mm 1 3780 1 3786 in Bearing ID 34 987 35 013 mm 1 3774 1 3785 in Bearing OD 71 987 72 013 mm 2 8341 2 8351 in Replace parts that are cracked or not within specification Continued on next page CTM100 06APR04 02 070 2 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 286 ...

Page 289: ...nstall bearing and shaft assembly into housing using JDG743A Bearing Driver Small end of shaft should extend through housing 5 Determine proper snap ring C thickness needed to obtain specified end play Specification Fan Drive Shaft End Play 0 10 mm 0 004 in 6 Install snap ring in housing groove Visually inspect snap ring installation for proper seating in housing groove NOTE Install grease seal B ...

Page 290: ...ve Hub to Shaft Torque 115 N m 85 lb ft On engines with dual pulleys tighten pulley to pulley cap screws to the following specifications Specification Fan Pulley to Pulley Cap Screws Torque 61 N m 45 lb ft 10 On fixed fan drive and later adjustable fan drive assemblies plug I figure on previous page should be driven in flush to slightly recessed in rear surface of camshaft gear access cover 11 On ...

Page 291: ...ensioner spring tension using a torque wrench and procedure outlined below 1 Release tension on belt using a long handle 3 4 in breaker bar in tension arm Remove belt from pulleys 2 Release tension on tension arm and remove breaker bar 3 Put a mark A on swing arm of tensioner as shown 4 Measure 25 mm 1 0 in from first mark A and put a second mark B on tensioner mounting base 5 Rotate the swing arm...

Page 292: ...ase tension on belt using a long handle 1 2 in breaker bar in tension arm Remove belt from pulleys 2 Release tension on tension arm and remove breaker bar 3 Put a mark A on swing arm of tensioner as shown 4 Measure 21 mm 0 83 in from first mark A and put a second mark B on tensioner mounting base 5 Rotate the swing arm using a torque wrench until marks A and B are aligned 6 Record torque wrench me...

Page 293: ...NOTE If cam access cover is equipped with two upper tensioner locating holes reinstall upper tensioner using locating hole previously marked on disassembly Apply LOCTITE 242 Thread Lock and Sealer TY9473 to tensioner shoulder bolt or cap screw before installing 4 Install tensioner using locator in upper tensioner only and tighten shoulder bolt or flanged head cap screw to specifications Specificat...

Page 294: ...e block RG RG34710 227 19 17SEP02 2 2 RG8825 UN 26JUL99 Removing Primary Fuel Filter RG8261B UN 06DEC97 Removing Coolant Pump A Primary Fuel Filter Water Separator B Oil Cooler and Housing Assembly C Coolant Pump D O Ring 2 On 6125ADW engines remove primary fuel filter water separator A and mounting bracket 3 On all engines remove engine oil cooler and housing assembly B See REMOVE OIL FILTER AND ...

Page 295: ...rough John Deere service parts as complete remanufactured assemblies 1 Clean all parts with solvent and dry with compressed air 2 Inspect coolant pump cover A and housing C for cracks or damage 3 Inspect gear D for damage 4 Be sure the weep hole in housing is clear and install new foam filter if required 5 If removed install coolant pump cover A with new O ring Tighten band clamp B to specificatio...

Page 296: ...specifications Specification Coolant Pump to Front Plate Cap Screws Torque 50 N m 37 lb ft 5 On engines with removable coolant pump inlet elbow install elbow and tighten cap screws to following specifications Specification Coolant Pump Inlet Elbow to Housing Cap Screws Torque 41 N m 30 lb ft 6 Install oil cooler and housing assembly See INSTALL OIL COOLER OIL FILTER VALVE HOUSING ASSEMBLY OR OIL C...

Page 297: ...e Always loosen radiator pressure cap or drain valve slowly to relieve pressure 1 Visually inspect area around thermostat housing for leaks Partially drain cooling system 2 Remove cap screws securing thermostat cover A to thermostat housing and engine block 3 Remove thermostat cover from thermostat housing 4 Remove gasket or seal B and remove both thermostats 5 Test each thermostat for proper open...

Page 298: ...maller non blocking thermostat in top position with vent wiggle wire at 12 o clock position Install larger blocking thermostat in bottom position 3 Install thermostat cover using a new gasket or seal B 4 If equipped install M10 x 35 cap screw C securing thermostat cover to housing and tighten to specifications Specification Thermostat Cover to Housing M10 x 35 Cap Screw Torque 35 N m 26 lb ft 5 In...

Page 299: ... 4 Stir the water as it heats Observe opening action of thermostat and compare temperatures with specification given in chart below Specification Thermostat Test Rating 82 C 180 F Initial Opening Range Temperature 80 84 C 175 182 F Full Open Nominal Temperature 94 C 202 F NOTE Due to varying tolerances of different supplies initial opening and full open temperatures may vary slightly from specifie...

Page 300: ...ket material from mounting surfaces Install Thermostat Housing 1 Apply clean engine oil to top liner cooling outlet adapter O ring 2 Position thermostat housing on engine using a new gasket Be sure housing is firmly seated on top liner cooling adapter O ring 3 Install mounting cap screws and tighten to specifications Specification Thermostat Cover Housing Assembly to Block Cap Screws Torque 50 N m...

Page 301: ...Keep electrical connectors clean to prevent arcing Only plug coolant heater into electrical power if heating element is immersed in coolant Otherwise sheath could burst causing personal injury 1 Unplug heater from electrical power source 2 Partially drain cooling system 3 Remove electrical cord A loosen nut and pull heater element B out of oil cooler housing NOTE The heater element cannot be repai...

Page 302: ...Cooling System 02 070 16 CTM100 06APR04 02 070 16 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 300 ...

Page 303: ...ld always be replaced with a line of equal size length and strength The easiest way to damage a turbocharger is through improper start up and shutdown procedures Always idle the engine for at least 30 seconds no load after start up and before shutdown Warming the engine up before applying a load allows oil pressure to build up and lines to fill with oil Idling the engine before shutdown allows the...

Page 304: ...ailure There are two primary reasons for restricted drainage A blocked drain tube due to either damage or a buildup of sludged oil or high crankcase pressure which can be due to restricted crankcase breather or excessive engine blow by Periodically check both the turbocharger oil drain tube and engine breather tube for damage or restriction Correction of these conditions leads to longer turbocharg...

Page 305: ... of a potential failure mode See TURBOCHARGER SEVEN STEP INSPECTION later in this group 1 Refer to your machine technical manual to disconnect air inlet and exhaust piping 2 Remove turbocharger air intake hose and exhaust elbow Remove turbocharger air outlet piping shown removed 3 Disconnect oil inlet line A and oil return pipe B from turbocharger 4 Remove four mounting cap screws and lift turboch...

Page 306: ...erature or debris generating engine failure in progress Correct as required Manufacturing defects Correct as required COMPRESSOR HOUSING OUTLET DEFECTS Oil and or Dirt in Housing Restricted air intake system Inspect and clean air cleaner Prolonged periods of low rpm engine Check with operator to confirm conditions See idling Operator s Manual Defective oil seal ring Repair as required this group R...

Page 307: ...gine Ask operator to run engine under load or at a higher idling rpm See Operator s Manual Restricted oil drain line Inspect and clear oil drain line as required EXTERNAL CENTER HOUSING AND JOINT DEFECTS Leaks from Casting Defective casting Replace turbocharger this group Defective gasket Verify if leaks are occurring at gasket joints Leaks from Joints Loose attaching screws Tighten to specificati...

Page 308: ...urbine Housing Outlet and Turbine Wheel External Center Housing and Joints Internal Center Housing Turbocharger Bench Test NOTE To enhance the turbocharger inspection an inspection sheet Form No DF 2280 available from Distribution Service Center English only can be used that lists the inspection steps in the proper order and shows potential failure modes for each step Check off each step as you co...

Page 309: ... housing itself and check the tips of the compressor wheel blades for damage DPSG OUO1004 945 19 28JUL99 4 13 RG8539 UN 10DEC97 Checking Compressor Outlet A Compressor Housing Outlet Compressor Housing Outlet 1 Check compressor housing outlet A The outlet should be clean and free of dirt or oil 2 Mark it on your checklist if dirt or oil is found and continue the inspection Continued on next page C...

Page 310: ...cessive carbon deposits an engine problem is likely Center wall erosion cracking or missing pieces indicates excessive exhaust temperature DPSG OUO1004 945 19 28JUL99 6 13 RG8540 UN 10DEC97 Checking Turbine Wheel and Outlet A Turbine Housing Outlet B Blades Turbine Housing Outlet and Turbine Wheel 1 Use a flashlight to look up inside the turbine housing outlet A and check blades B for foreign obje...

