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TECHNICAL MANUAL
POWERTECH 10.5 L & 12.5 L Diesel
EnginesBase Engine
CTM100 30AUG07 (ENGLISH)
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.
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:
CTM115Delphi/Lucas Electronic Fuel Systems
With Delphi/Lucas EUIs
CTM188Level 6 Electronic Fuel Systems With
Delphi/Lucas EUIs
CTM115 and CTM188 will cover fuel system repair,
formerly included in CTM100, Groups 35 and 36.
Other manuals will be added in the future to provide
added information on new electronic fuel systems.
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.
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.
Use this component technical manual in conjunction
with the machine technical manual. An application
RG,RG34710,1 1911OCT001/1
CTM100 (30AUG07)
PN=2
Introduction
OUO1004,0000BBC 1911OCT001/2
CTM100 (30AUG07)
PN=3
Introduction
SECTION 02GROUP 090 and 091(Fuel System)
NOTE: Repair procedures for fuel systems has been
moved to the following manuals:
CTM115Delphi/Lucas Electronic Fuel Systems
With Delphi/Lucas EUIs, Section 02, Group 090
CTM188Level 6 Electronic Fuel Systems With
Delphi/Lucas EUIs, Section 02, Group 090 (Dual
Rail System) and Group 091 (Single Rail System)
Later Tier II 12.5 L engines with dual- or single-rail fuel
systems are covered in CTM188.
SECTION 02GROUP 100 (Starting and Charging
Systems)
Updated torque specifications for alternator mounting
hardware.
SECTION 02GROUP 110 (Electrical Engine
Control)
OUO1004,0000BBC 1911OCT002/2
CTM100 (30AUG07)
PN=4
Introduction
CTM100 (30AUG07)
UN21MAY98
RG9033
RG9032
UN21MAY98
UN21MAY98
RG9031
RG9030
UN21MAY98
RG,RG34710,3 1906NOV001/1
PN=5
Introduction
UN20NOV00
CTM100 (30AUG07)
RG11172A
RG11171A
UN04DEC00
UN03NOV00
RG11175
RG11174
UN20NOV00
DPSG,OUO1004,915 1916NOV001/1
PN=6
Introduction
RG8222
RG8221
UN21MAY98
UN21MAY98
RG8223
RG8224
UN21MAY98
UN21MAY98
CTM100 (30AUG07)
RG,RG34710,3A 1930SEP971/1
PN=7
Introduction
RG8220
RG8219
UN21MAY98
UN21MAY98
CTM100 (30AUG07)
DPSG,OUO1004,916 1930JUN991/1
PN=8
Introduction
CTM100 (30AUG07)
UN21MAY98
RG8451
RG8453
UN21MAY98
UN21MAY98
RG8448
RG8454
UN21MAY98
RG,RG34710,5 1930SEP971/1
PN=9
Introduction
CTM100 (30AUG07)
RG11172A
RG11171A
UN04DEC00
UN03NOV00
OUO1080,000028D 1927AUG021/1
PN=10
Introduction
RG11171A
UN03NOV00
RG11172A
UN04DEC00
CTM100 (30AUG07)
RE38635,0000026 1920JUN031/1
PN=11
Introduction
RG8435
UN12JUL99
ECrankshaft
FCylinder Liner
GCylinder Liner O-Rings
HPiston
IPiston Rings
JConnecting Rod
KOil Spray Jet
LCamshaft
MValves
NElectronic Unit Injector
OTwo-Piece Rocker Arm
Shaft
RG,RG34710,8 1930SEP971/1
CTM100 (30AUG07)
PN=12
Contents
01
03
04
05
SECTION 04Diagnostics
Group 150Observable Diagnostics and Tests
SECTION 05Tools and Other Materials
Group 170Repair Tools and Other Materials
Group 180Diagnostic Service Tools
Group 190Dealer Fabricated Service Tools
06
SECTION 06Specifications
Group 200Repair and General OEM
Specifications
Group 210Diagnostic Specifications
INDX
CTM100 (30AUG07)
PN=1
Contents
01
02
03
04
05
06
INDX
CTM100 (30AUG07)
ii
PN=2
01
Section 01
General Information
Contents
Page
CTM100 (30AUG07)
01-1
PN=1
Contents
01
CTM100 (30AUG07)
01-2
PN=2
Group 000
Safety
01
000
1
TS227
UN23AUG88
DX,FLAME 1929SEP981/1
TS281
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
UN23AUG88
DX,RCAP 1904JUN901/1
TS291
UN23AUG88
DX,FIRE2 1903MAR931/1
CTM100 (30AUG07)
01-000-1
PN=17
Safety
UN23AUG88
TS204
Explosion
UN23AUG88
TS203
01
000
2
Acid
DPSG,OUO1004,2758 1911MAY001/1
CTM100 (30AUG07)
01-000-2
PN=18
Safety
01
000
3
X9811
UN23AUG88
DX,FLUID 1903MAR931/1
TS206
UN23AUG88
DX,WEAR 1910SEP901/1
CTM100 (30AUG07)
01-000-3
PN=19
Safety
TS228
UN23AUG88
DX,LOOSE 1904JUN901/1
TS220
UN23AUG88
DX,AIR 1917FEB991/1
UN18OCT88
T6642EJ
01
000
4
DX,CLEAN 1904JUN901/1
CTM100 (30AUG07)
01-000-4
PN=20
Safety
01
000
5
TS220
UN23AUG88
DX,PAINT 1924JUL021/1
TS953
UN15MAY90
DX,TORCH 1910DEC041/1
CTM100 (30AUG07)
01-000-5
PN=21
Safety
TS223
UN23AUG88
DX,LIGHT 1904JUN901/1
TS226
UN23AUG88
DX,LIFT 1904JUN901/1
UN01JUL97
LX1016749
01
000
6
DPSG,OUO1004,899 1919MAY991/1
CTM100 (30AUG07)
01-000-6
PN=22
Safety
01
000
7
TS218
UN23AUG88
DX,SERV 1917FEB991/1
TS779
UN08NOV89
DX,REPAIR 1917FEB991/1
CTM100 (30AUG07)
01-000-7
PN=23
Safety
TS1133
UN26NOV90
DX,DRAIN 1903MAR931/1
1907OCT88
TS231
01
000
8
DX,LIVE 1925SEP921/1
CTM100 (30AUG07)
01-000-8
PN=24
Group 001
6135HRW01 Engine
6 ............................................................................ Number of cylinders
13.5 ............................................................................. Liter designation
H ............................................................................................. Aspiration
RW ........................................................................................ User code
01 ............................................................................... Application Code
RG13879
Aspiration Code
H ............................................. Turbocharged and air-to-air aftercooled
Application Code
01, 02, etc., .............................................. Code for specific application
RG13887
UN26JUL05
User Code
DW .................................. Davenport (Construction Equipment) Works
F ......................................... OEM (Outside Equipment Manufacturers)a
H .............................................................. Harvester (Combines) Works
RW ................................................................ Waterloo (Tractor) Works
T ........................................ Dubuque (Construction Equipment) Works
T8 ............................................................................................. Cameco
Z ............................................. Zweibrucken (Forage Harvester) Works
a
OEM users are non-Deere users of John Deere engines.
Serial Number Plate Location
RE38635,000003D 1921JUL051/1
CTM100 (30AUG07)
01-001-1
PN=25
RG13879
01
001
2
RG6135H000000
RG ........................................................ Factory code producing engine
6135H ........................................................... Engine model designation
000000 .................................................................... Sequential number
Factory Code Producing Engine
RG ................................................................... Waterloo Engine Works
Engine Model Designation
6135H ..................... See Engine Model Designation on previous page
Sequential Number
000000 .......................................................... 6-digit sequential number
RE38635,000003E 1921JUL051/1
CTM100 (30AUG07)
01-001-2
PN=26
RG13880
UN06JUL05
RE38635,000003F 1921JUL051/1
CTM100 (30AUG07)
01-001-3
PN=27
Engine Model
6105HRW01, 6105HRW02,
6125HRW05 (30000 )
6125HRW10, 6125HRW13,
6125HRW16
6125HRW01, 6125HRW11,
6125HRW07 (30000 )
6125HRW13, 6125HRW16
6125HRW02, 6125HRW12,
6125HRW09 (30000 )
6125HRW15, 6125HRW17
6125HRW15, 6125HRW17
6125HRW18
6125HRW03,
(30000 )
6125HRW13,
6125HRW04,
(30000 )
6125HRW15,
6125HRW15,
6125HRW18
6125HRW06
6125HRW16
6125HRW08
6125HRW17
6125HRW17
6125HH003
6125HZ002, 6125HZ006
6125HZ001, 6125HZ005
6125HZ007
6125HZ008
6125HZ009
6125HZ009
6125HZ011
6125HZ012
6125HZ013
6125HZ013
6125HZ004
6125AT801
CTM100 (30AUG07)
01-001-4
Engine Model
6125ADW01, 6125HDW01
6125ADW70
6125HT001 (30000 )
6125HDW01
6125HT003
6125HDW01
RE38635,0000007 1930JAN071/2
PN=28
Marine ...........................................................................................................................................................
Engine Model
6105AF001
6105HF001
6125AF001
6125HF001 (30000 )
6125HF070 (30000 ) Tier II
6125AFM01, 6125AFM75-Tier II
RE38635,0000007 1930JAN072/2
CTM100 (30AUG07)
01-001-5
PN=29
CTM100 (30AUG07)
01-001-6
PN=30
Group 002
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
Sulfur content:
OURGP11,000018C 1912FEB041/1
CTM100 (30AUG07)
01-002-1
PN=31
Bio-Diesel Fuel
leaving deposits on injectors and in
the combustion chamber.
DX,FUEL7 1914NOV051/1
CTM100 (30AUG07)
01-002-2
PN=32
DX,FUEL5 1927OCT051/1
CTM100 (30AUG07)
DX,FUEL6 1914NOV051/1
01-002-3
PN=33
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
After engine overhaul, fill the engine with John Deere
ENGINE BREAK-IN OIL.
If John Deere ENGINE BREAK-IN OIL is not available,
use a diesel engine oil meeting one of the following
during the first 100 hours of operation:
CJ-4
CI-4 PLUS
CI-4
CH-4
CG-4
CF-4
CF-2
CF
ACEA
ACEA
ACEA
ACEA
ACEA
E7
E6
E5
E4
E3
CTM100 (30AUG07)
API
API
API
API
API
API
API
API
DX,ENOIL4 1913SEP061/1
01-002-4
PN=34
CI-4
CH-4
CG-4
CF-4
TS1661
UN10OCT97
CTM100 (30AUG07)
01-002-5
OUO1082,0000236 1917JAN021/1
PN=35
40C
104F
30C
86F
20C
68F
10C
50F
0C
32F
-10C
14F
-20C
-4F
-30C
-22F
-40C
-40F
SAE 0W-40
122F
SAE 10W-40
50C
SAE 5W-30
Diesel fuel quality and sulfur content must comply with all
existing emissions regulations for the area in which the
engine operates.
