Contents 00 Page Page Inspect and Clean Cylinder Head Nozzle Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 05-27 Clean and Inspect Push Rods . . . . . . . . . . 05-28 Inspect and Clean Ventilator Outlet Hose . . . 05-28 Clean and Inspect Top Deck of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 05-29 Measure Cylinder Liner Standout (Height above Block) . . . . . . . . . . . . . . . . . . . . 05-30 Assemble Valve Assembly . . . . . . . . . . . . . 05-31 Install Cylinder Head . . . . . . . . . . . . . . . . 05-32 Cylinder Head Cap Screw Types . . . . . . . . 05-33 Clean, Inspect and Install Cylinder Head Cap Screws . . . . . . . . . . . . . . . . . . . . .
05-34 Torque-To-Yield Special Flanged-Head Cap Screws . . . . . . . . . . . . . . . . . . . . . 05-36 Install Rocker Arm Assembly . . . . . . . . . . . 05-37 Complete Final Assembly Of Injection Pump Side . . . . . . . . . . . . . . . . . . . . . . 05-38 Complete Final Assembly On Exhaust Manifold Side . . . . . . . . . . . . . . . . . . . . 05-39 Perform Engine Break-In . . . . . . . . . . . . . . 05-42 Inspect Piston Pins and Bushings . . . . . . . . 10-26 Remove Piston Pin Bushing . . . . . . . . . . . . 10-27 Clean and Inspect Piston Pin Bushing Bore in Rod . . . . . . . . . . . . . . . . . . . . . 10-27 Install Piston Pin Bushing in Connecting Rod . . . . . . . . . . . . . . . . . . . .
. . . . . . 10-28 Complete Disassembly of Cylinder Block (If Required) . . . . . . . . . . . . . . . . . . . . . 10-29 Remove and Clean Piston Cooling Orifices . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Inspect and Clean Cylinder Block . . . . . . . . 10-30 Clean O-Ring Bore . . . . . . . . . . . . . . . . . . 10-32 Measure Cylinder Block . . . . . . . . . . . . . . 10-32 Install Piston Cooling Orifices and Gallery Plugs . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 Recheck Cylinder Liner Standout (Height above Block) . . . . . . . . . . . . . . . . . . . . 10-35 Install Liner Shims—If Required . . . . . . . . . 10-36 Install Cylinder Liner O-Rings and Packings . . . . .
. . . . . . . . . . . . . . . . . . 10-37 Install Cylinder Liners . . . . . . . . . . . . . . . . 10-38 Install Pistons and Connecting Rods . . . . . . 10-40 Torque-Turn Connecting Rod Cap Screws. . . 10-43 Check Engine Rotation for Excessive Tightness . . . . . . . . . . . . . . . . . . . . . . . 10-43 Complete Final Assembly . . . . . . . . . . . . . 10-44 01 02 03 04 05 10 Group 10—Cylinder Block, Liners, Pistons and Rods Special or Essential Tools . . . . . . . . . . . . . . 10-1 Service Equipment and Tools . . . . . . . . . . . . 10-3 Other Material . . . . . . . . . . . . . . . . . . . . . . 10-3 Cylinder Block, Liners, Pistons, and Rods Specifications . . . . . . . . . . . . . . . . .
. . . . 10-4 Preliminary Liner, Piston, and Rod Checks . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Remove Pistons and Connecting Rods . . . . . 10-9 Measure Cylinder Liner Standout (Height above Block) . . . . . . . . . . . . . . . . . . . . 10-12 Remove Cylinder Liners . . . . . . . . . . . . . . 10-13 Deglazing Cylinder Liners . . . . . . . . . . . . . 10-14 Clean Cylinder Liners . . . . . . . . . . . . . . . . 10-15 Disassemble and Clean Piston . . . . . . . . . . 10-15 Visually Inspect Pistons . . . . . . . . . . . . . . . 10-16 Check Piston Ring Groove Wear . . . . . . . . 10-17 Measure Oil Control Ring Groove . . . . . . . . 10-18 Install Piston Pin in Piston Pin Bore . . .
. . . 10-18 Visually Inspect Cylinder Liners . . . . . . . . . 10-19 Cylinder Liner Manufacturing Date Code Explanation . . . . . . . . . . . . . . . . . . . . . 10-20 Measure Piston Skirt OD . . . . . . . . . . . . . . 10-21 Measure Cylinder Liner ID . . . . . . . . . . . . . 10-22 Measure Liner Flange Thickness . . . . . . . . 10-22 Inspect and Measure Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . 10-23 Inspect Rod and Cap . . . . . . . . . . . . . . . . 10-24 15 16 Group 15—Crankshaft, Main Bearings and Flywheel Special or Essential Tools . . . . . . . . . . . . . . 15-1 Service Equipment and Tools . . . . . . . . . . . . 15-4 Other Material . . . . . . . . . . . .
. . . . . . . . . . 15-5 Crankshaft, Main Bearings, and Flywheel Specifications . . . . . . . . . . . . . . . . . . . . . 15-6 Failure Analysis . . . . . . . . . . . . . . . . . . . . . 15-8 Remove Crankshaft Rear Oil Seal Housing (With Oil Seal Housing Installed) . . . . . . . . 15-9 Install Crankshaft Rear Oil Seal and Wear Sleeve (Without Engine Disassembly) . . . . . . . . . 15-11 Inspect Vibration Damper . . . . . . . . . . . . . 15-12 Check Crankshaft End Play . . . . . . . . . . . . 15-13 Remove Damper Pulley . . . . . . . . . . . . . . 15-14 Remove Front Oil Seal (With Timing Gear Cover Installed on Engine) . . . . . . . . . . . . . . . . . . . . . .
15-16 20 25 30 35 100 105 Continued on next page CTM42 (24MAR95) ii 6076 Diesel Engines—S.N. (500000— ) 160101 PN=439