Page 311: ...ousing showing wear or damage DPSG OUO1004 945 19 28JUL99 8 13 RG4529 UN 05DEC97 Checking Center Housing External Center Housing and Joints Visually check the outside of the center housing all connections to the compressor and turbine housing for oil NOTE If oil is present make sure it is not coming from a leak at the oil supply or return line Continued on next page CTM100 06APR04 02 080 9 POWERTE...

Page 312: ...r bearings There should not be excess carbon deposits on the shaft or in the housing DPSG OUO1004 945 19 28JUL99 10 13 RG4531 UN 05DEC97 Checking for Oil Coking on Shaft 2 Excessive blueing or coking of oil along the complete length of the shaft indicates a possible lack of lubrication caused by an engine failure or improper operation such as hot shutdowns Continued on next page CTM100 06APR04 02 ...

Page 313: ...19 28JUL99 12 13 RG8498B UN 10DEC97 Checking for Contact of Compressor and Turbine Wheels IMPORTANT Use only moderate hand force 3 4 pounds on each end of shaft 3 Next pull up on the compressor end of the shaft and press down on the turbine end while rotating shaft Neither the compressor wheel nor the turbine wheel should contact the housing at any point NOTE There will be some play because the be...

Page 314: ...ic areas of the engine to correct the problems causing the turbocharger failure See TURBOCHARGER FAILURE ANALYSIS earlier in this group It is not unusual to find that a turbocharger has not failed If your turbocharger passes all the inspections the problem lies somewhere else IMPORTANT Before you finalize your conclusion that the turbocharger has not failed it is strongly recommended that the foll...

Page 315: ...te hand force 3 4 pounds on each end of shaft when checking clearance 3 Grasp rotating shaft at both ends and move the shaft toward the indicator then away from the indicator arrows Use care to move the shaft in the same direction as the dial indicator tip travels and apply equal pressure at both ends of the shaft 4 Observe and record total indicator movement Specification Garrett Turbocharger Sha...

Page 316: ...3 Observe and record total dial indicator movement and compare to following specification Specification Garrett Turbocharger Axial Bearing End Play 0 025 0 114 mm 0 0010 0 0045 in Borg Warner Turbocharger Axial Bearing End Play 0 0635 0 1143 mm 0 0025 0 0045 in If bearing end play is not within specification replace turbocharger RG RG34710 245 19 30SEP97 1 1 Repair Turbocharger Turbochargers used ...

Page 317: ...pressed air Damage to bearings can occur when using compressed air Fill oil inlet or drain port with clean engine oil and spin rotating assembly by hand to properly lubricate bearings If turbocharger is to be stored for an extended period of time lubricate internally and install protective covers on all openings CTM100 06APR04 02 080 15 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 315 ...

Page 318: ...hown Install stainless steel gasket B over guide pins 2 Position turbocharger on stainless steel gasket and exhaust manifold 3 Apply PT569 NEVER SEEZ Compound to turbocharger cap screws and tighten to specifications Specification Turbocharger to Exhaust Manifold Torque 50 N m 37 lb ft 4 If removed apply LOCTITE 242 Thread Lock and Sealant to turbocharger oil inlet fitting and install and tighten t...

Page 319: ...as detailed in machine technical manual RG RG34710 248 19 30SEP97 1 1 Turbocharger Break In IMPORTANT A new or repaired turbocharger DOES NOT have an adequate oil supply for immediate start up of engine Perform the steps below to prevent damage to turbocharger bearings 1 Remove ECU power fuse so engine does not start IMPORTANT DO NOT crank engine longer than 30 seconds at a time to avoid damage to...

Page 320: ...VE TURBOCHARGER earlier in this group 2 Remove upper cap screws A from front and rear exhaust manifold sections and install guide pins 3 Remove remaining exhaust manifold to cylinder head cap screws and remove exhaust manifold as an assembly 4 Separate three exhaust manifold sections Remove exhaust manifold to cylinder head gaskets and discard Continued on next page CTM100 06APR04 02 080 18 POWERT...

Page 321: ...ed with only one sealing ring ALWAYS use two sealing rings during engine reassembly and use outer grooves on manifold sections with three grooves 1 Inspect machined mating surfaces ID and OD for burrs cracks or other imperfections which may prevent sealing rings A from sealing properly 2 Inspect area past sealing ring locations for evidence of exhaust leakage Inspect all sections for cracks 3 Insp...

Page 322: ...er section 4 Install manifold assembly C onto guide pins 5 Apply PT569 NEVER SEEZ Compound to exhaust manifold cap screws and tighten bottom row of cap screws finger tight Be sure gaskets are properly positioned before installing cap screws 6 Remove guide pins from top row and install cap screws finger tight 7 Tighten all cap screws to specifications Specification Exhaust Manifold to Head Cap Scre...

Page 323: ...manifold NOTE If required note location of primary fuel filter water separator bracket C for assembly in same location as removed 3 Remove top cap screw on each end of intake manifold and install guide pins 4 Remove remaining cap screws and remove intake manifold with gasket Discard gasket Inspect Intake Manifold 1 Check intake manifold for damage or cracks 2 Thoroughly inspect interior of manifol...

Page 324: ...nder head cap screws to specifications Specification Intake Manifold to Cylinder Head Cap Screws Torque 35 N m 26 lb ft 5 If required connect fuel lines to final fuel filter mounting base Install final fuel filter 6 Reconnect intake piping sensors and starting aid detailed in machine technical manual NEVER SEEZ is a registered trademark of Emhart Chemical Group CTM100 06APR04 02 080 22 POWERTECH 1...

Page 325: ...oved 3 Remove coolant inlet hose A and outlet hose B from aftercooler end connections 4 Remove air inlet adapter C from aftercooler inlet 5 Refer to machine technical manual to disconnect all sensors and starting aid 6 Remove aftercooler assembly D with gasket using two guide pins at upper outside cap screw locations Discard gasket Install Aftercooler Assembly 1 Install aftercooler assembly using ...

Page 326: ...fications Specification Aftercooler Tube Clamp Cap Screw or Cap Screw with Nut Torque 50 N m 37 lb ft 5 Install air inlet adapter onto aftercooler inlet and tighten securely 6 Fill cooling system with proper coolant solution 7 Refer to machine technical manual to connect sensors and starting aid CTM100 06APR04 02 080 24 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 324 ...

Page 327: ...ged 3 Test the aftercooler for leaks by plugging outlet tube B 4 Apply compressed air to the inlet tube A while unit is submerged under water Use specified air pressure for testing Specification Aftercooler Test Pressure 140 170 kPa 1 4 1 7 bar 20 25 psi A minor leak that is accessible may be repaired However if the condition of the core is questionable replace aftercooler IMPORTANT Coolant leakag...

Page 328: ...Air Intake and Exhaust System 02 080 26 CTM100 06APR04 02 080 26 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 326 ...

Page 329: ...ectronic controls have been moved to the following manuals CTM115 Delphi Lucas Electronic Fuel Systems With Delphi Lucas EUIs CTM188 Level 6 Electronic Fuel Systems With Delphi Lucas EUIs Later Tier II 12 5 L engines with dual or single rail fuel systems are covered in CTM188 CTM100 06APR04 02 090 1 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 327 ...

Page 330: ...Fuel System 02 090 2 CTM100 06APR04 02 090 2 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 328 ...

Page 331: ...connect positive red wire A and regulator connector E shown disconnected 3 Remove alternator belt using a 1 2 in drive ratchet on the belt tensioner C 4 Remove mounting cap screws from adjusting strap B Remove cap screw and nut D and remove alternator 5 Install alternator in reverse order 6 Torque alternator mounting hardware to the following specifications Alternator Strap Mounting Hardware Speci...

Page 332: ... CTM 77 1 Disconnect battery ground cable 2 Disconnect all cables and wires from starter solenoid A shown disconnected 3 Remove starter motor using JDE80 Starter Wrench 4 Install starter motor in reverse order 5 Torque motor mounting hardware to the following specifications Specification Starter Motor Mounting Hardware Torque 125 N m 92 lb ft CTM100 06APR04 02 100 2 POWERTECH 10 5 L 12 5 L Diesel ...

Page 333: ...tion 03 120 4 Cooling System Operation 03 120 8 Fuel System Theory of Operation 03 120 10 Head Gasket Joint Construction and Operation 03 120 11 Intake and Exhaust System Operation 03 120 12 Turbocharger Operation 03 120 13 How the Turbocharger is Lubricated 03 120 13 CTM100 06APR04 03 1 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 1 ...

Page 334: ...Contents 03 CTM100 06APR04 03 2 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 2 ...