TS1668A
UN14DEC01
SAE 15W-40
01
002
6
CTM100 (30AUG07)
OUOD002,0000172 1915MAY021/1
01-002-6
PN=36
DX,ENOIL8 1913SEP061/1
DX,ALTER 1915JUN001/1
CTM100 (30AUG07)
01-002-7
PN=37
Mixing of Lubricants
In general, avoid mixing different brands or types of oil.
Oil manufacturers blend additives in their oils to meet
certain specifications and performance requirements.
DX,LUBMIX 1918MAR961/1
UN18OCT88
T6828AB
UN15JUN89
OILSCANand COOLSCAN
T6829AB
01
002
8
CTM100 (30AUG07)
DX,OILSCAN 1902DEC021/1
01-002-8
PN=38
Grease
Use grease based on NLGI consistency numbers and the
expected air temperature range during the service interval.
John Deere SD POLYUREA GREASE is preferred.
The following greases are also recommended
John Deere HD LITHIUM COMPLEX GREASE
John Deere HD WATER RESISTANT GREASE
John Deere GREASE-GARD
CTM100 (30AUG07)
TS1673
UN31OCT03
DX,GREA1 1907NOV031/1
01-002-9
PN=39
CTM100 (30AUG07)
01-002-10
DX,COOL3 1927OCT051/2
PN=40
01
002
11
DX,COOL3 1927OCT052/2
CTM100 (30AUG07)
DX,COOL4 1907NOV031/1
01-002-11
PN=41
CTM100 (30AUG07)
DX,COOL9 1919DEC031/1
01-002-12
PN=42
UN05DEC97
RG6262
RG6261
UN08DEC97
JT07298 Refractometer
CTM100 (30AUG07)
01-002-13
RG,01,DT7035 1914NOV001/2
PN=43
RG,01,DT7035 1914NOV002/2
DX,COOL6 1918MAR961/1
CTM100 (30AUG07)
01-002-14
PN=44
UN23AUG88
TS281
CTM100 (30AUG07)
01-002-15
RG,01,DT7033 1929OCT971/2
PN=45
RG,01,DT7033 1929OCT972/2
Disposing of Coolant
UN26NOV90
TS1133
01
002
16
RG,01,DT7032 1929OCT971/1
CTM100 (30AUG07)
01-002-16
PN=46
Section 02
02
Page
Page
02-1
PN=1
Contents
02
Page
Page
02-2
PN=2
Contents
Page
Page
02-3
PN=3
02
Contents
02
CTM100 (30AUG07)
02-4
PN=4
Group 010
02
010
1
DPSG,OUO1032,3410 1915JUN001/1
UN05DEC97
RG4929
RG,RG34710,1043 1923OCT971/1
CTM100 (30AUG07)
02-010-1
PN=49
Safety Precautions
02
010
2
CTM100 (30AUG07)
RG,RG34710,45 1930SEP971/1
02-010-2
PN=50
02
010
3
RG14421
UN22JUL05
DPSG,OUO1004,918 1930JUN991/1
RG8183
UN08DEC97
Specification
Engine Adapter-to-Repair Stand
Cap ScrewsTorque .................................................. 600 Nm (450 lb-ft)
RE38635,0000062 1920JUN071/1
CTM100 (30AUG07)
02-010-3
PN=51
UN13OCT99
Specification
Engine Lift Strap Cap Screws
Torque ............................................................................. 90 Nm (66 lb-ft)
RG10349
UN13OCT99
AAlternator
BFront Plate Lift Eye
CExhaust Shield
DJDG23 Lift Sling
ER128000 Rear Lift Strap1
FR503481 (OEM & AT801 Applications Only) or
R128001 Front Lift Strap1
RG10350
02
010
4
Engine Lifting
1
CTM100 (30AUG07)
02-010-4
RE38635,0000041 1915NOV061/2
PN=52
02
010
5
CTM100 (30AUG07)
RE38635,0000041 1915NOV062/2
02-010-5
PN=53
RG8184A
02
010
6
UN05DEC97
RG,RG34710,48 1913SEP021/3
UN05DEC97
RG8185
CTM100 (30AUG07)
02-010-6
RG,RG34710,48 1913SEP022/3
PN=54
UN05DEC97
Specification
Engine-to-Stand Adapter Cap
ScrewsTorque .......................................................... 400 Nm (300 lb-ft)
RG8186
BCap Screws
Clean Engine
1. Cap or plug all openings (air intake, exhaust, fuel,
coolant, etc.).
RG8188
UN21MAY98
RG,RG34710,49 1921DEC001/1
CTM100 (30AUG07)
02-010-7
PN=55
02
010
8
Reference
Remove alternator.
Remove compressor.
CTM100 (30AUG07)
02-010-8
RG,RG34710,50 1921AUG021/3
PN=56
Reference
Remove fuel supply pump (John Deere ECU controlled fuel system).
Remove front gear train access cover and timing gear cover.
Remove front and rear rocker arm and shaft assembly and EUI
wiring harness.
Remove electronic unit injectors on Delphi/Lucas ECU controlled fuel
systems.
Remove oil pump drive gear and remove oil pump assembly.
Remove flywheel.
CTM100 (30AUG07)
02-010-9
RG,RG34710,50 1921AUG022/3
PN=57
02
010
9
02
010
10
Reference
Remove crankshaft.
CTM100 (30AUG07)
RG,RG34710,50 1921AUG023/3
02-010-10
PN=58
02
010
11
CTM100 (30AUG07)
02-010-11
RG,RG34710,51 1916OCT001/2
PN=59
02
010
12
CTM100 (30AUG07)
02-010-12
RG,RG34710,51 1916OCT002/2
PN=60
02
010
13
Reference
Install flywheel.
Install new crankshaft vibration damper and pulley assembly (with oil
seal).
CTM100 (30AUG07)
02-010-13
RG,RG34710,52 1921AUG021/3
PN=61
02
010
14
Reference
Install valve bridges and push tubes. Install front and rear rocker arm
shaft assemblies. Install EUI wiring harness.
Install fuel supply pump (John Deere ECU controlled fuel system).
CTM100 (30AUG07)
02-010-14
RG,RG34710,52 1921AUG022/3
PN=62
Reference
Install alternator.
Install compressor.
02
010
15
RG,RG34710,52 1921AUG023/3
RG,RG34710,1053 1905DEC001/1
CTM100 (30AUG07)
02-010-15
PN=63
02
010
16
CTM100 (30AUG07)
02-010-16
RG,100,JW7645 1905NOV991/2
PN=64
RG,100,JW7645 1905NOV992/2
UN09JUL99
RG10239
DPSG,OUO1004,919 1930JUN991/1
CTM100 (30AUG07)
02-010-17
PN=65
UN12JUL99
RG8717A
Unloader Valve
UN12JUL99
RG8719A
02
010
18
DPSG,OUO1004,920 1909JUL991/1
RG,RG34710,1057 1923OCT971/1
CTM100 (30AUG07)
02-010-18
PN=66
UN12JUL99
RG8718A
AWeep Hole
CTM100 (30AUG07)
02-010-19
DPSG,OUO1004,922 1901JUL991/2
PN=67
UN06DEC97
TS281
RG8246
02
010
20
DPSG,OUO1004,922 1901JUL992/2
CTM100 (30AUG07)
02-010-20
PN=68
UN23AUG88
TS204
RG,RG34710,1059 1923OCT971/1
CTM100 (30AUG07)
02-010-21
PN=69
02
010
21
02
010
22
DPSG,OUO1004,921 1907NOV001/1
CTM100 (30AUG07)
02-010-22
PN=70
02
010
23
Detailed Reference
CTM115 or CTM188
Operators Manual
Operators Manual
CTM115 or CTM188, Operators Manual
This Group/Operators Manual
This Group/Operators Manual
This Group
This Group/Operators Manual
Operators Manual
This Group
Group 040/Operators Manual
Section 04, Group 150 of CTM115 or CTM188
Section 04, Group 150 of CTM115 or CTM188
Section 02, Group 020 of CTM115 or CTM188
Section 04, Group 150
Authorized Servicing Dealer
Section 04, Group 150
DPSG,OUO1004,923 1930AUG021/1
CTM100 (30AUG07)
02-010-23
PN=71
02
010
24
CTM100 (30AUG07)
02-010-24
PN=72
Group 020
02
020
1
RG8173
UN11DEC97
RG8818
CTM100 (30AUG07)
02-020-1
RG,RG34710,60 1913DEC051/2
PN=73
UN20JUL99
RG10242
02
020
2
RG,RG34710,61 1903SEP021/1
CTM100 (30AUG07)
02-020-2
PN=74
UN10DEC97
RG8784
CTM100 (30AUG07)
02-020-3
PN=75
RG8228A
UN05DEC97
RG8227D
UN30OCT00
RG11165
02
020
4
CTM100 (30AUG07)
02-020-4
RG,RG34710,63 1916OCT001/6
PN=76
02
020
5
CTM100 (30AUG07)
02-020-5
RG,RG34710,63 1916OCT002/6
PN=77
RG8773
UN19MAY98
02
020
6
UN05DEC97
RG8232
CTM100 (30AUG07)
02-020-6
RG,RG34710,63 1916OCT003/6
PN=78
02
020
7
Specification
Electronic Unit InjectorPreload ........... 0.00 mm (in.) clearance plus 1/2
turn in (180)
Electronic Unit Injector Adjusting
Screw Lock NutsTorque .............................................. 65 Nm (48 lb-ft)
CTM100 (30AUG07)
02-020-7
RG,RG34710,63 1916OCT004/6
PN=79
RG8774
UN19MAY98
02
020
8
RG8229
UN05DEC97
CTM100 (30AUG07)
02-020-8
RG,RG34710,63 1916OCT005/6
PN=80
02
020
9
RG9743
13. Check that all intake rocker arm adjusting screws (D)
have approximately the same number of threads
visible above lock nut. Normally flush to maximum of
two threads.
UN04DEC98
Inspect Valves
UN04DEC98
Specification
Timing Pin Plug (Below Oil
Cooler)Torque .............................................................. 33 Nm (24 lb-ft)
RG9626A
14. Install plug in timing pin hole below oil cooler and
tighten to specifications.
Adjusting Screws
AValve Bridges
BValve Stems
CPush Tubes
DAdjusting Screws
RG,RG34710,63 1916OCT006/6
CTM100 (30AUG07)
02-020-9
PN=81
RG8262B
UN21JUL99
RG8459A
02
020
10
UN06DEC97
CTM100 (30AUG07)
02-020-10
RG,RG34710,64 1921DEC001/2
PN=82
02
020
11
RG,RG34710,64 1921DEC002/2
CTM100 (30AUG07)
02-020-11
PN=83
UN05DEC97
RG8187A
02
020
12
CTM100 (30AUG07)
02-020-12
RG,RG34710,65 1913AUG991/5
PN=84
CTM100 (30AUG07)
02-020-13
RG,RG34710,65 1913AUG992/5
PN=85
UN06DEC97
RG8251A
UN06DEC97
RG8264B
RG8544B
02
020
14
CTM100 (30AUG07)
02-020-14
RG,RG34710,65 1913AUG993/5
PN=86
02
020
15
CTM100 (30AUG07)
02-020-15
RG,RG34710,65 1913AUG994/5
PN=87
UN21MAY98
RG8285
02
020
16
RG,RG34710,65 1913AUG995/5
CTM100 (30AUG07)
02-020-16
PN=88
;;;;;
@@@@@
;;;
@@@
;;;;;
@@@@@
;;;
@@@
;;;;;
@@@@@
;;;
@@@
;;;;;
@@@@@
;;;
@@@
;;;;;
@@@@@
;;;
@@@
;;;;;
@@@@@
;;;
@@@
@;@;
02
020
17
UN22MAY98
RG8430
CTM100 (30AUG07)
02-020-17
RG,RG34710,69 1901NOV001/2
PN=89
02
020
18
RG,RG34710,69 1901NOV002/2
CTM100 (30AUG07)
02-020-18
PN=90
RG8429
UN19MAY98
02
020
19
BGasket Body
CFront of Engine
Flange severed/expanded/cracked/deformed.
