CTM100 (06APR04) 02-1 P OWER T ECH 10.5 L & 12.5 L Diesel Engines 040604 PN=1 Section 02 Repair and Adjustments Contents 02 Page Page Group 010—Engine Rebuild Guide, Break-In and Remove Valve Assembly. . . . . . . . . . . . . . . .02-020-24 Tune-Up Inspect and Measure Valve Springs . . . . . . .02-020-25 Engine Overhaul Guidelines . . . . . . . . . . . . . .02-010-1 Inspect Valve Rotators . . . . . . . . . . . . . . . . .02-020-26 Engine Repair Stand . . . . . . . . . . . . . . . . . . . .02-010-1 Clean, Inspect, and Measure Valves . . . . . . .02-020-27 Safety Precautions . . . . . . . . . . . . . . . . . . . . .02-010-2 Grind Valves . . . . . . . . . . . . . . . . . . . . . . . .
.02-020-28 Disconnect Turbocharger Oil Inlet Line . . . . . .02-010-3 Clean and Inspect Cylinder Head . . . . . . . . .02-020-29 Install Engine Adapter Onto Repair Stand. . . .02-010-3 Check Cylinder Head Flatness . . . . . . . . . . .02-020-30 Engine Lifting Procedure . . . . . . . . . . . . . . . . .02-010-4 Measure Cylinder Head Thickness . . . . . . . .02-020-31 Mount Engine Onto Repair Stand . . . . . . . . . .02-010-6 Resurface Cylinder Head Combustion Clean Engine . . . . . . . . . . . . . . . . . . . . . . . . .02-010-7 Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-020-32 6105 and 6125 Engine Disassembly Measure Valve Guide ID . . . . . . . . . . . . . . .
.02-020-33 Sequence . . . . . . . . . . . . . . . . . . . . . . . . . .02-010-8 Replace Valve Guides. . . . . . . . . . . . . . . . . .02-020-33 Sealant Application Guidelines . . . . . . . . . . .02-010-11 Clean and Inspect Valve Seats . . . . . . . . . . .02-020-34 6105 and 6125 Engine Assembly Grind Valve Seats . . . . . . . . . . . . . . . . . . . . .02-020-35 Sequence . . . . . . . . . . . . . . . . . . . . . . . . .02-010-13 Remove Valve Seat Inserts. . . . . . . . . . . . . .02-020-36 Engine Break-In Guidelines. . . . . . . . . . . . . .02-010-15 Measure Valve Seat Bore in Cylinder Perform Engine Break-In. . . . . . . . . . . . . . . .02-010-16 Head . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .02-020-37 Check Crankcase Ventilation System . . . . . .02-010-17 Install Valve Seat Inserts. . . . . . . . . . . . . . . .02-020-38 Check Air Intake System. . . . . . . . . . . . . . . .02-010-18 Install Valves. . . . . . . . . . . . . . . . . . . . . . . . .02-020-38 Check Exhaust System . . . . . . . . . . . . . . . . .02-010-18 Replace Unit Injector Sleeve in Cylinder Check and Service Cooling System . . . . . . .02-010-19 Head Using JDG981 . . . . . . . . . . . . . . . . .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 Group 020—Cylinder Head and Valves Above Block) . . . . . . . . . . . . . . . . . . . . . . .02-020-56 Remove and Install Rocker Arm Cover . . . . . .02-020-1 Install Cylinder Head . . . . . . . . . . . . . . . . . . .02-020-57 Clean and Inspect Crankcase Ventilation Torque-Turn Cylinder Head Cap Screws. . . .02-020-59 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .
.02-020-2 Install Rocker Arm Assembly. . . . . . . . . . . . .02-020-61 Replace Rocker Arm Cover Gasket. . . . . . . . .02-020-3 Complete Final Assembly for Cylinder Head Check and Adjust Valve Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . .02-020-68 Clearances and Injector Preload . . . . . . . . .02-020-4 Remove Rocker Arm Assembly. . . . . . . . . . .02-020-10 Group 030—Cylinder Block, Liners, Pistons, and Remove Cylinder Head . . . . . . . . . . . . . . . . .02-020-12 Rods Diagnosing Head Gasket Joint Failures. . . . .02-020-17 Remove and Install Cylinder Block Front Head Gasket Inspection and Repair Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.02-030-1 Sequence . . . . . . . . . . . . . . . . . . . . . . . . .02-020-19 Preliminary Liner, Piston, and Rod Checks . . .02-030-5 Disassemble and Inspect Rocker Arms and Connecting Rods—General Information . . . . .02-030-6 Shaft Assembly . . . . . . . . . . . . . . . . . . . . .02-020-21 Remove Pistons and Connecting Rods . . . . . .02-030-7 Preliminary Cylinder Head and Valve Measure Cylinder Liner Standout (Height Checks . . . . . . . . . . . . . . . . . . . . . . . . . . .02-020-22 Above Block) . . . . . . . . . . . . . . . . . . . . . . .02-030-11 Assemble Rocker Arms and Shaft Remove Cylinder Liners Using D01062AA Assembly. . . . . . . . . . . . . . . . . . . . . . . . .
.02-020-23 or D01073AA Cylinder Liner Puller . . . . . .02-030-12 Check Valve Height in Relation to Head Surface (Valve Recess) . . . . . . . . . . . . . . .02-020-23 Continued on next page