Page 335: ...ng Rod O Two Piece Rocker Arm Shaft The 6105 and 6125 engines include a cam in head actuating four valves per cylinder and an electronic unit injector EUI fuel system They are vertical stroke in line valve in head 6 cylinder diesel engines The firing order is 1 5 3 6 2 4 The cast block has ribbed walls to add strength and rigidity and to decrease noise and vibration The 6105 and 6125 use the same ...

Page 336: ...iers are cast integrally in the piston to greatly improve the life of the ring grooves 6125 engines use an articulated or two piece piston H The crown of the piston is steel This adds strength and durability for the higher power output of the 6125 engine The skirt of the piston is aluminum to reduce the overall weight of the piston The 6105 and 6125 pistons have a centered symmetrical bowl to prov...

Page 337: ...directly into the center of the cylinder The injectors deliver fuel at a much higher pressure approximately 23 200 psi than what is achievable with an in line or rotary injection pump The valve rocker arms push on a short push rod The push rod actuates a bridge that will then operate two valves Four valves per cylinder increases engine air flow compared to using one large intake and one large exha...

Page 338: ...4 RG RG34710 1519 19 16SEP02 1 3 Lubrication System Operation A B C E D F G H I J K L M N O P P Q R S U V W X T RG12421 UN 11SEP02 CTM100 06APR04 03 120 4 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 336 Continued on next page ...

Page 339: ...p The remaining oil is routed to the main oil galley then distributed to the piston spray jets J crankshaft main bearings K connecting rod bearings L the two rocker arm shaft assemblies M upper idler gear bushing N and auxiliary drive The piston spray jets receive oil directly from the main oil galley These spray jets allow for precise targeting of the oil spray onto the bottom of the piston Drill...

Page 340: ...ng to each end of the rocker arm At the roller end oil flows through the roller bushing R and out to spray and lubricate the adjacent valve rocker arm rollers S Oil then sprays on to the camshaft lobes At the front of the unit injector rocker arms oil sprays out the adjusting screw to lubricate the unit injector T and the adjacent valves and adjusting screws Some oil is routed from the top of the ...

Page 341: ...Base Engine Operation 03 120 7 CTM100 06APR04 03 120 7 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 339 ...

Page 342: ...20 8 RG RG34710 1521 19 09SEP02 1 3 Cooling System Operation A B C E F G I J G M N O P D H K L RG12420 UN 11SEP02 Cooling System CTM100 06APR04 03 120 8 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 340 Continued on next page ...

Page 343: ...dition there are more holes and larger holes at the rear of the cylinder head than at the front Cylinders 1 and 2 have one 6 3 mm 0 25 in and one 9 mm 0 35 in hole Cylinders 3 and 4 have two 6 3 mm 0 25 in and two 10 mm 0 39 in holes Cylinders 5 and 6 have two 10 mm 0 39 in and two 16 mm 0 63 in holes The larger and higher number of coolant flow holes around cylinders 5 and 6 force more coolant to...

Page 344: ...cond external line J Coolant also flows in passages O around the unit injector sleeves P This helps to regulate the temperature of injected fuel OUO1004 0000C29 19 09SEP02 1 1 Fuel System Theory of Operation NOTE Fuel system operation is now covered in the following companion manuals CTM115 Lucas Electronic Fuel Systems With Lucas EUIs CTM188 Level 6 Electronic Fuel Systems With Lucas EUIs CTM115 ...

Page 345: ... Combustion Seal I Graphite Gasket Body B Cylinder Head Cap Screws E Cylinder Block H Stainless Steel Flange J Perforated Steel Core C Dowel Pins F Solid Steel Core The head gasket joint consists of Cylinder head gasket body I Cylinder head A Cylinder block E Cylinder liners D Cylinder head cap screws B CTM100 06APR04 03 120 11 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 343 Continued on next...

Page 346: ...mponents do not conform to specification gasket joint may fail resulting in combustion leaks coolant leaks or oil leaks Operating conditions such as coolant oil and combustion temperatures and combustion pressures can reduce the ability of the head gasket joint to function properly Failure of head gasket and mating parts may occur when coolant and oil temperatures become excessive or when abnormal...

Page 347: ...nders Engine oil under pressure from the engine lubrication system is forced through passages in center housing D to bearings RG RG34710 1524 19 30SEP97 1 1 How the Turbocharger is Lubricated RG8099 UN 18NOV97 Turbocharger Lubrication A Pressure Oil B Discharge Oil Engine oil under pressure from the engine lubrication system is pumped through a passage in the bearing housing and directed to the be...

Page 348: ...Base Engine Operation 03 120 14 CTM100 06APR04 03 120 14 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 346 ...

Page 349: ... 04 150 9 Engine Oil Consumption 04 150 10 Check Engine Oil Pressure 04 150 11 Check for Excessive Engine Crankcase Pressure Blow By 04 150 12 Check for Turbocharger Oil Seal Leak 04 150 13 Inspect Thermostat and Test Opening Temperature 04 150 14 Pressure Test Cooling System and Radiator Cap 04 150 15 Check for Head Gasket Failures 04 150 17 Check Intake Manifold Pressure Turbo Boost 04 150 19 Ch...

Page 350: ...Contents 04 CTM100 06APR04 04 2 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 2 ...

Page 351: ...est or repair is recommended then based on the results another test or repair is recommended Other symptoms are formatted in a symptom problem solution format In these symptoms the problems are arranged in the most likely or easiest to check first Symptoms arranged in both formats refer to testing procedures in the second part of this section The second part of this section of the manual contains ...

Page 352: ...k for too low or too high engine oil level Check for too low viscosity coolant in oil or fuel diluted in engine oil Check for excessive external oil leaks 1 1 1 Oil in Coolant Test Check the coolant for signs of oil No oil found in coolant GO TO 2 Oil found in coolant See C3 COOLANT IN OIL OR OIL IN COOLANT later in this Group CTM100 06APR04 04 150 2 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 P...

Page 353: ...used by boost pressure is most likely caused by faulty piston rings cylinder liners not providing an adequate combustion seal Perform a compression test to verify this See DST ENGINE TEST INSTRUCTIONS RELATIVE COMPRESSION TEST in CTM115 Section 04 Group 160 OR See DST ENGINE TEST INSTRUCTIONS RELATIVE COMPRESSION TEST in CTM188 Section 04 Group 160 1 1 3 Turbocharger Oil Seal Leak Test Check for t...

Page 354: ...m as needed Oil control rings worn or broken Scored cylinder liners or pistons Piston ring groves excessively worn Piston rings stuck in ring groves Insufficient piston ring tension Piston ring gaps not staggered Cylinder liners glazed insufficient load during break in Worn valve guides or stems Problem found with pistons rings and or liners or valve guides Repair problem as necessary 04 150 4 CTM...

Page 355: ...Remove and inspect oil pressure regulating valve See REMOVE INSPECT AND INSTALL OIL PRESSURE REGULATING VALVE in Section 02 Group 060 Plugged piston spray jet Replace piston spray jet See REMOVE AND INSTALL PISTON SPRAY JETS in Section 02 Group 030 Stuck or damaged filter bypass valve Remove and inspect filter bypass valve See REMOVE INSPECT AND INSTALL OIL COOLER AND OIL FILTER BYPASS VALVES in S...

Page 356: ...OIL PUMP AND DRIVE GEAR in Section 02 Group 060 Incorrect oil Drain crankcase and refill with correct oil Oil pressure regulating valve failure Remove and inspect oil pressure regulating valve See Group REMOVE INSPECT AND INSTALL OIL PRESSURE REGULATING VALVE in Section 02 Group 060 Broken piston spray jet Replace piston spray jet See REMOVE AND INSTALL PISTON SPRAY JETS in Section 02 Group 030 Cl...

Page 357: ... crankcase oil level Fill crankcase to proper oil level Loose or defective fan belt Replace tighten fan belt as required Defective thermostat s Test thermostat opening temperature replace thermostats as required See REMOVE THERMOSTATS in Section 02 Group 070 Damaged cylinder head gasket Replace cylinder head gasket See CHECK FOR HEAD GASKET FAILURES in this group Defective coolant pump Replace coo...

Page 358: ... Coolant Symptom Problem Solution 10 5L 12 5L C3 Coolant in Oil Faulty cylinder head gasket Look for signs of head gasket failure or Oil in Coolant See CHECK FOR HEAD GASKET FAILURES in this group Faulty oil cooler Remove and inspect engine oil cooler See REMOVE CLEAN AND INSPECT ENGINE OIL COOLER in Section 02 Group 060 Leaking cylinder liner seals Remove and inspect cylinder liners See VISUALLY ...