Adjacent body area burned/eroded.
Fire ring severed/displaced/missing.
Flange sealing pattern eccentric/contains voids.
Discoloration of flange and adjacent body areas.
Flange surfaces rough/abraided/channelled.
CTM100 (30AUG07)
02-020-19
RG,RG34710,70 1930SEP971/2
PN=91
02
020
20
RG,RG34710,70 1930SEP972/2
CTM100 (30AUG07)
02-020-20
PN=92
02
020
21
RG8395
UN21MAY98
UN21MAY98
Specification
Rocker Arm BushingID ........................... 38.064 0.013 mm (1.4986
0.0005 in.)
Rocker Arm ShaftOD .............................. 38.000 0.013 mm (1.4961
0.0005 in.)
Rocker Arm Shaft-to-Bushing
Oil Clearance ................................................ 0.064 0.026 mm (0.0025
0.0010 in.)
Rocker Arm Shaft Intake and
Exhaust RollerOD .................................................. 39.99540.045 mm
(1.57461.5766 in.)
Rocker Arm Shaft Unit Injector
RollerOD ................................................................ 37.99538.045 mm
(1.49591.4978 in.)
RG8392
RG8390
RG,RG34710,71 1930SEP971/1
CTM100 (30AUG07)
02-020-21
PN=93
Lack of lubrication.
Cylinder head distortion.
Excessive heat.
Unevenly tightened cylinder head cap screws.
RG,RG34710,72 1930SEP971/1
CTM100 (30AUG07)
02-020-22
PN=94
RG8460
02
020
23
UN21MAY98
RG8304
UN06DEC97
UN09DEC97
Specification
Intake and Exhaust Valves
Recess ................................................. 1.852.35 mm (0.0730.093 in.)
RG8330A
RG,RG34710,74 1903NOV991/1
CTM100 (30AUG07)
02-020-23
PN=95
RG8305
UN06DEC97
RG8306B
02
020
24
RG,RG34710,75 1930SEP971/1
CTM100 (30AUG07)
02-020-24
PN=96
RG2732
UN04DEC97
in.)
in.)
RG7427
Specification
Intake and Exhaust Valve Springs
(All)1Height at 0 N (0 lb-force)
Free Length ............................................. 67.972.1 mm (2.672.84
Intake and Exhaust Valve Springs
(R116585)Height at 352396
N (7989 lb-force) (Valve
Closed) ......................................................................... 59.4 mm (2.34
Intake and Exhaust Valve Springs
(R116585)Height at 845935
N (190-210 lb-force) (Valve
Open) ............................................................................ 45.5 mm (1.79
Intake and Exhaust Valve Springs
(R133891)Height at 527593
N (118133 lb-force) (Valve
Closed) ......................................................................... 59.4 mm (2.34
Intake and Exhaust Valve Springs
(R133891)Height at 1187
1313 N (267295 lb-force)
(Valve Open) ................................................................ 46.4 mm (1.83
UN21MAY98
in.)
in.)
CTM100 (30AUG07)
02-020-25
PN=97
02
020
25
RG8323
02
020
26
RG,RG34710,77 1930SEP971/1
CTM100 (30AUG07)
02-020-26
PN=98
02
020
27
RG8322
UN21MAY98
UN05DEC97
RG4234
Specification
Intake and Exhaust Valve
StemsOD................................................... 8.999 0.013 mm (0.3543
0.0005 in.)
Measuring Valve Face Runout
Specification
Intake and Exhaust Valve
Face1Maximum Runout ....................................... 0.038 mm (0.0015 in.)
CTM100 (30AUG07)
02-020-27
PN=99
Grind Valves
Specification
Intake and Exhaust Valve Face
Angle ................................................................................... 29.25 0.25
RG4755
02
020
28
UN31OCT97
RG,RG34710,79 1930SEP971/1
CTM100 (30AUG07)
02-020-28
PN=100
02
020
29
RG8266
CTM100 (30AUG07)
02-020-29
RG,RG34710,80 1903SEP021/2
PN=101
RG,RG34710,80 1903SEP022/2
UN21MAY98
RG8309
02
020
30
RG,RG34710,81 1930SEP971/1
CTM100 (30AUG07)
02-020-30
PN=102
RG8324
02
020
31
UN21MAY98
RG8325
UN21MAY98
Specification
Cylinder Head (Rocker Arm
Cover-to-Combustion Face)
New Part Thickness .............................................. 124.975125.025 mm
(4.92034.9222 in.)
Minimum Acceptable Thickness ......................... 124.840 mm (4.9150 in.)
CTM100 (30AUG07)
02-020-31
PN=103
02
020
32
RG,RG34710,83 1930SEP971/1
CTM100 (30AUG07)
02-020-32
PN=104
UN21MAY98
RG8308
Specification
Valve GuideID ........................................... 9.045 0.013 mm (0.3583
0.0005 in.)
Valve StemOD .......................................... 8.999 0.013 mm (0.3543
0.0005 in.)
Valve Stem-to-GuideClearance ................................. 0.0770.129 mm
(0.00300.0050 in.)
RG,RG34710,84 1901NOV001/1
UN11DEC97
RG8823
Specification
Valve Guide Bore in HeadID ...................... 14.94 0.02 mm (0.5882
0.0008 in.)
CTM100 (30AUG07)
02-020-33
RG,RG34710,85 1916OCT001/2
PN=105
UN11DEC97
RG8824
02
020
34
RG,RG34710,85 1916OCT002/2
RG,RG34710,86 1930SEP971/1
CTM100 (30AUG07)
02-020-34
PN=106
02
020
35
RG8311
UN06DEC97
UN06DEC97
RG8312
UN21MAY98
RG8313
Specification
Valve Seat GrindingContact
Angle ..................................................................................................... 30
Width ................................................... 1.502.00 mm (0.0590.079 in.)
Maximum Runout ....................................................... 0.16 mm (0.006 in.)
Grinding Valve Seat
APilot
BGrinding Stone
CArbor
CTM100 (30AUG07)
02-020-35
RG,RG34710,87 1928NOV001/2
PN=107
UN03NOV97
RG6318
RG,RG34710,87 1928NOV002/2
RG8314
02
020
36
RG,RG34710,88 1930SEP971/1
CTM100 (30AUG07)
02-020-36
PN=108
02
020
37
RG8315
Specification
Intake and Exhaust Valve Seat
BoreID ..................................................... 49.424 0.013 mm (1.9458
0.0005 in.)
Bore Depth ............................................................... 11.50 mm (0.443 in.)
Radius at Lower Bore .............................. 0.64 0.25 mm (0.025 0.001
in.)
Standard Intake and Exhaust
Valve SeatOD ........................................................ 49.48749.513 mm
(1.94831.9493 in.)
RG,RG34710,89 1913AUG991/1
CTM100 (30AUG07)
02-020-37
PN=109
UN06DEC97
RG8319
UN21MAY98
RG8318
RG,RG34710,90 1903NOV991/1
Install Valves
1. Lubricate valve stems and guides with AR44402 Valve
Stem Lubricant or clean engine oil.
UN06DEC97
RG8306A
02
020
38
3. Slide valve stem seals (A) over valve stems and onto
intake and exhaust valve guide tower until firmly
seated.
CTM100 (30AUG07)
02-020-38
RG,RG34710,91 1913AUG991/2
PN=110
RG8326
02
020
39
UN06DEC97
RG8327
UN06DEC97
RG8328
UN21MAY98
CTM100 (30AUG07)
02-020-39
PN=111
RG8151
02
020
40
AMAY-25010 Punch
BWood Block
CTM100 (30AUG07)
02-020-40
RE38635,000016A 1915NOV061/6
PN=112
02
020
41
RG8152
ASquare Packing
RE38635,000016A 1915NOV062/6
RG12417
UN04SEP02
RG12415
UN04SEP02
AInjector Sleeve
BOld Injector Sleeve
CNew Injector Sleeve
CTM100 (30AUG07)
02-020-41
RE38635,000016A 1915NOV063/6
PN=113
RG8154
UN05DEC97
02
020
42
CTM100 (30AUG07)
02-020-42
RE38635,000016A 1915NOV064/6
PN=114
UN05DEC97
RG8155
UN05DEC97
RG8157
RG8156
UN05DEC97
CTM100 (30AUG07)
02-020-43
RE38635,000016A 1915NOV065/6
PN=115
UN13AUG99
RG10279
UN21MAY98
RG8159
02
020
44
RE38635,000016A 1915NOV066/6
CTM100 (30AUG07)
02-020-44
PN=116
UN23AUG88
TS281
UN21JUL99
RG8708A
Drain Coolant
Continued on next page
CTM100 (30AUG07)
02-020-45
RE38635,0000169 1915NOV061/15
PN=117
02
020
45
UN21JUL99
RG9159A
Specification
Fuel Temperature Sensor
Torque ............................................................................ 10 Nm (7.5 lb-ft)
AFuel
BFuel
CFuel
DFuel
UN21JUL99
Specification
Fuel LinesTorque ......................................................... 24 Nm (18 lb-ft)
Outlet Line
Temperature Sensor
Rail Inlet Line
Rail Outlet Line
RG8264C
UN24AUG99
RG10291
02
020
46
CTM100 (30AUG07)
02-020-46
RE38635,0000169 1915NOV062/15
PN=118
UN21JUL99
RG9160A
Cap Plug
ACap Plug
CTM100 (30AUG07)
02-020-47
RE38635,0000169 1915NOV063/15
PN=119
UN21JUL99
RG9161A
RE38635,0000169 1915NOV064/15
12. Install EUI hold-down clamp and cap screw (A) over
protector sleeve. Tighten cap screws to 40 Nm (30
lb-ft).
