BAIC Diesel Engine Technical Service Manual (10.5L & 12.5L) (EN)

P OWER T ECH 10.5 L & 12.5 L Diesel Engines Base Engine TECHNICAL MANUAL P OWER T ECH 10.5 L & 12.5 L Diesel Engines—Base Engine CTM100 06APR04 (ENGLISH) For complete service information also see: P OWER T ECH 10.5 L & 12.5 L Diesel Engines—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM115 P OWER T ECH 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.

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Introduction Forward This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. 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 tolerances, and torque values. This manual (CTM100) covers only the base engine.

It is one of three volumes on 10.5 L and 12.5 L engines. The following two companion manuals cover electronic fuel system repair, operation and diagnostics: CTM115—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs CTM188—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs Before beginning repair on an engine, clean the engine and mount on a repair stand. (See Section 2, Group 010.) CTM115 and CTM188 will cover fuel system repair, formerly included in CTM100, Groups 35 and 36. This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric.

Other manuals will be added in the future to provide added information on new electronic fuel systems. Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manual for information on this and for engine removal and installation procedures. A complete set of all three manuals covering the 10.5 L and 12.5 L engines can be procured by ordering CTM650 Binder Set. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the engine model number you are working on. If only one procedure is given, that procedure applies to all the engines in the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

Use this component technical manual in conjunction with the machine technical manual. An application RG,RG34710,1 –19–11OCT00–1/1 CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines 040604 PN=2

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Introduction John Deere Dealers The changes listed below make your CTM obsolete. Repair, operation and diagnostics on 10.5 L and 12.5 L diesel engines is now covered in three manuals. Fuel system repair has been removed from CTM100 and incorporated into its two companion manuals. Discard CTM100 dated 20MAR01 and replace with the following new manuals. 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.

CTM100—10.5 L and 12.5 L Diesel Engines—Base Engine CTM115—10.5 L and 12.5 L Diesel Engines— Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs CTM188—10.5 L and 12.5 L Diesel Engines—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs SECTION 02, GROUP 030 (Cylinder Block, Liners, Pistons and Rods) Revised procedure for connecting rod inspection. SECTION 02, GROUP 040 (Crankshaft, Main Bearings and Flywheel) Also, copy these pages listing changes and route through your Service Department. Revised procedure for installing timing gear cover. Revised procedure for checking flywheel housing face runout.

SECTION 01, GROUP 000 (Safety) SECTION 02, GROUP 050 (Camshaft and Timing Gear Train) Updated safety information. SECTION 01, GROUP 001 (Engine Identification and Applications) Revised procedure for adjusting front timing gear backlash. Updated engine model designation chart. Updated engine application charts. SECTION 02, GROUP 060 (Lubrication System) Added torque specifications for remote filter lines. Revised procedure for installation of oil pump. Revised specifications for oil pan cap screw torque. SECTION 01, GROUP 002 (Fuels, Lubricants and Coolants) Revised diesel/bio-diesel fuel guidelines and specifications. Revised diesel engine oil guidelines.

Revised oilscan and coolscan guidelines. Revised diesel engine coolant guidelines. SECTION 02, GROUP 070 (Cooling System) Revised procedure for replacement of fan drive bearings. Revised procedure for replacement of belt tensioners. Revised procedures for removal and installation of thermostats. SECTION 02, GROUP 010 (Engine Rebuild) Added new engine front lift strap. Revised engine disassembly sequence. Revised engine assembly sequence. SECTION 02, GROUP 080 (Air Intake and Exhaust System) SECTION 02, GROUP 020 (Cylinder Head and Valves) Added new information for extending turbocharger life.

OUO1004,0000BBC –19–11OCT00–1/2 CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines 040604 PN=3

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Introduction SECTION 02—GROUP 090 and 091(Fuel System) NOTE: Fuel system theory of operation has been moved to Section 03, Group 130 of the following manuals: NOTE: Repair procedures for fuel systems has been moved to the following manuals:

CTM115—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs, Section 02, Group 090 CTM188—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs, Section 02, Group 090 (Dual Rail System) and Group 091 (Single Rail System) 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) Later Tier II 12.5 L engines with dual- or single-rail fuel systems are covered in CTM188. Base engine observable tests and diagnostics are covered in this section/group. SECTION 02—GROUP 100 (Starting and Charging Systems) NOTE:

Fuel system testing and diagnostics has been moved to Section 04, Group 150 in two other technical manuals: CTM115—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs and CTM188—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs. Updated torque specifications for alternator mounting hardware. SECTION 02—GROUP 110 (Electrical Engine Control) SECTION 5 (Tools and Other Materials) NOTE: Repair procedures for electrical engine control components has been moved to section 02, group 110 of the following manuals: All essential tools, service tools, dealer fabricated tools and other materials listed throughout this manual are consolidated in this section for ease of reference.

CTM115—Delphi/Lucas Electronic Fuel Systems With Delphi/Lucas EUIs CTM188—Level 6 Electronic Fuel Systems With Delphi/Lucas EUIs SECTION 6 (Specifications) SECTION 03—GROUP 120 (Base Engine Operation) All repair, test and diagnostic specifications listed throughout this manual are consolidated in this section for ease of reference. Updated dynamometer test specifications. Updated intake manifold pressure specifications. Base engine theory of operation is covered in this section/group. OUO1004,0000BBC –19–11OCT00–2/2 CTM100 (06APR04) P OWER T ECH 10.5 L & 12.5 L Diesel Engines 040604 PN=4

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