Page 359: ... speed is reduced to rated speed rpm 5 Read horsepower on dynamometer and record reading 6 Compare readings taken with power rating level for your engine application in Section 06 Group 210 NOTE Refer to appropriate machine technical manual for average power ratings of vehicle applications Allow 5 for minimum and maximum power Altitude and temperatures can also affect power levels See DYNAMOMETER ...

Page 360: ...ves do not have valve stem seals and some oil deposits on the valve stem tulip are normal When changing to a premium oil such as TORQ GARD SUPREME PLUS 50 little oil consumption change is expected although a small percentage of engines may experience a noticeable change in consumption rates This may be due to the following The previous oil may have left deposits on internal components Use of PLUS ...

Page 361: ...gauge to oil galley IMPORTANT To achieve an accurate oil pressure reading warm engine oil to 105 C 220 F 3 Start engine run at speeds given below measure oil pressure and compare readings Specification Engine Oil Minimum Pressure at No Load Idle 138 kPa 1 38 bar 20 psi Maximum Pressure at Full Load Rated Speed 310 kPa 3 1 bar 45 psi NOTE The oil pressure regulating valve is designed so that adjust...

Page 362: ...excessive Run engine at high idle and check crankcase breather tube Look for significant fumes and or dripping oil coming out of the breather tube at fast idle with no load If excessive blow by is observed perform the following to determine if the turbocharger is causing the blow by 1 Remove the turbocharger oil drain line where it connects to the engine block and run the line into a bucket 2 Run ...

Page 363: ...ger oil return line can cause the housing to pressurize causing oil to leak by the seals Additionally intake or exhaust restrictions can cause a vacuum between the compressor and turbocharger housing causing oil to leak by the seals 1 Remove intake tube A and exhaust pipe B NOTE The intake tube from the air cleaner not included in picture would not have to be removed for this test 2 Inspect the in...

Page 364: ...rt below NOTE Due to varying tolerances of different suppliers initial opening and full open temperatures may vary slightly from specified temperatures THERMOSTAT TEST SPECIFICATIONS Initial Opening Full Open Rating Range Nominal 71 C 160 F 69 72 C 156 162 F 84 C 182 F 77 C 170 F 74 78 C 166 172 F 89 C 192 F 82 C 180 F 80 84 C 175 182 F 94 C 202 F 89 C 192 F 86 90 C 187 194 F 101 C 214 F 90 C 195 ...

Page 365: ...04ST Tester using appropriate adaptor as shown 2 Verify with the applications specification manual that the correct cap is being used 3 Pressurize cap to cap s specified pressure 1 Gauge should hold pressure for 10 seconds within normal range if cap is acceptable 4 Remove the cap from gauge turn it 180 and retest cap This will verify that the first measurement was accurate Test Cooling System NOTE...

Page 366: ... overall engine for leaks If leakage is detected correct as necessary and pressure test system again If no leakage is detected but the gauge indicated a drop in pressure coolant may be leaking internally within the system or at the block to head gasket See CHECK FOR HEAD GASKET FAILURES in this group 2 Test pressures recommended are for all Deere OEM cooling systems On specific vehicle application...

Page 367: ...sket joint failure occurs or is suspected 1 Start and warm up engine if it can be safely operated Examine all potential leakage areas again as outlined previously Using appropriate test and measurement equipment check the following White smoke excessive raw fuel or moisture in exhaust system Rough irregular exhaust sound or misfiring Air bubbles gas trapped in radiator overflow tank Loss of coolan...

Page 368: ...nt discharge form crankcase vent Possible Causes Excessive liner standout Excessive liner standout differential between cylinders Low head bolt clamping loads Out of flat damaged rough block surface Out of flat damaged rough cylinder head surface Oil or coolant overheating Cracks creases in gasket body surfaces Damage voids in elastomer beading If above symptoms are found see HEAD GASKET INSPECTIO...

Page 369: ...rm up engine to allow the lubricating oil to reach operating temperature IMPORTANT Engine speed and load should be stabilized before taking a gauge reading Be sure that gauge works properly and familiarize yourself with the use of the gauge 3 Observe pressure reading on gauge Compare reading to the specifications when engine is developing rated power at full load rated speed See INTAKE MANIFOLD PR...

Page 370: ... power low boost pressure and excessive black exhaust smoke can be caused by an intake air or exhaust restriction 1 Inspect exhaust piping A the muffler B and the rain cap C for damage or any possible restrictions 2 Inspect the intake piping D elbows and any connections Look for collapsed pipes dented pipes and loose connections Replace components as needed CTM100 06APR04 04 150 20 POWERTECH 10 5 ...

Page 371: ...m Using a plastic bag to seal the intake air filter is used as an example CAUTION Do not start engine during this test procedure Plastic bag or whatever material object is used to seal intake can be sucked into the engine 1 Remove air cleaner cover and main filter element 2 Put a plastic bag over secondary filter element and install main element cover 3 Remove plug from manifold and using a suitab...

Page 372: ...he turbocharger will cause the turbocharger turbine to rotate at reduced speed resulting in low boost pressure low power and excessive black smoke Inspect the exhaust manifold gasket the exhaust manifold and turbocharger gasket for damage and any signs of leakage Replace components as needed See REMOVE INSPECT AND INSTALL EXHAUST MANIFOLD in Section 02 Group 080 CTM100 06APR04 04 150 22 POWERTECH ...

Page 373: ...r timing slot can be found by viewing camshaft timing lobe through camshaft timing pin bore while rotating engine The double timing slot E will be at approximately 11 o clock viewed from rear of engine when pin is installed in slot D This ensures that engine is locked at TDC of No 1 cylinder s compression stoke Intake and exhaust rocker arms on No 1 cylinder should be loose 4 Remove threaded plug ...

Page 374: ...haft and camshaft to determine piston position and the optimum time to start and stop injecting fuel This crank sensor sends the crank position to the ECU 1 Disconnect crankshaft position sensor wiring connector 2 Remove sensor B from timing gear cover 3 Install JDG1334 Tool C in sensor bore in timing gear cover until the tool is hand tight within the timing gear cover 4 Push in on pin C until it ...

Page 375: ...Flywheel Group 040 Essential Tools 05 170 16 Crankshaft Main Bearings and Flywheel Group 040 Service Equipment and Tools 05 170 18 Crankshaft Main Bearings and Flywheel Group 040 Other Material 05 170 20 Camshaft and Timing Gear Train Group 050 Essential Tools 05 170 21 Camshaft and Timing Gear Train Group 050 Service Equipment and Tools 05 170 23 Camshaft and Timing Gear Train Group 050 Other Mat...

Page 376: ...Contents 05 CTM100 06APR04 05 2 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 2 ...

Page 377: ...BC3 19 01NOV00 1 16 Cylinder Head and Valves Group 020 Essential Tools NOTE Order tools according to information given in the U S SERVICEGARD Catalog or from the European Microfiche Tool Catalog MTC SERVICEGARD is a trademark of Deere Company OUO1004 0000BC3 19 01NOV00 2 16 RG7056 UN 05DEC97 JDG820 Flywheel Turning Tool JDG820 Used to rotate engine flywheel to check engine timing and adjust valve ...

Page 378: ... to bridge clearance OUO1004 0000BC3 19 01NOV00 5 16 RG8502A UN 10MAR04 JDG970A Rocker Arm Assembly Lifting Fixture JDG970A Use to correctly position rocker arm assembly during removal and installation Set consists of a holding plate and two 221808 Ball Locking Pins Note A second set of pins has been added to this tool With Tier II engines engine serial no 030000 the holes in the rocker arm shaft ...

Page 379: ...pring Compressor JDG982 Use to compress exhaust and intake valve springs for removal and installation OUO1004 0000BC3 19 01NOV00 8 16 RG5061 UN 05DEC97 D01168AA Spring Compression Tester D01168AA Test valve spring compression OUO1004 0000BC3 19 01NOV00 9 16 RG5065 UN 05DEC97 JDG164A Valve Seat Pilot Driver JDG164A Use with JDG1166 Adapter to install intake and exhaust valve seat inserts and with J...

Page 380: ... OUO1004 0000BC3 19 01NOV00 11 16 RG5071 UN 05DEC97 JDE41296 Valve Seat Puller JDE41296 Remove valve seat inserts OUO1004 0000BC3 19 01NOV00 12 16 RG5066 UN 23AUG88 JDG1166 Valve Seat Insert Installing Adapter JDG1166 Use with JDG164A Pilot Driver to install intake and exhaust valve seat inserts Continued on next page CTM100 06APR04 05 170 4 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 378 ...