UN21JUL99
RG9162A
02
020
48
CTM100 (30AUG07)
02-020-48
RE38635,0000169 1915NOV065/15
PN=120
02
020
49
RG9163A
AJDG1184-1-1 Tap
BJDG1184-1-5 Tap Guide
RE38635,0000169 1915NOV066/15
UN21JUL99
RG9164A
RG9165
UN21JUL99
Remove Sleeve
Continued on next page
CTM100 (30AUG07)
02-020-49
RE38635,0000169 1915NOV067/15
PN=121
UN05DEC97
RG8226
RE38635,0000169 1915NOV068/15
RG9162B
02
020
50
CTM100 (30AUG07)
02-020-50
RE38635,0000169 1915NOV069/15
PN=122
UN04SEP02
RG12418
RG12415
UN04SEP02
Installing Sleeve
RE38635,0000169 1915NOV0610/15
RG9167A
UN21JUL99
Seat Sleeve
CTM100 (30AUG07)
02-020-51
RE38635,0000169 1915NOV0611/15
PN=123
02
020
51
RG9168A
UN21JUL99
RE38635,0000169 1915NOV0612/15
UN21JUL99
ADrive Nut
RG9169A
02
020
52
Drive Nut
CTM100 (30AUG07)
02-020-52
RE38635,0000169 1915NOV0613/15
PN=124
RG9170A
UN21JUL99
CTM100 (30AUG07)
02-020-53
RE38635,0000169 1915NOV0614/15
PN=125
UN21JUL99
RG9171A
02
020
54
Remove Swedge
A8132 Adapter
BJDG1184-2-1 Swedge Arbor
CD01300AA Slide Hammer
RE38635,0000169 1915NOV0615/15
CTM100 (30AUG07)
02-020-54
PN=126
RG14902
CTM100 (30AUG07)
02
020
55
UN22JUN06
02-020-55
RE38635,0000121 1924OCT061/2
PN=127
UN15JUN06
RG14891
UN15JUN06
RG14892
UN15JUN06
RG14893
02
020
56
Removed Sleeve
RE38635,0000121 1924OCT062/2
CTM100 (30AUG07)
02-020-56
PN=128
RG8210A
02
020
57
UN05DEC97
UN21MAY98
RG8208
5. Clean all oily residue and dirt from top deck before
installing head gasket.
AJDG978 Special Tap
Measuring Block Top Deck Flatness
RG,RG34710,93 1916OCT001/1
CTM100 (30AUG07)
02-020-57
PN=129
UN03NOV97
RG6439
Liner Standout
UN06DEC97
Specification
Cylinder LinerHeight Above
Block (Standout) ............................................................ 0.0300.117 mm
(0.00120.0046 in.)
Cylinder LinerMax. Height
Difference at Nearest Point of
Two Adjacent Liners or Within
One Liner ................................................................ 0.051 mm (0.0020 in.)
RG8329A
02
020
58
RG,RG34710,94 1930SEP971/1
CTM100 (30AUG07)
02-020-58
PN=130
RG8189
RG8285
UN21MAY98
CTM100 (30AUG07)
02
020
59
UN05DEC97
02-020-59
RG,RG34710,95 1927NOV001/2
PN=131
RG8347
UN19MAY98
02
020
60
RG,RG34710,95 1927NOV002/2
CTM100 (30AUG07)
02-020-60
PN=132
02
020
61
UN09DEC97
RG8346
AFront of Engine
CTM100 (30AUG07)
02-020-61
RG,RG34710,96 1928NOV001/2
PN=133
02
020
62
CTM100 (30AUG07)
02-020-62
PN=134
RG8227A
UN05DEC97
ATiming Pin
RE38635,000016B 1915NOV061/9
RG8304
UN06DEC97
CTM100 (30AUG07)
02-020-63
RE38635,000016B 1915NOV062/9
PN=135
RG8262A
UN09SEP99
RG10343
02
020
64
Specification
Rocker Arm Shaft Hold-Down
Clamp Cap Screws (All
Engines)Initial Torque .................................................. 30 Nm (22 lb-ft)
CTM100 (30AUG07)
02-020-64
RE38635,000016B 1915NOV063/9
PN=136
UN30JUL99
RG9200A
RG9202A
UN30JUL99
ALine on Socket
BLine on Shaft Clamp
CLine on Spacer
CTM100 (30AUG07)
02-020-65
RE38635,000016B 1915NOV064/9
PN=137
02
020
65
02
020
66
UN30JUL99
RG9201A
UN30JUL99
Specification
Rocker Arm Shaft Hold-Down
Clamp Cap Screws (Dual Rail
Fuel System)Final Torque-Turn ................................................. 60 5
RG9203A
Specification
Unit Injector Wiring Harness
Bracket-to-Rear of HeadTorque .................................. 25 Nm (18 lb-ft)
Unit Injector Wiring Harness
Solenoid Wire Retaining Nut1
Torque ........................................................................... 3.0 Nm (27 lb-in.)
Unit Injector Harness
Clips-to-Rocker Arm Shaft
ClampsTorque.............................................................. 35 Nm (26 lb-ft)
Apply LOCTITE 222 (TY24311) Thread Lock and Sealer (Low Strength)
to nut only.
Continued on next page
CTM100 (30AUG07)
02-020-66
RE38635,000016B 1915NOV065/9
PN=138
02
020
67
UN04DEC98
RG9743
CTM100 (30AUG07)
02-020-67
RE38635,000016B 1915NOV066/9
PN=139
RG10281
UN20AUG99
RG10282
UN20AUG99
UN23SEP99
RG10283
02
020
68
Specification
Unit Injector Wiring Harness
Bracket-to-Rear of HeadTorque .................................. 25 Nm (18 lb-ft)
CTM100 (30AUG07)
02-020-68
RE38635,000016B 1915NOV067/9
PN=140
02
020
69
Apply LOCTITE 222 (TY24311) Thread Lock and Sealer (Low Strength)
to nut only.
RE38635,000016B 1915NOV068/9
RG9743
UN04DEC98
RE38635,000016B 1915NOV069/9
CTM100 (30AUG07)
02-020-69
PN=141
RG,RG34710,98 1916OCT001/1
CTM100 (30AUG07)
02-020-70
PN=142
Group 030
RG8787
UN10DEC97
02
030
1
CTM100 (30AUG07)
02-030-1
RG,RG34710,106 1901NOV001/4
PN=143
02
030
2
CTM100 (30AUG07)
02-030-2
RG,RG34710,106 1901NOV002/4
PN=144
02
030
3
UN20MAY98
Specification
Front Plate-to-Cylinder Block Cap
ScrewsTorque .............................................................. 50 Nm (37 lb-ft)
RG8814
CTM100 (30AUG07)
02-030-3
RG,RG34710,106 1901NOV003/4
PN=145
02
030
4
RG,RG34710,106 1901NOV004/4
CTM100 (30AUG07)
02-030-4
PN=146
Overheating.
Overfueling.
Insufficient lubrication.
Insufficient cooling.
Improper piston-to-liner clearance.
Coolant leakage into crankcase.
Misaligned or bent connecting rod.
Improperly installed piston.
Low oil level.
Improper operation.
Incorrect connecting rod bearing clearance.
Carbon build-up in ring groove.
Improper engine break-in.
Worn piston.
Contaminated oil.
Distorted cylinder liner.
Plugged piston cooling orifice.
Ingestion of dust through air intake.
02
030
5
Insufficient lubrication.
Insufficient cooling.
Improper ring installation.
Improper timing.
Abrasives in combustion chamber.
Improper oil.
Excessive blow-by.
Contaminated oil.
Improper periodic service.
Low operating temperature.
Stuck Rings:
RG,RG34710,1112 1906MAY991/1
CTM100 (30AUG07)
02-030-5
PN=147
UN27AUG99
RG10300
UN02DEC98
RG9616
02
030
6
CTM100 (30AUG07)
DPSG,OUO1004,871 1930JUL991/1
02-030-6
PN=148
02
030
7
RG8203
UN06DEC97
RG8299B
CTM100 (30AUG07)
02-030-7
RG,RG34710,107 1901NOV001/4
PN=149
RG8302
02
030
8
Specification
Cylinder Liner Cap Screws (For
Checking Liner Standout)
Torque ............................................................................. 68 Nm (50 lb-ft)
CTM100 (30AUG07)
02-030-8
RG,RG34710,107 1901NOV002/4
PN=150
02
030
9
RG8364
CTM100 (30AUG07)
02-030-9
RG,RG34710,107 1901NOV003/4
PN=151
UN09DEC97
RG8396A
UN21MAY98
RG8398
02
030
10
CTM100 (30AUG07)
RG,RG34710,107 1901NOV004/4
02-030-10
PN=152
02
030
11
UN03NOV97
RG6439
UN09DEC97
Specification
Cylinder Liner Cap Screws (For
Checking Liner Standout)
Torque ............................................................................. 68 Nm (50 lb-ft)
RG8330B
ALiner Height
BJDG451 Gauge
CKJD10123 Gauge
CTM100 (30AUG07)
02-030-11
RG,RG34710,108 1913AUG991/2
PN=153
RG,RG34710,108 1913AUG992/2
UN05DEC97
RG1179
02
030
12
Specification
Cylinder Liner Height
(Standout)Height Above Block................................... 0.0300.117 mm
(0.00120.0046 in.)
Maximum Permissible Height
Difference at Nearest Point of
Two Adjacent Liners or Within
One Liner .................................................................... 0.05 mm (0.002 in.)
Cylinder Liner Shims Available
Thickness.................................................................... 0.05 mm (0.002 in.)
Thickness.................................................................... 0.10 mm (0.004 in.)
CTM100 (30AUG07)
02-030-12
RG,RG34710,109 1913AUG991/2
PN=154
02
030
13
RG6668
UN05DEC97
RG,RG34710,109 1913AUG992/2
CTM100 (30AUG07)
02-030-13
PN=155
UN10SEP99
RG10341
JDG1145 Installation
UN09SEP99
RG10339
02
030
14
CTM100 (30AUG07)
02-030-14
DPSG,OUO1004,1026 1909SEP991/2
PN=156
02
030
15
RG6668
UN05DEC97
DPSG,OUO1004,1026 1909SEP992/2
CTM100 (30AUG07)
02-030-15
PN=157
UN05DEC97
RG4643
02
030
16
ALiner Pitting
BErosion
CPitting Depth Is One-Half Liner Thickness
DErosion Depth Is One-Half Packing Step
CTM100 (30AUG07)
02-030-16
RG,RG34710,110 1903AUG991/2
PN=158
02
030
17
UN04DEC97
RG1188
Liner ID Inspection
ACracks In The Flange Area
BCracks In The Ring Travel Area
RG,RG34710,110 1903AUG992/2
R26164
UN13DEC88
Deglazing Liners
Continued on next page
CTM100 (30AUG07)
02-030-17
RG,RG34710,111 1930SEP971/2
PN=159
UN13DEC88
R26165
02
030
18
Liner Cross-hatch
RG,RG34710,111 1930SEP972/2
RG,RG34710,112 1930SEP971/1
CTM100 (30AUG07)
02-030-18
PN=160
UN27JAN92
SJ96 15
S ............................................................................. Liner
J ............................................................ Month Liner was
96 ........................................................... Year Liner was
15 ............................................. Day of Month Liner was
02
030
19
RG6091
RG,RG34710,113 1901NOV001/1
CTM100 (30AUG07)
02-030-19
PN=161
UN22MAY98
Early Engines
Engine
Piston
Ring Size
10.5 L
RE52836, RE504801
4 mm
12.5 L
RE66125
4 mm
RG8400
02
030
20
Later Engines
10.5 L
RE504343
3 mm
12.5 L
RE503969,
RE505901
3 mm
mm (0.0170.027 in.)
mm (0.0400.050 in.)
mm (0.0190.029 in.)
mm (0.0530.065 in.)
