Engine Rebuild Guide, Break-In and Tune-Up CTM100 (06APR04) 02-010-13 P OWER T ECH 10.5 L & 12.5 L Diesel Engines 040604 PN=61 6105 and 6125 Engine Assembly Sequence The following assembly sequence is suggested when IMPORTANT: ALWAYS replace vibration damper engine has been completely disassembled. Be sure to whenever crankshaft is replaced or check runout, clearance, and all critical physical part after a major engine overhaul. specifications prior to assembling engine. Replace parts as necessary and tighten retaining hardware to specifications given. Refer to the appropriate repair group when assembling engine.
ENGINE ASSEMBLY SEQUENCE Procedure Reference Install all plugs in cylinder block that were removed to service See COMPLETE DISASSEMBLY OF CYLINDER BLOCK in Group cylinder block. 030. IMPORTANT: If new piston and liner kits are being installed, See INSTALL CYLINDER LINERS in Group 030. install them as an assembly after crankshaft has been installed. Install cylinder liners without O-rings and measure liner stand-out. Install liners with packing. Install crankshaft. See INSTALL CRANKSHAFT in Group 040. Install main bearings. See INSTALL MAIN BEARING INSERTS IN BLOCK in Group 040. Rotate crankshaft by hand to ensure correct assembly. Check See CHECK CRANKSHAFT END PLAY in Group 040.
crankshaft end play. Install pistons 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 040. Install flywheel housing. See REMOVE AND INSTALL FLYWHEEL HOUSING in Group 040. Install cylinder block front plate. See REMOVE AND INSTALL CYLINDER BLOCK FRONT PLATE in Group 030. Install engine oil pump and drive gear.
See INSTALL ENGINE OIL PUMP in Group 060. Install cylinder head using a new gasket. See INSTALL CYLINDER HEAD in Group 020. Install camshaft and camshaft drive gear. See REMOVE AND INSTALL CAMSHAFT in Group 050. Install timing gear cover. See INSTALL TIMING GEAR COVER in Group 040. Install oil pickup tube. See REMOVE AND INSTALL OIL PICKUP TUBE in Group 060. Install engine oil pan. See INSTALL ENGINE OIL PAN in Group 060. Install idler gear. Pin camshaft and crankshaft. Adjust idler See ADJUST FRONT TIMING GEAR BACKLASH in Group 050. gear-to-camshaft gear and idler gear-to-oil pump gear backlash.
Install new crankshaft vibration damper and pulley assembly (with oil See INSTALL CRANKSHAFT VIBRATION DAMPER AND FRONT seal). OIL SEAL in Group 040. (Continued on next page) Continued on next page RG,RG34710,52 –19–21AUG02–1/3 02 010 13 ENGINE ASSEMBLY SEQUENCE Procedure Reference Install all plugs in cylinder block that were removed to service cylinder block. See COMPLETE DISASSEMBLY OF CYLINDER BLOCK in Group 030. IMPORTANT: If new piston and liner kits are being installed, install them as an assembly after crankshaft has been installed. Install cylinder liners without O-rings and measure liner stand-out. Install liners with packing. See INSTALL CYLINDER LINERS in Group 030.
Install crankshaft. See INSTALL CRANKSHAFT in Group 040. Install main bearings. See INSTALL MAIN BEARING INSERTS IN BLOCK in Group 040. Rotate crankshaft by hand to ensure correct assembly. Check crankshaft end play. See CHECK CRANKSHAFT END PLAY in Group 040. Install pistons and connecting rods. Rotate crankshaft by hand to ensure correct assembly. See in INSTALL PISTONS AND CONNECTING RODS in Group 030. 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 040.
Install flywheel housing. See REMOVE AND INSTALL FLYWHEEL HOUSING in Group 040. Install cylinder block front plate. See REMOVE AND INSTALL CYLINDER BLOCK FRONT PLATE in Group 030. Install engine oil pump and drive gear. See INSTALL ENGINE OIL PUMP in Group 060. Install cylinder head using a new gasket. See INSTALL CYLINDER HEAD in Group 020. Install camshaft and camshaft drive gear. See REMOVE AND INSTALL CAMSHAFT in Group 050. Install timing gear cover. See INSTALL TIMING GEAR COVER in Group 040. Install oil pickup tube. See REMOVE AND INSTALL OIL PICKUP TUBE in Group 060. Install engine oil pan. See INSTALL ENGINE OIL PAN in Group 060. Install idler gear. Pin camshaft and crankshaft.
Adjust idler gear-to-camshaft gear and idler gear-to-oil pump gear backlash. See ADJUST FRONT TIMING GEAR BACKLASH in Group 050. Install new crankshaft vibration damper and pulley assembly (with oil seal). See INSTALL CRANKSHAFT VIBRATION DAMPER AND FRONT OIL SEAL in Group 040. (Continued on next page)