Page 381: ...rew M8 x 1 25 x 40 mm 220089 Hex Head Cap Screw M16 x 2 x 150 mm and MAY 25010 Punch JDG981 2 Swedge is obsolete Use JDG1184 2 1 Swedge Arbor and 8132 Adapter from JDG1184 EUI Nozzle Sleeve Replacement Kit in its place 05 170 5 OUO1004 0000BC3 19 01NOV00 14 16 RG10265 UN 29JUL99 JDG1184 EUI Nozzle Sleeve Replacement Set JDG1184 Used to install injector sleeves in cylinder head with head installed ...

Page 382: ...to cylinder block top deck OUO1004 0000BC4 19 01NOV00 1 9 Cylinder Head and Valves Group 020 Service Equipment and Tools NOTE Order tools according to information given in the U S SERVICEGARD Catalog or from the European Microfiche Tool Catalog MTC Some tools may be available from a local supplier SERVICEGARD is a trademark of Deere Company OUO1004 0000BC4 19 01NOV00 2 9 Valve Inspection Center Ch...

Page 383: ...vy Duty Seat Grinder Set JT05893 Grind valve seats 05 170 7 OUO1004 0000BC4 19 01NOV00 7 9 Eccentrimeter Measure valve seat runout OUO1004 0000BC4 19 01NOV00 8 9 Slider Hammer D01300AA Use with JDG1184 1 2 Adapter to remove EUI sleeve with cylinder head installed in engine OUO1004 0000BC4 19 01NOV00 9 9 Torque Angle Gauge JT05993 Tighten flanged head cylinder head cap screws CTM100 06APR04 05 170 ...

Page 384: ...anadian head and block 277 LOCTITE AR44402 U S Valve Stem Lubricant Lubricate valve stems JDT405 U S High Temperature Grease Apply to injector sleeve square packing TY24311 U S Thread Lock and Sealer Low Apply to EUI solenoid wire retaining CXTY24311 Canadian Strength nut 222 LOCTITE LOCTITE is a registered trademark of Loctite Corp CTM100 06APR04 05 170 8 POWERTECH 10 5 L 12 5 L Diesel Engines 04...

Page 385: ...piston and liner heights 1 A dial indicator is not supplied with JDG451 Use D17526CI English in or D17527CI Metric mm Dial Indicator with JDG451 OUO1004 0000BCC 19 02NOV00 3 16 RG6246 UN 05DEC97 D17526CI D17527CI Dial Indicator D17526CI English in or D17527CI Metric mm Use with JDG451 to measure valve recess and cylinder liner height to cylinder block top deck OUO1004 0000BCC 19 02NOV00 4 16 RG501...

Page 386: ... counterbore 05 170 10 OUO1004 0000BCC 19 02NOV00 6 16 RG5074 UN 07NOV97 D17006BR Flexible Cylinder Hone D17006BR Hone cylinder liners OUO1004 0000BCC 19 02NOV00 7 16 RG7406 UN 21MAY98 JDG967 Piston Ring Expander JDG967 Use to control the expansion of the piston rings during removal and installation of the pistons This tool prevents over expansion and damage to the rings Continued on next page CTM...

Page 387: ...ear Gauge JDG1335 Use as a go no go gauge to measure wear on the two top compression piston ring grooves on later 6105 and 6125 engines with RE504343 6105 RE503969 6125 and RE505901 6125 pistons with 3 mm compression rings OUO1004 0000BCC 19 02NOV00 10 16 RG8517 UN 20MAY98 JDG1022 Piston Ring Groove Wear Gauge JDG1022 Use as a go no go gauge to measure wear on the two top compression piston ring g...

Page 388: ...t 6 JDE98 7 Driver 7 JDE98 8 Cup 8 JDE98 9 Pilot 9 JDE98 10 Bushing Remover Installer 10 and STD36104 Forcing Screw 05 170 12 OUO1004 0000BCC 19 02NOV00 12 16 RG6612 UN 29JAN93 JDG782 Oil Gallery Plug Tool JDG782 Use to remove and install cylinder block oil gallery plug OUO1004 0000BCC 19 02NOV00 13 16 RG5075 UN 07NOV97 D17015BR O Ring Groove Cleaning Brush D17015BR Clean cylinder liner O ring gro...

Page 389: ...70 13 OUO1004 0000BCC 19 02NOV00 15 16 RG8515 UN 20MAY98 JDG1017 Piston Ring Compressor JDG1017 Use to compress piston rings during installation of the piston OUO1004 0000BCC 19 02NOV00 16 16 RG5698 UN 05DEC97 JT05993 Torque Angle Gauge JT05993 Used to torque turn cylinder head and connecting rod cap screws CTM100 06APR04 05 170 13 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 387 ...

Page 390: ...ailable from a local supplier SERVICEGARD is a trademark of Deere Company 05 170 14 OUO1004 0000BC9 19 01NOV00 2 4 Cylinder Liner Bore Ridge Reamer JT07277 Remove carbon from liner bore prior to piston removal OUO1004 0000BC9 19 01NOV00 3 4 Piston Ring Groove Cleaning Tool Used to clean piston ring grooves OUO1004 0000BC9 19 01NOV00 4 4 Precision Bevelled Edge Straightedge D05012ST Check cylinder ...

Page 391: ... AR54749 U S Soap Lubricant Coat O rings on cylinder liners JDT405 U S High Temperature Grease Apply to O rings for piston spray jets T43512 U S Thread Lock and Sealer Medium Apply to threads of oil gallery plugs TY9473 Canadian Strength 242 LOCTITE PLASTIGAGE is a registered trademark of DANA Corp LOCTITE is a registered trademark of Loctite Corp CTM100 06APR04 05 170 15 POWERTECH 10 5 L 12 5 L D...

Page 392: ...16 OUO1004 0000BD0 19 02NOV00 2 9 RG6246 UN 05DEC97 D17526CI D17527CI Dial Indicator D17526CI English in or D17527CI Metric mm Use to check vibration damper radial runout crankshaft end play flywheel housing runout and flywheel face flatness OUO1004 0000BD0 19 02NOV00 3 9 RG7056 UN 05DEC97 JDG820 Flywheel Turning Tool JDG820 Use to rotate engine flywheel to check damper radial runout and piston pr...

Page 393: ...r bearing surface these caps are installed with an increased interference fit OUO1004 0000BD0 19 02NOV00 6 9 RG8510 UN 20MAY98 JDG977 Timing Gear Cover Rear Seal Housing Oil Pan Rail Aligner JDG977 Use to align the timing gear cover to the engine block oil pan mounting surface and align the rear seal housing to the same surface When installing the timing gear seal housing use JDG975 Timing Gear Co...

Page 394: ... on damper prior to damper installation and to install rear oil seal in rear seal housing when housing is on engine OUO1004 0000BD0 19 02NOV00 9 9 RG8509 UN 13AUG99 JDG973 Damper Puller Installer JDG973 Use to safely remove and install engine damper with engine in vehicle chassis The damper weighs approximately 18 kg 40 lb and is mounted with an interference press fit OUO1004 0000BD1 19 02NOV00 1 ...

Page 395: ...ywheel is removed from engine OUO1004 0000BD1 19 02NOV00 3 4 Slide Hammer D01300AA Use with JDG996 Puller to remove crankshaft main bearing caps OUO1004 0000BD1 19 02NOV00 4 4 17 1 2 and 30 Ton Puller Set D01047AA Remove crankshaft gear from crankshaft 05 170 19 CTM100 06APR04 05 170 19 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 393 ...

Page 396: ... prior to installation TY16285 U S Clean and Cure Primer Clean sealant from mating gasket surfaces on timing gear cover and camshaft gear access cover T43512 U S Thread Lock and Sealer Medium Apply to both sides of timing gear TY9473 Canadian Strength cover gasket and to camshaft gear 242 LOCTITE access cover gasket on earlier engines using Fel Pro gaskets TY6304 U S Flexible Sealant Apply to timi...

Page 397: ...urning Tool JDG820 Use to rotate engine flywheel to check camshaft to crankshaft timing adjust gear train backlash and valve stem to valve bridge clearance OUO1004 0000BD4 19 02NOV00 3 8 RG8519 UN 20MAY98 JDG971 Cam Crankshaft Timing Lock Pins JDG971 Set of two Use to lock camshaft and crankshaft at Top Dead Center during timing gear backlash adjustment Use on crankshaft only for valve clearance a...

Page 398: ...70 22 OUO1004 0000BD4 19 02NOV00 5 8 RG10275 UN 04AUG99 JDG969A Camshaft Holding Tool JDG969A Use with overhead hoist to control position of camshaft during removal and installation Use with JDG972 Camshaft Pilot OUO1004 0000BD4 19 02NOV00 6 8 RG8504 UN 20MAY98 JDG972 Camshaft Pilot JDG972 Use with JDG969A Camshaft Holding Tool to remove and install the camshaft Continued on next page CTM100 06APR...