CTM100 (30AUG07)
02-030-20
RG,RG34710,114 1901NOV001/2
PN=162
UN09DEC97
RG8367
02
030
21
RG,RG34710,114 1901NOV002/2
CTM100 (30AUG07)
02-030-21
PN=163
UN21MAY98
RG8373
RGR24201
02
030
22
RG,RG34710,115 1901NOV001/1
CTM100 (30AUG07)
02-030-22
PN=164
02
030
23
RG8522
UN10DEC97
RG8523
RG,RG34710,116 1901NOV001/1
CTM100 (30AUG07)
02-030-23
PN=165
UN05DEC97
Early Engines
Engine
Piston
10.5 L
RE52836, RE504801
4.8 mm
RE66125
4.8 mm
12.5 L
RG5234
02
030
24
Later Engines
10.5 L
RE504343
4 mm
12.5 L
RE503969,
RE505901
4 mm
RG,RG34710,117 1901NOV001/1
CTM100 (30AUG07)
02-030-24
PN=166
RG5231
UN05DEC97
RG4984
RG,RG34710,118 1913AUG991/1
CTM100 (30AUG07)
02-030-25
PN=167
02
030
25
UN03NOV97
RG7403
02
030
26
Specification
Piston Skirt (6105)OD 29.97
mm (1.180 in.) from Bottom of
Piston ..................................................................... 126.872126.898 mm
(4.99504.9960 in.)
Piston Skirt (6125)OD 35.0 mm
(1.380 in.) from Bottom of Skirt ............................. 126.910126.930 mm
(4.99654.9972 in.)
CTM100 (30AUG07)
02-030-26
RG,RG34710,119 1913AUG991/2
PN=168
UN07JAN03
RG10049
02
030
27
Measuring Liner ID
RG,RG34710,119 1913AUG992/2
CTM100 (30AUG07)
02-030-27
PN=169
RG8199
02
030
28
RG,RG34710,120 1930SEP971/1
CTM100 (30AUG07)
02-030-28
PN=170
UN30JUL99
RG10246
CTM100 (30AUG07)
02-030-29
RG,RG34710,121 1913AUG991/3
PN=171
RG,RG34710,121 1913AUG992/3
UN04DEC97
RG3824
02
030
30
RG,RG34710,121 1913AUG993/3
CTM100 (30AUG07)
02-030-30
PN=172
RG3749
UN04DEC97
UN27AUG99
RG10301
CTM100 (30AUG07)
02-030-31
RG,RG34710,122 1902AUG991/4
PN=173
02
030
31
UN05DEC97
RG4982
02
030
32
Specification
Tongue-and-Groove Connecting
Rod Cap ScrewInitial Torque....................................... 27 Nm (20 lb-ft)
CTM100 (30AUG07)
02-030-32
RG,RG34710,122 1902AUG992/4
PN=174
02
030
33
UN20NOV97
Specification
Connecting Rod Bore (For
Crankshaft Journal Bearing)ID .................................. 93.7693.79 mm
(3.69153.6925 in.)
RG1549
RG,RG34710,122 1902AUG993/4
RG8420
UN09DEC97
RG,RG34710,122 1902AUG994/4
CTM100 (30AUG07)
02-030-33
PN=175
RG3172
02
030
34
AConnecting Rod
BPiston Pin
CTM100 (30AUG07)
02-030-34
RG,RG34710,123 1913AUG991/2
PN=176
Specification
Piston PinOD ......................................................... 50.77250.787 mm
(1.99891.9995 in.)
Rod Pin Bore Without Bushing
ID ............................................................................... 55.52955.555 mm
(2.18622.1872 in.)
Installed Rod Pin Bushing (Before
Boring)ID ................................................................ 50.72950.781 mm
(1.99721.9992 in.)
Installed Rod Pin Bushing (After
Boring)ID ................................................................ 50.80550.830 mm
(2.00022.0012 in.)
Piston Pin Bushing Bore
Out-of-Round .......................................................... 0.038 mm (0.0015 in.)
Piston Pin-to-BushingOil
Clearance ...................................................................... 0.0170.059 mm
(0.00070.0023 in.)
Max. Acceptable Wear ........................................... 0.076 mm (0.0030 in.)
Press Fit of Bushing in Rod Pin
BorePress Fit ............................................................. 0.1000.163 mm
(0.00390.0064 in.)
RG4924
RG,RG34710,123 1913AUG992/2
CTM100 (30AUG07)
02-030-35
PN=177
02
030
35
UN20NOV97
RG4723
02
030
36
RG,RG34710,124 1930SEP971/1
CTM100 (30AUG07)
02-030-36
PN=178
02
030
37
UN09DEC97
Specification
Piston Pin Bushing (After
Boring)ID ................................................................ 50.80550.830 mm
(2.00022.0012 in.)
Piston PinOD ......................................................... 50.77250.787 mm
(1.99891.9995 in.)
Piston Pin-to-BushingClearance ................................ 0.0170.059 mm
(0.00070.0023 in.)
RG8421
CTM100 (30AUG07)
02-030-37
PN=179
02
030
38
CTM100 (30AUG07)
02-030-38
RE38635,0000059 1911AUG051/2
PN=180
02
030
39
UN11AUG05
6. Install rivet plug (A) into hole on right side front, near
head deck, flush to 1.5 mm below surface.
RG14454
Specification
Oil Galley Pipe Plugs to Block
Torque ............................................................................. 25 Nm (19 lb-ft)
UN11AUG05
Specification
Rear Oil Galley Plug to Block
Torque ............................................................................. 60 Nm (45 lb-ft)
11. Apply LOCTITE 680 to the plug bore for the front oil
galley hole. Install the plug (F) flush to 1.5 mm below
block face.
12. Apply LOCTITE 680 to the plug bore for the oil pump
core clean out hole. Install the plug (G) flush to 1.5
mm below front block face.
CTM100 (30AUG07)
RG14455
10. Apply LOCTITE 680 to the rear plug bore for the top
coolant cross hole. Install plug (E) flush to 1.5 mm
below surface.
RE38635,0000059 1911AUG052/2
02-030-39
PN=181
UN21MAY98
RG8210
02
030
40
CTM100 (30AUG07)
02-030-40
RG,RG34710,127 1909SEP991/2
PN=182
UN05DEC97
Specification
Cylinder Liner Flange
CounterboreDepth in Block........................................ 9.4619.512 mm
(0.37250.3745 in.)
Cylinder Liner FlangeThickness ................................ 9.5259.575 mm
(0.37500.3770 in.)
RG7142
RG10340
UN09SEP99
RG,RG34710,127 1909SEP992/2
CTM100 (30AUG07)
02-030-41
PN=183
02
030
41
UN21MAY98
RG8208
02
030
42
Specification
Main and Thrust Bearings
Assembled ID Without Bearings ........................... 133.097133.123 mm
(5.24005.2410 in.)
Main Bearing Surface Width ................. 37.7738.03 mm (1.4871.497
in.)
Thrust Bearing Surface Width
(No. 5 Main) .......................................... 37.5138.29 mm (1.4761.507
in.)
Overall Thrust Bearing Cap Width ........ 43.2543.75 mm (1.7031.722
in.)
CTM100 (30AUG07)
02-030-42
RG,RG34710,128 1903AUG991/2
PN=184
02
030
43
RG,RG34710,128 1903AUG992/2
CTM100 (30AUG07)
02-030-43
PN=185
UN05DEC97
RG7142
UN21MAY98
RG8329
02
030
44
RG,RG34710,129 1930SEP971/1
CTM100 (30AUG07)
02-030-44
PN=186
02
030
45
UN04DEC97
RG3826
RG,RG34710,130 1901NOV001/2
UN04DEC97
RG3827
RG,RG34710,130 1901NOV002/2
CTM100 (30AUG07)
02-030-45
PN=187
UN04DEC97
RG2772
02
030
46
Installing Liner
CTM100 (30AUG07)
02-030-46
RG,RG34710,131 1901NOV001/2
PN=188
UN23FEB89
Seating Liner
UN10SEP99
T48319
RG10342
ASlide Hammer
BLiner Service Set
RG,RG34710,131 1901NOV002/2
CTM100 (30AUG07)
02-030-47
PN=189
02
030
47
UN09DEC97
RG8401
UN22MAY98
RG8400A
02
030
48
CTM100 (30AUG07)
02-030-48
RG,RG34710,132 1901NOV001/2
PN=190
Piston
Compression
Ring Size
Oil Control
Ring Size
10.5 L
RE52836,
RE504801
4 mm
4.8 mm
12.5 L
RE66125
4 mm
4.8 mm
10.5 L
RE504343
3 mm
4 mm
12.5 L
RE503969,
RE505901
3 mm
4 mm
Later Engines
RG,RG34710,132 1901NOV002/2
UN27AUG99
RG10300
CTM100 (30AUG07)
02-030-49
RG,RG34710,133 1926AUG021/6
PN=191
UN11DEC97
RGR31127
RG,RG34710,133 1926AUG022/6
UN09DEC97
RG8404
02
030
50
APiston Head
BTop Compression Ring Gap
COil Control Ring Gap
DExpander Ring Gap
EBottom Compression Ring Gap
FFront of Engine
CTM100 (30AUG07)
02-030-50
RG,RG34710,133 1926AUG023/6
PN=192
02
030
51
UN21MAY98
RG8366
RG,RG34710,133 1926AUG024/6
RG8409B
UN09DEC97
UN21MAY98
RG8396
CTM100 (30AUG07)
02-030-51
RG,RG34710,133 1926AUG025/6
PN=193
Specification
Tongue-and-Groove Connecting
Rod Cap ScrewInitial Torque....................................... 27 Nm (20 lb-ft)
UN05DEC97
RG4375
02
030
52
CTM100 (30AUG07)
RG,RG34710,133 1926AUG026/6
02-030-52
PN=194
RG9102
UN27MAR98
RG5698
UN05DEC97
RG,RG34710,134 1903AUG992/2
CTM100 (30AUG07)
02-030-53
PN=195
02
030
54
RG,RG34710,135 1930SEP971/1
Specification
Piston (Early Engines)
Protrusion Above Block Deck ................................. 0.2290.787 mm
(0.0090.031 in.)
Piston (RE505901) (Later 12.5
L Engines)Protrusion Above
Block Deck .............................................................. 0.0790.637 mm
(0.0030.025 in.)
RG,RG34710,136 1901NOV001/1
CTM100 (30AUG07)
02-030-54
PN=196
UN06DEC97
RG8299A
RG,RG34710,137 1913AUG991/1
CTM100 (30AUG07)
02-030-55
PN=197
02
030
56
Specification
Oil Gallery PlugTorque.......................................... 20 Nm (15 lb-ft)
Main Oil Gallery (Front)
Expansion PlugInstalled
Depth ......................................................... Flush1.5 mm (0.059 in.)
