Contents Page Page Remove Cylinder Liners Using JDG1145 Remove Timing Gear Cover . . . . . . . . . . . . . .02-040-6 Check Flywheel Housing Face Runout . . . . . .02-040-7 Cylinder Liner Service Set . . . . . . . . . . . . .02-030-14 Visually Inspect Cylinder Liners. . . . . . . . . . .02-030-16 Check Flywheel Face Flatness . . . . . . . . . . . .02-040-8 Remove Flywheel . . . . . . . . . . . . . . . . . . . . . .02-040-8 Deglaze Cylinder Liners . . . . . . . . . . . . . . . .02-030-17 Clean Cylinder Liners . . . . . . . . . . . . . . . . . .02-030-18 Inspect and Repair Flywheel . . . . . . . . . . . . . .02-040-9 Replace Flywheel Ring Gear. . . . . . . . . . . .
.02-040-10 Cylinder Liner Manufacturing Date Code 02 Explanation . . . . . . . . . . . . . . . . . . . . . . . .02-030-19 Remove and Install Flywheel Housing. . . . . .02-040-11 Install Flywheel . . . . . . . . . . . . . . . . . . . . . . .02-040-12 Disassemble Piston/Rod Assembly and Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-20 Remove Rear Crankshaft Oil Seal and Housing Assembly . . . . . . . . . . . . . . . . . . .02-040-13 Check Piston Compression Ring Groove Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-15 Check Piston Compression Ring Groove Wear—6105 Engines. . . . . . . . . . . . . . . .
.02-030-22 Crankshaft and Main Bearing Failure Wear—6125 Engines. . . . . . . . . . . . . . . . .02-030-23 Remove Crankshaft Main Bearings . . . . . . . .02-040-16 Check Main Bearing-to-Journal Oil Check Piston Oil Control Ring Groove Wear—6105 and 6125 Engines . . . . . . . . .02-030-24 Clearance . . . . . . . . . . . . . . . . . . . . . . . . .02-040-18 Remove Crankshaft. . . . . . . . . . . . . . . . . . . .02-040-19 Inspect Piston Pin and Pin Bore in Piston . . .02-030-25 Determine Piston-to-Liner Clearance. . . . . . .02-030-26 Inspect Crankshaft . . . . . . . . . . . . . . . . . . . .02-040-20 Measure Assembled ID of Bearings and Measure Liner Flange Thickness. . . . . . . . .
.02-030-28 Inspect and Measure Connecting Rod OD of Crankshaft Journals. . . . . . . . . . . . .02-040-22 Measure Assembled ID of Main Bearing Bearings . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-29 Inspect Connecting Rod and Cap . . . . . . . . .02-030-31 Caps (Without Bearings) . . . . . . . . . . . . . .02-040-23 Crankshaft Grinding Guidelines. . . . . . . . . . .02-040-24 Inspect Piston Pins and Rod Bushings . . . . .02-030-34 Remove Piston Pin Bushing, Clean, and Crankshaft Grinding Specifications . . . . . . . .02-040-25 Replace Crankshaft Drive Gear. . . . . . . . . . .02-040-26 Inspect Bushing Bore. . . . . . . . . . . . . . . . .02-030-36 Install Piston Pin Bushing . .
. . . . . . . . . . . . .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 and Wear Recheck Cylinder Liner Standout (Height Above Block) . . . . . . . . . . . .
. . . . . . . . . . .02-030-43 Sleeve Assembly . . . . . . . . . . . . . . . . . . . .02-040-33 Install Timing Gear Cover . . . . . . . . . . . . . . .02-040-34 Install Cylinder Liner O-Rings and Front Oil Seal . . . . . . . . . . . . . . . . . . . . . .02-040-39 Install Cylinder Liners . . . . . . . . . . . . . . . . . .02-030-45 Assemble Pistons and Connecting Rods. . . .02-030-47 Complete Final Assembly . . . . . . . . . . . . . . .02-040-43 Install Pistons and Connecting Rods. . . . . . .02-030-48 Torque-Turn Connecting Rod Cap Group 050—Camshaft and Timing Gear Train Camshaft Gear Access Cover Torque Screws. . . . . . . . . . . . . . . . . . . . . . . . . . .
.02-030-52 Check Engine Rotation for Excessive Sequence . . . . . . . . . . . . . . . . . . . . . . . . . .02-050-1 Check and Adjust Camshaft-to-Crankshaft Tightness. . . . . . . . . . . . . . . . . . . . . . . . . .02-030-53 Measure Piston Protrusion . . . . . . . . . . . . . .02-030-53 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-050-2 Adjust Front Timing Gear Backlash. . . . . . . . .02-050-4 Remove and Install Piston Spray Jets. . . . . .02-030-54 Complete Final Assembly . . . . . . . . . . . . . . .02-030-55 Remove and Install Camshaft . . . . . . . . . . . . .02-050-9 Replace Fuel Supply Pump Drive Pin . . . . .
.02-050-18 Visually Inspect Camshaft and Roller Group 040—Crankshaft, Main Bearings, and Packings . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-44 Install Crankshaft Vibration Damper and Flywheel Followers . . . . . . . . . . . . . . . . . . . . . . . . . .02-050-18 Inspect and Measure Camshaft Bushing Crankshaft Vibration Damper Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-1 ID and Journal OD. . . . . . . . . . . . . . . . . . .02-050-19 Measure Camshaft Lobe Lift Height . . . . . . .02-050-20 Inspect Crankshaft Vibration Damper . . . . . . .02-040-2 Check Crankshaft End Play . . . . . . . . . . . . . .02-040-3 Inspect Camshaft Position Sensor Lobe .
. . .02-050-20 Replace Camshaft Bushings . . . . . . . . . . . . .02-050-21 Remove Crankshaft Vibration Damper and Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-4 CTM100 (06APR04) 02-2 P OWER T ECH 10.5 L & 12.5 L Diesel Engines Continued on next page Remove Crankshaft Front Oil Seal . . . . . . . . .02-040-5 040604 PN=2