Page 399: ...13793 Forcing Screw Assembly 05 170 23 OUO1004 0000BD4 19 02NOV00 8 8 RG9040 UN 21MAY98 JDG1144 Front Auxiliary Drive Alignment Tool JDG1144 Use to center front SAE A auxiliary drive adapter with gear spline OUO1004 0000BD5 19 02NOV00 1 2 Camshaft and Timing Gear Train Group 050 Service Equipment and Tools NOTE Order tools according to information given in the U S SERVICEGARD Catalog or from the E...

Page 400: ...d Lock and Sealer Medium Apply to idler gear carrier cap TY9473 Canadian Strength screws camshaft gear retainer cap 242 LOCTITE screws and fuel supply pump drive coupler cap screws TY6333 or TY6347 U S High Temperature Grease Coat cam roller followers camshaft lobes journals and bushings during installation Coat idler gear and bushing during installation LOCTITE is a registered trademark of Loctit...

Page 401: ...VICEGARD Catalog or from the European Microfiche Tool Catalog MTC SERVICEGARD is a trademark of Deere Company 05 170 25 OUO1022 0000008 19 25OCT00 2 2 RG5061 UN 05DEC97 D01168AA Spring Compression Tester D01168AA Test oil bypass valve spring and oil pressure regulating valve spring compression CTM100 06APR04 05 170 25 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 399 ...

Page 402: ...gh Temperature Grease Apply to inside cavities of oil pump and ID of oil pump drive gear bushing TY16285 U S Clean and Cure Primer Apply to oil pan and block sealing CXTY16285 Canadian surfaces 7649 LOCTITE TY16021 U S High Flex Form In Place Gasket Used to seal oil pan 1 TY9484 Canadian 17430 LOCTITE TY9375 U S Pipe Sealant Apply to oil pan drain hose and drain TY9480 Canadian valve 592 LOCTITE L...

Page 403: ...ive housing OUO1022 000000C 19 18SEP02 1 1 Cooling System Group 070 Other Material Number Name Use TY6333 or TY6347 U S High Temperature Grease Pack bearings in fan drive and coolant pump T43512 U S Thread Lock and Sealer Medium Tensioner mounting shoulder bolt or TY9473 Canadian Strength cap screw idler mounting cap screw 242 LOCTITE and coolant pump mounting cap screws TY9375 U S Pipe Sealant Oi...

Page 404: ... clearance and axial bearing end play DPSG OUO1004 954 19 29JUL99 1 1 Air Intake and Exhaust System Group 080 Other Material Number Name Use PT569 U S NEVER SEEZ Compound Apply to turbocharger cap screws intake manifold to cylinder head cap screws exhaust manifold to cylinder head cap screws aftercooler to cylinder head cap screws and turbocharger oil return line cap screws T43512 U S Thread Lock ...

Page 405: ...ng to information given in the U S SERVICEGARD Catalog or from the European Microfiche Tool Catalog MTC SERVICEGARD is a trademark of Deere Company 05 170 29 DPSG OUO1004 861 19 28APR99 2 2 RW17441 UN 16NOV89 JDE80 Starter Wrench JDE80 Remove and install starter motor CTM100 06APR04 05 170 29 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 403 ...

Page 406: ...Repair Tools and Other Materials 05 170 30 CTM100 06APR04 05 170 30 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 404 ...

Page 407: ...og MTC SERVICEGARD is a trademark of Deere Company 05 180 1 OUO1004 0000C1D 19 27NOV00 2 6 RG6612 UN 29JAN93 JDG782 Oil Galley Plug Tool JDG782 Used to remove and install oil galley plug OUO1004 0000C1D 19 27NOV00 3 6 R26406N UN 29NOV88 D05104ST Cooling System Pressure Pump D05104ST Used to pressure test radiator cap and cooling system Continued on next page CTM100 06APR04 05 180 1 POWERTECH 10 5 ...

Page 408: ...V00 5 6 RG8519 UN 20MAY98 JDG971 Cam Crankshaft Timing Lock Pins JDG971 Set of 2 Use to lock camshaft and crankshaft at Top Dead Center during timing gear backlash adjustment Use on crankshaft only for valve clearance adjustments Set consists of Holding Plate and 221808 Ball Locking Pins OUO1004 0000C1D 19 27NOV00 6 6 RG10381 UN 21OCT99 JDG1334 Depth Tool JDG1334 Check crankshaft position sensor d...

Page 409: ...ing common shop tools and locally obtained materials 05 190 1 RG RG34710 276 19 30SEP97 1 1 DFRG4 Camshaft Locking Tool RG8534 UN 10DEC97 DFRG4 Camshaft Locking Tool A 12 7 mm 0 50 in C 57 15 mm 2 25 in D 28 57 mm 1 12 in E 50 8 mm 2 00 in B 95 25 mm 3 75 in CTM100 06APR04 05 190 1 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 407 ...

Page 410: ... mm 5 in 9 63 5 mm 0 25 in 15 2 used 21 60 45 mm 2 38 in 3 38 1 mm 1 5 in 10 25 4 mm 1 in 16 304 8 mm 12 in 22 5 16 in times 1 in Cap 4 405 4 mm 16 in 11 6 35 mm 0 25 in 17 5 16 in 18 Tap Screw 5 330 2 mm 13 in 12 152 4 mm 6 in 18 69 85 mm 2 75 in Radius 23 38 1 mm 1 5 in Angle 6 9 52 mm 0 38 in 13 0 328 in Drill Through 19 101 6 mm 4 in Iron 7 12 7 mm 0 5 in CTM100 06APR04 05 190 2 POWERTECH 10 5...

Page 411: ...aft Main Bearings and Flywheel Group 040 Specifications 06 200 14 Camshaft and Timing Gear Train Group 050 Specifications 06 200 17 Lubrication System Group 060 Specifications 06 200 19 06 Cooling System Group 070 Specifications 06 200 21 Air Intake and Exhaust System Group 080 Specifications 06 200 23 Starting and Charging Systems Group 100 Specifications 06 200 24 Group 210 Diagnostic Specificat...

Page 412: ...Contents 06 CTM100 06APR04 06 2 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 2 ...

Page 413: ... Bore mm 127 127 127 127 127 in 5 00 5 00 5 00 5 00 5 00 Displacement L 10 5 10 5 12 5 12 5 12 5 cu in 640 640 766 766 766 Compression Ratio 16 1 16 1 16 1 16 1 17 1 Physical Dimensions Width mm 741 808 741 808 808 in 29 2 31 8 29 2 31 8 31 8 Height mm 1224 1239 1224 1239 1239 in 48 2 48 8 48 2 48 8 48 8 Length mm 1326 1326 1326 1326 1326 in 52 2 52 2 52 2 52 2 52 2 Basic Dry Weight kg 1211 1200 1...

Page 414: ...8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500 1 1 2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 a Grade 2 applies for hex cap screws not hex bolts up to 6 in 152 mm long Grade 1 applies for hex cap screws over 6 in 152 mm long and for all other types of bolts and screws of any length b Lubricated means coated with a lubricant such as engine...

Page 415: ...M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000 M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500 a Lubricated means coated with a lubricant such as engine oil or fasteners with phosphate and oil coatings b Dry means plain or zinc plated without any lubri...

Page 416: ...p 010 Specifications Item Measurement Specification Engine Adapter to Repair Stand Cap Torque 135 N m 100 lb ft Screws Engine Lift Strap Cap Screws Torque 90 N m 66 lb ft Engine to Stand Adapter Cap Torque 400 N m 300 lb ft Screws 06 200 4 CTM100 06APR04 06 200 4 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 414 ...

Page 417: ...it Injector Preload 0 00 mm in clearance plus 1 2 turn in 180 Electronic Unit Injector Adjusting Torque 65 N m 48 lb ft Screw Lock Nuts Timing Pin Plug Below Oil Cooler Torque 33 N m 24 lb ft Rocker Arm Bushing ID 38 064 0 013 mm 1 4986 0 0005 in Rocker Arm Shaft OD 38 000 0 013 mm 1 4961 0 0005 in Rocker Arm Shaft to Bushing Oil Clearance 0 064 0 026 mm 0 0025 0 0010 in Rocker Arm Shaft Intake an...

Page 418: ...nd Exhaust Valve Face3 Maximum Runout 0 038 mm 0 0015 in Intake and Exhaust Valve Head OD 46 35 46 61 mm 1 825 1 835 in Intake and Exhaust Valve Face Angle 29 25 0 25 Cylinder Head Maximum Acceptable Out of Flat for 0 10 mm 0 004 in Entire Length of Head Maximum Acceptable Out of Flat for 0 025 mm 0 0009 in Every 305 mm 12 0 in Cylinder Head Rocker Arm New Part Thickness 124 975 125 025 mm 4 9203 ...