Below Surface
CTM100 (30AUG07)
RG,RG34710,138 1930AUG021/1
02-030-56
PN=198
Group 040
RG10247
UN30JUL99
DPSG,OUO1004,940 1926JUL991/1
CTM100 (30AUG07)
02-040-1
PN=199
02
040
1
RG8536
UN10DEC97
RG8537
02
040
2
RG,RG34710,149 1923OCT001/1
CTM100 (30AUG07)
02-040-2
PN=200
RG8538
02
040
3
Specification
CrankshaftEnd Play ................................................... 0.0380.380 mm
(0.00150.0150 in.)
RG,RG34710,150 1930SEP971/1
CTM100 (30AUG07)
02-040-3
PN=201
UN05DEC97
RG8175A
UN05DEC97
RG8176
02
040
4
CTM100 (30AUG07)
02-040-4
RG,RG34710,151 1930SEP971/2
PN=202
02
040
5
UN05DEC97
RG8168
RG8169
UN05DEC97
UN21MAY98
RG8119
RG,RG34710,152 1930SEP971/1
CTM100 (30AUG07)
02-040-5
PN=203
UN05DEC97
RG8178
02
040
6
RG,RG34710,153 1912SEP021/1
CTM100 (30AUG07)
02-040-6
PN=204
UN02AUG99
RG10271
RG10272
Specification
SAE 1 Flywheel Housing
Maximum Face Deviation (A) .....................................
Maximum Bore Eccentricity (B) ..................................
SAE 2 Flywheel Housing
Maximum Face Deviation (A) .....................................
Maximum Bore Eccentricity (B) ..................................
SAE 0 Flywheel Housing
Maximum Face Deviation (A) .....................................
Maximum Bore Eccentricity (B) ..................................
UN02AUG99
Bore Eccentricity
AMeasure Face Deviation
BMeasure Bore Eccentricity
RG,RG34710,154 1912SEP021/1
CTM100 (30AUG07)
02-040-7
PN=205
02
040
7
UN14DEC88
R22213
Specification
Flywheel Face Flatness
Maximum Variation ..................................................... 0.23 mm (0.009 in.)
Maximum Variation per 25 mm
(1.0 in.) of Travel .................................................... 0.013 mm (0.0005 in.)
RG,RG34710,155 1905SEP021/1
Remove Flywheel
UN05DEC97
RG8134A
02
040
8
Removing Flywheel
ACap Screws
BThreaded Guide Pins
RG,RG34710,156 1927JUL991/1
CTM100 (30AUG07)
02-040-8
PN=206
RG,RG34710,157 1905SEP021/1
CTM100 (30AUG07)
02-040-9
PN=207
UN14OCT88
T90596
UN14OCT88
RG3838
02
040
10
RG,RG34710,158 1917DEC001/1
CTM100 (30AUG07)
02-040-10
PN=208
Specification
Flywheel Housing Front Plate
Cap ScrewsTorque ............................................... 50 Nm (37 lb-ft)
Flywheel Housing Timing Hole
Cover Cap ScrewsTorque...................................... 5 Nm (44 lb-in.)
RG,RG34710,159 1923OCT001/1
CTM100 (30AUG07)
02-040-11
PN=209
02
040
11
Install Flywheel
CAUTION: Flywheel is heavy. Plan proper
handling procedures to avoid injuries.
UN21MAY98
RG8134
Installing Flywheel
UN30JUL99
RG10248
02
040
12
RG,RG34710,160 1927JUL991/1
CTM100 (30AUG07)
02-040-12
PN=210
02
040
13
RG8291
RG,RG34710,161 1913AUG991/4
RG8293
UN21MAY98
CTM100 (30AUG07)
02-040-13
RG,RG34710,161 1913AUG992/4
PN=211
UN09DEC97
RG8344
ACap Screw
BJDG1020 Rear Seal and Housing Remover
C12:00 Oclock Position
RG,RG34710,161 1913AUG993/4
UN06DEC97
RG8295
13. Clean all oil and sealant from crankshaft flange using
Brake Kleen or ignition cleaner. Polish burrs with fine
emery cloth.
UN09DEC97
ASeal Assembly
BJDG1020 Remover
RG8345
02
040
14
CTM100 (30AUG07)
02-040-14
PN=212
02
040
15
Oil starvation.
Contaminated oil.
Engine parts failure.
Excessive heat.
Poor periodic service.
Improper installation.
Dirt between bearing and crankshaft journal.
Low oil pressure.
Oil pump failure.
Overspeeding.
Excessive idling.
Lugging.
Excessive oil clearance.
Improper installation.
RG,15,DT7461 1918MAY001/1
CTM100 (30AUG07)
02-040-15
PN=213
UN20NOV97
RG8127
UN20NOV97
RG8126
02
040
16
CTM100 (30AUG07)
02-040-16
RG,RG34710,162 1913AUG991/2
PN=214
02
040
17
RG8128
UN21MAY98
CTM100 (30AUG07)
RG,RG34710,162 1913AUG992/2
02-040-17
PN=215
UN21MAY98
RG8128
02
040
18
CTM100 (30AUG07)
RG,RG34710,163 1912SEP021/1
02-040-18
PN=216
Remove Crankshaft
1. Remove timing gear cover. (See REMOVE TIMING
GEAR COVER, earlier in this group.)
02
040
19
UN09DEC97
RG8409A
CTM100 (30AUG07)
02-040-19
RG,RG34710,164 1913AUG991/2
PN=217
UN21MAY98
RG8200
02
040
20
RG,RG34710,164 1913AUG992/2
Inspect Crankshaft
NOTE: If crankshaft damper damage was discovered
during teardown, it is recommended that the
crankshaft be magna-fluxed. This will verify
whether or not it has microscopic cracks or
fissures. (See INSPECT CRANKSHAFT
VIBRATION DAMPER, earlier in this group.)
1. Thoroughly clean crankshaft. Clear restrictions from
all oil passages.
2. Inspect crankshaft for signs of load stress, cracks,
or scratches on journals. Also check each journal
for evidence of excessive overheating or
discoloration. If either condition exists, replace
crankshaft, since heat treatment has probably been
destroyed.
3. Inspect (front) crankshaft gear and timing wheel for
cracks, chipped teeth, or excess wear. Inspect
keyway and index pin for damage and proper
indexing on flange. Replace gear(s) as required.
CTM100 (30AUG07)
02-040-20
RG,RG34710,165 1913AUG991/2
PN=218
02
040
21
RG5093
UN05DEC97
RG,RG34710,165 1913AUG992/2
CTM100 (30AUG07)
02-040-21
PN=219
02
040
22
RG,RG34710,166 1905SEP021/1
CTM100 (30AUG07)
02-040-22
PN=220
Specification
Crankshaft Main Bearing Cap
ScrewsFinal Torque .......................................... 320 Nm (236 lb-ft)
Specification
Crankshaft Main Bearing Cap
Surface Width ......................................................... 39.7540.25 mm
(1.5651.585 in.)
RG,RG34710,167 1905SEP021/1
CTM100 (30AUG07)
02-040-23
PN=221
02
040
23
02
040
24
CTM100 (30AUG07)
02-040-24
RG,RG34710,168 1913AUG991/2
PN=222
02
040
25
RG,RG34710,168 1913AUG992/2
Bearing Size
Standard .........................................
0.25 mm (0.010 in.) ........................
0.50 mm (0.02 in.) ..........................
RG,RG34710,170 1913AUG991/1
CTM100 (30AUG07)
02-040-25
PN=223
RG8411
UN19MAY98
02
040
26
CWoodruff Key
DTiming Wheel
RG,RG34710,171 1930SEP971/1
CTM100 (30AUG07)
02-040-26
PN=224
UN11DEC97
RGR24545
RG,RG34710,173 1913AUG991/1
RG5269
UN20NOV97
CTM100 (30AUG07)
02-040-27
PN=225
UN19NOV97
RGR24545N
02
040
28
RG,RG34710,175 1930SEP971/1
CTM100 (30AUG07)
02-040-28
PN=226
Install Crankshaft
RG8125B
RG8128A
UN05DEC97
UN20NOV97
02
040
29
CTM100 (30AUG07)
02-040-29
RG,RG34710,176 1905SEP021/3
PN=227
02
040
30
Specification
Crankshaft Main Bearing Cap
ScrewsFinal Torque .......................................... 320 Nm (236 lb-ft)
Specification
Crankshaft Main Bearing Cap
ScrewsInitial Torque.............................................. 68 Nm (50 lb-ft)
CTM100 (30AUG07)
02-040-30
RG,RG34710,176 1905SEP022/3
PN=228
UN21MAY98
RG8409
12. Install rear oil seal and wear sleeve. (See INSTALL
CRANKSHAFT REAR OIL SEAL AND WEAR
SLEEVE ASSEMBLY later in this group.)
13. Install flywheel. (See INSTALL FLYWHEEL earlier in
this group.)
14. Install flywheel housing. (See REMOVE AND
INSTALL FLYWHEEL HOUSING earlier in this
group.)
15. Install six piston spray jets. (See REMOVE AND
INSTALL PISTON SPRAY JETS in Group 030.)
16. Check crankshaft end play. (See CHECK
CRANKSHAFT END PLAY earlier in this group.)
17. Install timing gear cover. (See INSTALL TIMING
GEAR COVER later in this group.)
RG,RG34710,176 1905SEP023/3
CTM100 (30AUG07)
02-040-31
PN=229
1. Install JDG977 Pan Rail Aligner (A) onto rear pan rail
(as shown) using two cap screws provided. Tighten
cap screws securely.
UN05DEC97
RG8162
RG8163
UN05DEC97
Specification
Rear Oil Seal Housing Cap
ScrewsTorque .............................................................. 25 Nm (18 lb-ft)
UN20MAY98
RG8816
02
040
32
NOTE: Clean all gasket material and sealant from oil pan
gasket rail prior to installing rear seal housing for
proper housing alignment.
RG,RG34710,177 1913AUG991/1
CTM100 (30AUG07)
02-040-32
PN=230
02
040
33
RG8164
UN05DEC97
RG8165
RG8810
UN20MAY98
CTM100 (30AUG07)
RG,RG34710,178 1913AUG991/1
02-040-33
PN=231
UN10DEC97
RG8788
3. Install JDG977 Pan Rail Aligner (A) onto front pan rail
(as shown) using cap screws provided. Tighten cap
screws securely.
NOTE: If necessary, guide pins may be used to ensure
correct gasket (B, earlier engines) and timing gear
cover (C) alignment with mounting holes.
UN10DEC97
RG8786
02
040
34
CTM100 (30AUG07)
02-040-34
RG,RG34710,179 1905SEP021/6
PN=232
RG,RG34710,179 1905SEP022/6
RG8790
UN11DEC97
Specification
Timing Gear Cover Cap Screws
(Early Engines Only)1Initial
Torque ............................................................................. 45 Nm (33 lb-ft)
UN20MAY98
RG8812
Initial torque is required only on early timing gear covers using Fel-Pro
gaskets with sealant.