Page 419: ...mum Runout 0 16 mm 0 006 in Intake and Exhaust Valve Seat Bore ID 49 424 0 013 mm 1 9458 0 0005 in Bore Depth 11 25 mm 0 443 in Radius at Lower Bore 0 64 0 25 mm 0 025 0 001 in Standard Intake and Exhaust Valve OD 49 487 49 513 mm 1 9483 Seat 1 9493 in Fuel Temperature Sensor Torque 10 N m 7 5 lb ft Fuel Lines Torque 24 N m 18 lb ft Cylinder Liner Height Above Block Standout 0 030 0 117 mm 0 0012 ...

Page 420: ...crews All Engines Rocker Arm Shaft Hold Down Clamp Final Torque Turn 60 5 Cap Screws Dual Rail Fuel System Rocker Arm Shaft Hold Down Clamp Final Torque Turn 90 10 0 Cap Screws Single Rail Fuel System Unit Injector Wiring Harness Torque 25 N m 18 lb ft Bracket to Rear of Head Unit Injector Wiring Harness Torque 3 0 N m 27 lb in Solenoid Wire Retaining Nut6 Unit Injector Harness Clips to Rocker Tor...

Page 421: ...s or Within One Liner Cylinder Liner Shims Available Thickness 0 05 mm 0 002 in Thickness 0 10 mm 0 004 in Cylinder Liner Wall Thickness 9 39 9 43 mm 0 370 0 371 in Cylinder Liner Packing Step Dimension 2 14 2 30 mm 0 084 0 090 in Cylinder Liners Flange Area OD 151 565 151 615 mm 5 9671 5 9691 in Upper OD for Seating Liner OD 145 795 145 845 mm 5 7400 5 7419 in Water Jacket Area OD 144 73 144 99 m...

Page 422: ...95 50 805 mm 1 9998 2 0002 in Piston Skirt Bushing 6125 ID 50 798 50 808 mm 1 9999 2 0003 in Piston Crown Bushing 6125 ID 50 810 50 825 mm 2 0004 2 0010 in Piston Skirt 6105 OD 29 97 mm 1 180 in from 126 872 126 898 mm 4 9950 Bottom of Piston 4 9960 in Piston Skirt 6125 OD 35 0 mm 1 380 in from Bottom 126 910 126 930 mm 4 9965 of Skirt 4 9972 in Cylinder Liner ID 126 990 127 010 mm 4 9996 5 0004 i...

Page 423: ...5 in New Part Max Oil Clearance 0 15 mm 0 006 in Connecting Rod Bore For ID 93 76 93 79 mm 3 6915 3 6925 Crankshaft Journal Bearing in Connecting Rod Centerline of Piston Dimension 263 95 264 05 mm 10 392 Pin Bore to Crankshaft Bore New 10 396 in Part Rod Pin Bore Without Bushing ID 55 529 55 555 mm 2 1862 2 1872 in Installed Rod Pin Bushing Before ID 50 729 50 781 mm 1 9972 Boring 1 9992 in Insta...

Page 424: ...gs 133 097 133 123 mm 5 2400 5 2410 in Main Bearing Surface Width 37 77 38 03 mm 1 487 1 497 in Thrust Bearing Surface Width No 5 37 51 38 29 mm 1 476 1 507 in Main Overall Thrust Bearing Cap Width 43 25 43 75 mm 1 703 1 722 in Cylinder Block Top Deck Surface Surface Finish Surface Mill Only 3 2 micrometers 125 micro in Finish Max Wave Height 0 008 micrometers 0 0002 micro in Max Wave Depth 2 0 mi...

Page 425: ... mm 0 004 in Piston Early Engines Protrusion Above Block Deck 0 229 0 787 mm 0 009 0 031 in Piston RE505901 Later 12 5 L Protrusion Above Block Deck 0 079 0 637 mm 0 003 0 025 in Engines Piston Spray Jet Cap Screws Torque 15 N m 11 lb ft Oil Gallery Plug Torque 20 N m 15 lb ft Main Oil Gallery Front Expansion Installed Depth Flush 1 5 mm 0 059 in Below Plug Surface 200 13 CTM100 06APR04 06 200 13 ...

Page 426: ...m Variation per 25 mm 1 0 0 013 mm 0 0005 in in of Travel Flywheel Housing to Cylinder Block Torque 325 N m 240 lb ft Cap Screws SAE 1 With Rear PTO Flywheel Housing to Cylinder Block Torque 365 N m 270 lb ft Cap Screws SAE 0 1 and 2 Without Rear PTO Flywheel Housing Front Plate Cap Torque 50 N m 37 lb ft Screws Flywheel Housing Timing Hole Cover Torque 5 N m 44 lb in Cap Screws Starter Motor Cap ...

Page 427: ...429 92 430 07 mm 16 926 16 932 in Crankshaft Main Bearing Cap Surface Width 39 75 40 25 mm 1 565 1 585 in Crankshaft Main Bearings Available Undersize 0 25 0 50 mm 0 010 0 020 in Oversize Thrust Washers Available Thickness 0 18 mm 0 007 in Thrust Bearing New Part Thrust Washer Clearance Base 162 24 163 76 mm 6 387 6 447 Specifications Circle in Thrust Surface Width 42 05 42 12 mm 1 656 1 658 in Re...

Page 428: ... m 37 lb ft Screws Early Engines Only 1 Camshaft Gear Access Cover Cap Final Torque 68 N m 50 lb ft Screws Adjustable Fan Drive Assembly Torque 90 N m 66 lb ft Mounting Cap Screws Damper Hub Cap Screws Torque 125 N m 92 lb ft Pulley to Damper Cap Screws Torque 125 N m 92 lb ft Front Oil Seal Cap Screws Torque 15 N m 11 lb ft 1 Initial torque is required only on early timing gear covers using Fel P...

Page 429: ...s Upper Idler Gear Thrust Plate Cap Final Torque 35 N m 26 lb ft Screws Camshaft and Supply Pump Drive Torque 4 N m 3 lb ft Coupler Set Screw Fuel Supply Pump to Cylinder Head Torque 50 N m 37 lb ft Camshaft Thrust Ring to Head Torque 35 N m 26 lb ft Camshaft Position Sensor Torque 14 N m 10 lb ft Camshaft Journal OD 101 987 102 013 mm 4 0152 4 0162 in Camshaft Bushing ID 102 091 102 167 mm 4 0193...

Page 430: ...0 643 in 30000 SAE A Front Auxiliary Drive Torque 50 N m 37 lb ft Adapter Housing Nuts SAE A Front Auxiliary Drive Idler Torque 220 N m 162 lb ft Gear Support Bushing SAE B Rear Auxiliary Drive Adapter Torque 110 N m 81 lb ft SAE B Rear Auxiliary Drive Adapter Torque 110 N m 81 lb ft SAE A Front Auxiliary Drive Torque 50 N m 37 lb ft Adapter Housing Nuts 200 18 CTM100 06APR04 06 200 18 POWERTECH 1...

Page 431: ...ilter Bypass Valve Plug Torque 100 N m 74 lb ft Oil Pressure Relief Valve Spring Free Length 79 0 mm 3 11 in Working Load 196 222 N 44 65 0 mm 2 56 in 50 lb force Oil Cooler Test Pressure 140 170 kPa 1 4 1 7 bar 20 25 psi Oil Cooler to Housing Nuts Torque 50 N m 37 lb ft Oil Cooler Drain Cock Handle Torque 3 N m 25 lb in Oil Cooler Expansion Plug Installed Depth Flush to 1 5 mm 0 059 in Below Surf...

Page 432: ... Turn 90 1 4 Turn Oil Pump Drive Gear to Idler Gear Backlash 0 25 mm 0 010 in Oil Pickup Tube to Block Cap Torque 35 N m 26 lb ft Screws Oil Pickup Tube to Oil Pan Cap Torque 25 N m 18 lb ft Screws Oil Pan to Cylinder Block Cap Torque 25 N m 18 5 lb ft plus 90 Turn Screws Clockwise Oil Pan to Rear Oil Seal Housing Torque 25 N m 18 5 lb ft plus 90 Turn Cap Screws Clockwise Oil Pan to Timing Gear Co...