Continued on next page
CTM100 (30AUG07)
02-040-35
RG,RG34710,179 1905SEP023/6
PN=233
02
040
35
UN05NOV99
RG10268
02
040
36
CTM100 (30AUG07)
02-040-36
RG,RG34710,179 1905SEP024/6
PN=234
02
040
37
UN05NOV99
Specification
Camshaft Gear Access Cover
Cap Screws (Early Engines
Only)1Initial Torque ...................................................... 50 Nm (37 lb-ft)
RG10268
RG8811
UN20MAY98
AGasket
BM10 x 110 mm
CA/C Compressor Bracket
DM10 x 130 mm (w/Compressor Bracket)
M10 x 110 mm (w/o Compressor Bracket)
EM10 x 30 mm (005482 )
M10 x 100 mm ( 005481)
FM10 x 100 mm (005482 )
M120 x 30 mm ( 005481)
GM10 x 100 mm
HFlange Nut
IM10 x 100 mm (005482 )
M10 x 30 mm ( 005481)
JCamshaft Gear Access Cover
Camshaft Gear Cover Torque Sequence
Initial torque is required only on early timing gear covers using Fel-Pro
gaskets with sealant.
Continued on next page
CTM100 (30AUG07)
02-040-37
RG,RG34710,179 1905SEP025/6
PN=235
02
040
38
Specification
Adjustable Fan Drive Assembly
Mounting Cap ScrewsTorque ...................................... 90 Nm (66 lb-ft)
RG,RG34710,179 1905SEP026/6
CTM100 (30AUG07)
02-040-38
PN=236
02
040
39
UN09DEC97
RG8422
UN09DEC97
RG8423
CTM100 (30AUG07)
02-040-39
RG,RG34710,180 1913AUG991/4
PN=237
UN09DEC97
RG8424
UN20MAY98
RG8535
02
040
40
CTM100 (30AUG07)
02-040-40
RG,RG34710,180 1913AUG992/4
PN=238
02
040
41
RG8425
UN09DEC97
RG8426
CTM100 (30AUG07)
02-040-41
RG,RG34710,180 1913AUG993/4
PN=239
UN21MAY98
Specification
Damper Hub Cap Screws
Torque ........................................................................... 125 Nm (92 lb-ft)
Specification
Pulley-to-Damper Cap Screws
Torque ........................................................................... 125 Nm (92 lb-ft)
RG8175
RG10247
UN30JUL99
Specification
Front Oil Seal Cap Screws
Torque ............................................................................. 15 Nm (11 lb-ft)
UN20MAY98
RG8809
02
040
42
RG,RG34710,180 1913AUG994/4
CTM100 (30AUG07)
02-040-42
PN=240
2. Install oil pan and service engine with clean engine oil.
(See INSTALL ENGINE OIL PAN, in Group 060.)
3. Fill cooling system with proper coolant (See DIESEL
ENGINE COOLANT RECOMMENDATIONS in Section
01, Group 002.)
4. Perform engine break-in. (See ENGINE BREAK-IN
GUIDELINES in Group 010.)
RG,RG34710,182 1913AUG991/1
CTM100 (30AUG07)
02-040-43
PN=241
02
040
44
CTM100 (30AUG07)
02-040-44
PN=242
Group 050
RG8811
UN20MAY98
02
050
1
RG,RG34710,188 1930SEP971/1
CTM100 (30AUG07)
02-050-1
PN=243
UN05DEC97
RG8228A
UN05DEC97
RG8227D
UN30OCT00
RG11165
02
050
2
CTM100 (30AUG07)
02-050-2
RG,RG34710,189 1913AUG991/3
PN=244
02
050
3
RG,RG34710,189 1913AUG992/3
UN06DEC97
RG8251C
UN05DEC97
RG8227D
Specification
Camshaft Gear Retainer
Plate-to-CamshaftInitial Torque ................................. 100 Nm (74 lb-ft)
Second Torque ............................................................ 150 Nm (110 lb-ft)
Final Retorque ............................................................. 150 Nm (110 lb-ft)
RG,RG34710,189 1913AUG993/3
CTM100 (30AUG07)
02-050-3
PN=245
RG8228A
UN05DEC97
UN05DEC97
RG8227D
UN30OCT00
RG11165
02
050
4
CTM100 (30AUG07)
02-050-4
RE38635,000015A 1923OCT061/6
PN=246
02
050
5
RE38635,000015A 1923OCT062/6
UN05DEC97
RG8237
Specification
Upper Idler Gear Thrust Plate
Cap ScrewsInitial Torque............................................. 35 Nm (26 lb-ft)
CTM100 (30AUG07)
02-050-5
RE38635,000015A 1923OCT063/6
PN=247
RG8791
UN17NOV00
02
050
6
CIdler Gear
ECamshaft Gear
Specification
Camshaft Gear-to-Upper Idler
GearBacklash ................................................... 0.13 mm (0.005 in.)
Oil Pump Gear-to-Upper Idler
GearBacklash ................................................... 0.25 mm (0.010 in.)
CTM100 (30AUG07)
02-050-6
RE38635,000015A 1923OCT064/6
PN=248
UN16SEP02
RG12422
10. Remove three idler gear carrier cap screws (C), one
at a time, and apply LOCTITE 242 Thread Lock and
Sealer. Re-install and tighten to specifications.
Specification
Upper Idler Cap ScrewsTorque
Turn ....................................................................... 40 Nm (30 lb-ft) + 45
CTM100 (30AUG07)
02-050-7
RE38635,000015A 1923OCT065/6
PN=249
02
050
7
Specification
Camshaft Gear Retainer
Plate-to-CamshaftSecond
Torque ......................................................................... 150 Nm (110 lb-ft)
RG8813
02
050
8
15. Remove two lower idler gear thrust plate cap screws
and backlash template and rotate engine flywheel to
remove shims. Apply LOCTITE 242 Thread Lock and
Sealer to two cap screws. Re-install and tighten to
specifications.
Specification
Upper Idler Gear Thrust Plate
Cap ScrewsFinal Torque ............................................. 35 Nm (26 lb-ft)
CTM100 (30AUG07)
RE38635,000015A 1923OCT066/6
02-050-8
PN=250
UN10DEC97
RG8544A
RG,RG34710,191 1925OCT001/14
RG8288
UN21MAY98
CTM100 (30AUG07)
02-050-9
RG,RG34710,191 1925OCT002/14
PN=251
UN06DEC97
RG8251A
UN06DEC97
RG8286B
UN30JUL99
ACamshaft Holder
RG10243
02
050
10
CTM100 (30AUG07)
02-050-10
RG,RG34710,191 1925OCT004/14
PN=252
02
050
11
RG8822B
RG,RG34710,191 1925OCT005/14
RG8289A
UN06DEC97
ACamshaft Pilot
CTM100 (30AUG07)
02-050-11
RG,RG34710,191 1925OCT006/14
PN=253
UN30JUL99
RG10244
02
050
12
CTM100 (30AUG07)
02-050-12
RG,RG34710,191 1925OCT007/14
PN=254
RG10245
UN30JUL99
CTM100 (30AUG07)
02-050-13
RG,RG34710,191 1925OCT008/14
PN=255
02
050
13
RG8289
UN21MAY98
02
050
14
CTM100 (30AUG07)
02-050-14
RG,RG34710,191 1925OCT009/14
PN=256
UN11DEC97
RG8822A
Specification
Camshaft and Supply Pump Drive
Coupler Set ScrewTorque ............................................... 4 Nm (3 lb-ft)
Installing Supply Pump Drive Coupler
Specification
Fuel Supply Pump-to-Cylinder
HeadTorque ................................................................. 50 Nm (37 lb-ft)
CTM100 (30AUG07)
02-050-15
RG,RG34710,191 1925OCT0010/14
PN=257
RG10243
UN30JUL99
02
050
16
RG,RG34710,191 1925OCT0011/14
UN06DEC97
Specification
Camshaft Thrust Ring-to-Head
Torque ............................................................................. 35 Nm (26 lb-ft)
RG8286A
CTM100 (30AUG07)
02-050-16
RG,RG34710,191 1925OCT0012/14
PN=258
02
050
17
RG8228A
UN05DEC97
RG,RG34710,191 1925OCT0013/14
UN06DEC97
RG8251B
ACamshaft Gear
BRetainer Washer
RG,RG34710,191 1925OCT0014/14
CTM100 (30AUG07)
02-050-17
PN=259
RG10344
DPSG,OUO1004,1021 1908SEP991/1
RG8385B
UN09DEC97
UN21MAY98
AIntake Lobe
BExhaust Lobe
CUnit Injector Lobe
DBushing Journal
RG8388
02
050
18
CTM100 (30AUG07)
02-050-18
PN=260
RG8341
02
050
19
RG8331
UN21MAY98
Specification
Camshaft JournalOD ......................................... 101.987102.013 mm
(4.01524.0162 in.)
Camshaft BushingID .......................................... 102.091102.167 mm
(4.01934.0223 in.)
Camshaft Journal-to-BushingOil
Clearance ...................................................................... 0.0780.180 mm
(0.00310.0071 in.)
Camshaft BushingBore in Head ........................ 105.987106.013 mm
(4.17274.1737 in.)
RG,RG34710,193 1913AUG991/1
CTM100 (30AUG07)
02-050-19
PN=261
UN21MAY98
RG8387
UN21MAY98
Camshaft LobeSpecification
Intake LobeLift ................................. 8.738.99 mm (0.3430.353 in.)
Exhaust LobeLift .............................. 7.938.19 mm (0.3120.322 in.)
EUI Lobe 10.5 L Engines and
12.5 L Engines ( 29999)Lift ........... 14.1614.42 mm (0.5570.567
in.)
EUI Lobe 12.5 L Engine S.N.
(30000 )Lift ..................................... 16.0916.35 mm (0.6330.643
in.)
RG8386
RG8385A
02
050
20
RG,RG34710,195 1930SEP971/1
CTM100 (30AUG07)
02-050-20
PN=262
RG8333
UN09DEC97
CTM100 (30AUG07)
02-050-21
RG,RG34710,196 1925OCT001/7
PN=263
RG,RG34710,196 1925OCT002/7
UN09DEC97
RG8334
02
050
22
ANotch Alignment
BAlignment Sleeve
CBushing Installer
CTM100 (30AUG07)
02-050-22
RG,RG34710,196 1925OCT003/7
PN=264
02
050
23
RG8335
UN09DEC97
RG8336
AAlignment Groove
BJDG968-3 Guide
CJDG968-5 Alignment Pin
RG,RG34710,196 1925OCT004/7
RG8337
AAlignment Pin
CTM100 (30AUG07)
02-050-23
RG,RG34710,196 1925OCT005/7
PN=265
UN21MAY98
RG8338
UN21MAY98
RG8339
02
050
24
CTM100 (30AUG07)
02-050-24
RG,RG34710,196 1925OCT006/7
PN=266
02
050
25
RG,RG34710,196 1925OCT007/7
CTM100 (30AUG07)
02-050-25
PN=267
RG9038
UN09AUG99
02
050
26
HSnap Ring1
IBearing
JSplined Gear
KO-Ring
DCover Plate
EGasket
F"B" Adapter Housing
GO-Ring
L"A" Adapter
MGasket
NCover Plate
Specification
SAE A Front Auxiliary Drive
Adapter Housing NutsTorque ............................... 50 Nm (37 lb-ft)
SAE A Front Auxiliary Drive
Idler Gear Support Bushing
Torque................................................................... 220 Nm (162 lb-ft)
A shim may be used with snap ring (H) to set gear shaft end play.