Page 433: ...ft Gear Access Cover Cap Screws Belt Tensioner Lower Spring Tension 81 99 N m 60 73 lb ft Belt Tensioner Upper Spring Tension 18 23 N m 13 17 lb ft Belt Tensioner Shoulder Bolt or Torque 50 N m 37 lb ft Flanged Head Cap Screw Fan Belt Idler Pulley Torque 68 N m 50 lb ft Coolant Pump Housing to Cover Torque 10 N m 7 5 lb ft Band Clamp Coolant Pump to Front Plate Cap Torque 50 N m 37 lb ft Screws Co...

Page 434: ... Assembly to Block Cap Screws Thermostat Test Rating 82 C 180 F Initial Opening Range Temperature 80 84 C 175 182 F Full Open Nominal Temperature 94 C 202 F Coolant Temperature Sensor Torque 10 N m 7 5 lb ft Thermostat Housing Pipe Plugs Torque 20 N m 15 lb ft 06 200 22 CTM100 06APR04 06 200 22 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 432 ...

Page 435: ... Turbocharger Axial End Play 0 0635 0 1143 mm 0 0025 Bearing 0 0045 in Turbocharger to Exhaust Manifold Torque 50 N m 37 lb ft Turbocharger Oil Inlet Fitting Torque 50 N m 37 lb ft Turbocharger Oil Return Torque 50 N m 37 lb ft Pipe to Turbocharger Turbocharger Oil Inlet Line Both Torque 35 N m 26 lb ft Ends Exhaust Manifold to Head Cap Torque 70 N m 52 lb ft Screws Intake Manifold to Cylinder Hea...

Page 436: ...ounting Hardware M8 Cap Screw Torque 25 N m 18 lb ft M10 Cap Screw Torque 50 N m 37 lb ft 1 2 in Cap Screw Torque 61 N m 45 lb ft Alternator Foot Mounting Hardware M10 Cap Screw Torque 70 N m 52 lb ft M12 Cap Screw Torque 60 N m 44 lb ft Starter Motor Mounting Hardware Torque 125 N m 92 lb ft 200 24 CTM100 06APR04 06 200 24 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 434 ...

Page 437: ...ation Engine Oil Minimum Pressure at No Load Idle 138 kPa 1 38 bar 20 psi Maximum Pressure at Full Load 310 kPa 3 1 bar 45 psi Rated Speed Intake Manifold Test Pressure 13 8 20 8 kPa 0 13 0 21 bar 2 3 psi Crankshaft Position Sensor Torque 14 N m 10 lb ft 06 210 1 CTM100 06APR04 06 210 1 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 435 ...

Page 438: ...601 1611 1621 1631 317 425 2100 850 2225 1602 1612 1622 1632 336 450 2100 850 2225 1603 1613 1623 1633 354 475 2100 850 2225 1604 1614 1624 1634 373 500 2100 850 2225 6125HF 30000 16A1 16A2 16A3 16A4 224 300 2100 900 2225 16B1 16B2 16B3 16B4 242 325 2100 900 2225 16C1 16C2 16C3 16C4 261 350 2100 900 2225 16D1 16D2 16D3 16D4 280 375 2100 900 2225 16E1 16E2 16E3 16E4 298 400 2100 900 2225 16F1 16F2 ...

Page 439: ...08 1618 1628 1638 352 472 1500 900 1550 1606 1616 1626 1636 360 483 1800 900 1850 1605 1615 1625 1635 420 563 1800 900 1850 1639 1640 1641 1642 460 616 1800 900 1850 6125HF 30000 164J 164K 164L 164M 300 402 1500 900 1550 163A 163B 163C 163D 330 442 1800 900 1850 165J 165K 165L 165M 350 469 1500 900 1550 164A 164B 164C 164D 360 483 1800 900 1850 166J 166K 166L 166M 387 519 1500 900 1550 165A 165B 1...

Page 440: ...298 400 2100 144 165 kPa 1 4 1 6 bar 21 24 psi 16F1 16F2 16F3 16F4 317 425 2100 157 180 kPa 1 6 1 8 bar 23 26 psi 16G1 16G2 16G3 16G4 336 450 2100 168 193 kPa 1 7 1 9 bar 24 28 psi 16H1 16H2 16H3 16H4 354 475 2100 177 203 kPa 1 8 2 0 bar 26 29 psi 16J1 16J2 16J3 16J4 373 500 2100 185 212 kPa 1 8 2 1 bar 27 31 psi OEM GENERATOR SET STANDBY APPLICATIONS 6125AF 1607 1617 1628 1638 233 312 1500 136 15...

Page 441: ...Fuel System Option Power Rating Rated Rated Pressure Specification Codes Speed Without Fan kW Speed hp rpm 6125AFM M1 254 340 1800 124 152 kPa 1 2 1 5 bar 18 22 psi M2 280 375 1900 145 172 kPa 1 4 1 7 bar 21 25 psi M3 298 400 2000 159 187 kPa 1 6 1 9 bar 23 27 psi M4 1601 1602 336 450 2100 186 214 kPa 1 9 2 1 bar 27 31 psi Gen Set Prime 300 402 1800 165 193 kPa 1 6 1 9 bar 24 28 psi Gen Set Prime ...

Page 442: ...T Track Type Tractor 2100 113 130 kPa 1 1 1 3 bar 16 19 psi 6125HRW04 9400T Track Type Tractor 2100 144 166 kPa 1 4 1 7 bar 21 24 psi 6125HRW08 30000 9400T Track Type Tractor 2100 153 175 kPa 1 5 1 7 bar 22 25 psi 6125HZ001 6850 Forage Harvester 2100 149 172 kPa 1 5 1 7 bar 22 25 psi 6125HZ005 6850 Forage Harvester 6125HZ002 6750 Forage Harvester 2100 115 132 kPa 1 1 1 3 bar 17 19 psi 6125HZ006 67...

Page 443: ... 1610 19 13SEP02 4 4 Engine Model Deere Model Rated Speed rpm Pressure Specification 6125HH003 9860 Special Canadian Combine 137 kPa 1 3 1 4 bar 20 psi 06 210 7 CTM100 06APR04 06 210 7 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 441 ...

Page 444: ...Diagnostic Specifications 06 210 8 CTM100 06APR04 06 210 8 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 442 ...

Page 445: ...Break in engine oil 01 002 4 Install 02 070 10 Remove 02 070 8 Cooling system Check and service 02 010 19 C Diagnostics Indx Camshaft Coolant in oil or oil in coolant 04 150 8 1 Inspect camshaft and roller followers 02 050 18 Engine coolant temperature above Inspect sensor lobe 02 050 20 normal 04 150 7 Engine coolant temperature below Measure bushing ID and journal OD 02 050 19 Measure lobe lift ...

Page 446: ...r oil in coolant 04 150 8 Specifications 06 200 9 Engine coolant temperature above Top deck clean and inspect 02 020 55 normal 04 150 7 Cylinder head Engine coolant temperature below Cap screws torque turn 02 020 59 normal 04 150 8 Check flatness 02 020 30 Lubrication system malfunctions Clean and inspect 02 020 29 Engine oil pressure high 04 150 5 Complete final assembly 02 020 68 Engine oil pres...

Page 447: ...lues 06 200 2 Exhaust restrictions check 04 150 20 Injector Exhaust system Adjust preload 02 020 4 Operation theory of 03 120 12 Intake air leak check 04 150 21 Exhaust system check 02 010 18 Intake and exhaust system Check for restrictions 04 150 20 Indx Operation theory of 03 120 12 3 Intake manifold F Remove inspect and install 02 080 21 Intake manifold pressure turbo boost Fan drive bearings r...

Page 448: ...adapter inspect and replace 02 060 2 Rocker arm assembly Assemble 02 020 23 Oil filter and housing oil cooler cover and valve housing Check and adjust clearance and preload 02 020 4 Exploded view 02 060 1 Install 02 060 8 Disassemble and inspect 02 020 21 Install 02 020 61 Remove 02 060 2 Oil pan Remove 02 020 10 Rocker arm cover Install 02 060 15 Remove 02 060 13 Gasket replace 02 020 3 Indx 4 Oi...

Page 449: ...lve rotators inspect 02 020 26 Remove 02 070 11 Valve seats Test 02 070 13 Clean and inspect 02 020 34 Timing adjustment Grind 02 020 35 camshaft to crankshaft 02 050 2 Install inserts 02 020 38 Timing gear cover Measure bores in head 02 020 37 Indx Install 02 040 34 5 Remove inserts 02 020 36 Remove 02 040 6 Valve springs Torque values Inspect and measure 02 020 25 Inch 06 200 2 Valves intake and...

Page 450: ...Index Page Install 02 070 10 Remove 02 070 8 Indx 6 CTM100 06APR04 Index 6 POWERTECH 10 5 L 12 5 L Diesel Engines 040604 PN 6 ...

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