RG,RG34710,197 1926OCT001/1
CTM100 (30AUG07)
02-050-26
PN=268
UN30OCT00
RG11166
UN30OCT00
2. Determine correct size snap ring (C) and shim (D) (if
required) to achieve 0.11 mm (0.004 in.) maximum
clearance between bearing cone and snap ring. See
parts catalog for snap ring and shim sizes.
3. Support back side of adapter housing. Press gear and
bearing assembly into housing until assembly bottoms.
IMPORTANT: Make sure oil drain port (H) is
positioned on bottom as shown.
RG11167
Three snap ring sizes and one shim size are available to set gear shaft
end play. See parts catalog for sizes and part numbers.
RG,RG34710,198 1926OCT001/1
CTM100 (30AUG07)
02-050-27
PN=269
02
050
27
UN25MAR99
RG9036
UN16NOV00
RG9037
02
050
28
RG,RG34710,199 1913AUG991/1
CTM100 (30AUG07)
02-050-28
PN=270
Group 060
Lubrication System
Oil Filter and Oil Conditioning Housing Assembly
RG10264
UN03NOV99
02
060
1
Oil Filter Base, Oil Cooler, and Valve Assembly (Remote Filter Option Shown on Lower Portion of Figure)
APressure Relief Valve
Assembly (If Equipped)
BOil Cooler Bypass Valve
Assembly
COil Cooler Cover/Valve
Housing (Remote Filter
Applications)
DPort to Remote Oil Filter
Inlet
EPort to Remote Oil Filter
Outlet
RG,RG34710,206 1928JUL991/1
CTM100 (30AUG07)
02-060-1
PN=271
Lubrication System
UN06DEC97
RG8245A
UN06DEC97
RG8247A
RG,RG34710,207 1928JUL991/1
UN19MAY98
RG8433
02
060
2
CTM100 (30AUG07)
RG,RG34710,208 1930SEP971/1
02-060-2
PN=272
Lubrication System
RG8245B
02
060
3
UN06DEC97
5. Dip all parts in clean engine oil. Insert valve and spring
assembly in housing.
6. Install plug using a new O-ring and tighten to
specifications.
Specification
Oil Pressure Regulating Valve
PlugTorque................................................................. 100 Nm (74 lb-ft)
RG,RG34710,209 1928JUL991/1
CTM100 (30AUG07)
02-060-3
PN=273
Lubrication System
UN06DEC97
RG8245C
02
060
4
5. Dip all parts in clean engine oil. Insert valve and spring
assembly in housing.
6. Install plug using a new O-ring and tighten to
specifications.
Specification
Oil Cooler Bypass Valve Plug
Torque ........................................................................... 100 Nm (74 lb-ft)
Oil Filter Bypass Valve Plug
Torque ........................................................................... 100 Nm (74 lb-ft)
RG,RG34710,210 1906NOV001/1
CTM100 (30AUG07)
02-060-4
PN=274
Lubrication System
RG8245D
02
060
5
UN06DEC97
5. Dip all parts in clean engine oil. Insert valve and spring
assembly in housing.
6. Install plug using a new O-ring and tighten securely.
RG,RG34710,211 1913AUG991/1
CTM100 (30AUG07)
02-060-5
PN=275
Lubrication System
UN06DEC97
RG8248A
UN06DEC97
AGuide Pins
BHex Socket Head Cap Screws
COil Cooler Housing
DOil Cooler
RG8249B
02
060
6
CTM100 (30AUG07)
02-060-6
RG,RG34710,212 1912AUG991/3
PN=276
Lubrication System
4. Remove two large hex nuts (D) securing oil cooler (C)
to housing (A) and remove cooler from housing.
Remove and discard gasket (B) and O-rings (E).
5. Clean all parts and flush oil cooler with solvent. Dry
with compressed air.
02
060
7
UN10DEC97
RG8771
Specification
Oil CoolerTest Pressure ........................... 140170 kPa (1.41.7 bar)
(2025 psi)
Oil Cooler and Housing Assembly
CTM100 (30AUG07)
02-060-7
RG,RG34710,212 1912AUG992/3
PN=277
Lubrication System
11. If removed, apply LOCTITE 242 Thread Lock and
Sealer to oil pressure sending unit. Install sending
unit and tighten securely.
02
060
8
RG,RG34710,212 1912AUG993/3
RG8249A
UN06DEC97
3. Install two hex socket head cap screws (B) and tighten
to specifications.
RG8248B
Specification
Oil Cooler Housing-to-Block Cap
ScrewsTorque .............................................................. 68 Nm (50 lb-ft)
CTM100 (30AUG07)
02-060-8
RG,RG34710,213 1924SEP021/2
PN=278
Lubrication System
4. Install oil filter/valve housing (or oil cooler cover/valve
housing on remote applications) using a new gasket.
Tighten cap screws to specifications using sequence
shown in lower illustration.
RG8247
02
060
9
UN21MAY98
Specification
Oil Filter/Valve Housing or Oil
Cooler Cover/Valve Housing1
Torque ............................................................................. 68 Nm (50 lb-ft)
RG8815
Specification
Remote Filter Inlet Hose or
LineTorque ............................................................... 190 Nm (140 lb-ft)
Remote Filter Outlet Hose or
LineTorque ............................................................... 142 Nm (105 lb-ft)
UN20MAY98
CTM100 (30AUG07)
02-060-9
PN=279
Lubrication System
RG8256A
RG,RG34710,214 1925OCT001/3
UN06DEC97
RG8257
02
060
10
CTM100 (30AUG07)
02-060-10
RG,RG34710,214 1925OCT002/3
PN=280
Lubrication System
5. Remove oil pump-to-cylinder block gasket (B). Discard
gasket.
AOil Pump Assembly
BOil Pump-to-Cylinder Block Gasket
RG8258B
UN06DEC97
02
060
11
RG,RG34710,214 1925OCT003/3
Specification
Oil Pump Drive Gear Bushing
ID ........................................................................ 135.70135.80 mm
(5.3435.346 in.)
RG,RG34710,215 1913AUG991/1
CTM100 (30AUG07)
02-060-11
PN=281
Lubrication System
RG8258A
RG8259
02
060
12
Specification
Oil Pump-to-Block Cap Screws
Initial Torque ................................................................. 20 Nm (177 lb-in.)
CTM100 (30AUG07)
02-060-12
RG,RG34710,216 1924SEP021/2
PN=282
Lubrication System
4. Second: Starting with first cap screw tightened, apply
90 torque turn to each cap screw.
Specification
Oil Pump-to-Block Cap Screws
Torque Turn .......................................................................... 90 (1/4 Turn)
UN30AUG02
RG12611
02
060
13
90 Torque Turn
RG8256
Specification
Oil Pump Drive Gear-to-Idler
GearBacklash.......................................................... 0.25 mm (0.010 in.)
RG,RG34710,216 1924SEP022/2
RG8819
2. Remove all 30 oil pan cap screws and remove oil pan
from cylinder block.
Removing Oil Pan
4. Clean all oil from oil pan and cylinder block sealing
surfaces and dry completely.
RG,RG34710,217 1930SEP971/1
CTM100 (30AUG07)
02-060-13
PN=283
Lubrication System
RG8122
02
060
14
RG,RG34710,218 1913AUG991/1
CTM100 (30AUG07)
02-060-14
PN=284
Lubrication System
RG10273A
UN03APR02
UN06AUG99
RG10274
CTM100 (30AUG07)
AFront T-Joints
CRear T-Joints
02-060-15
RG,RG34710,219 1924SEP021/2
PN=285
02
060
15
Lubrication System
NOTE: Locate rear of oil pan flush to 0.05 mm
(0.002 in.) with rear face of cylinder block.
Specification
Oil Pan-to-Cylinder Block Cap
ScrewsTorque .................................... 25 Nm (18.5 lb-ft) plus 90 Turn
Clockwise
UN20MAY98
Specification
Oil Pan Drain Plug 1-1/4 in. Hex
PlugTorque................................................................... 46 Nm (34 lb-ft)
Oil Pan Drain Plug 1-1/2 in. Hex
PlugTorque................................................................... 64 Nm (47 lb-ft)
RG8817
02
060
16
CTM100 (30AUG07)
RG,RG34710,219 1924SEP022/2
02-060-16
PN=286
Group 070
Cooling System
Replace Bearings in Fan Drive Assembly
RG12423
UN17SEP02
02
070
1
CSnap Ring
DBall Bearing (2 used)
EShaft
HPipe Plug
IPlug
CTM100 (30AUG07)
02-070-1
RG,RG34710,224 1917SEP021/5
PN=287
Cooling System
02
070
2
Specification
Heavy Duty Fan Drive
Housing ID .......................................................... 71.99972.025 mm
(2.83462.8356 in.)
Shaft OD ............................................................. 35.00135.017 mm
(1.37801.3786 in.)
Bearing ID ........................................................... 34.98735.013 mm
(1.37741.3785 in.)
Bearing OD ......................................................... 71.98772.013 mm
(2.83412.8351 in.)
CTM100 (30AUG07)
02-070-2
RG,RG34710,224 1917SEP022/5
PN=288
Cooling System
RG12423
UN17SEP02
02
070
3
CSnap Ring
DBall Bearing (2 used)
EShaft
HPipe Plug
IPlug
Specification
Fan Drive ShaftEnd Play ................................. 0.10 mm (0.004 in.)
CTM100 (30AUG07)
02-070-3
RG,RG34710,224 1917SEP023/5
PN=289
Cooling System
UN20MAY98
RG8811
02
070
4
Specification
Fan Drive Hub-to-ShaftTorque .................................. 115 Nm (85 lb-ft)
CTM100 (30AUG07)
02-070-4
RG,RG34710,224 1917SEP024/5
PN=290
Cooling System
To install fixed fan drive/camshaft gear access cover
assembly, see INSTALL TIMING GEAR COVER in Group
040.
RG,RG34710,224 1917SEP025/5
RG8728
UN10DEC97
UN10DEC97
RG8729
Specification
Belt Tensioner Lower Spring
Tension ............................................................. 8199 Nm (6073 lb-ft)
CTM100 (30AUG07)
02-070-5
RG,RG34710,225 1930SEP971/2
PN=291
02
070
5
Cooling System
Checking Upper Tensioner Spring Tension
UN10DEC97
RG8727
UN10DEC97
RG8726
02
070
6
RG,RG34710,225 1930SEP972/2
CTM100 (30AUG07)
02-070-6
PN=292
Cooling System
UN30JUL99
RG10270
CTM100 (30AUG07)
02-070-7
RG,RG34710,226 1918SEP021/2
PN=293
Cooling System
7. Install belt and position onto tensioner.
02
070
8
RG,RG34710,226 1918SEP022/2
RG8246
UN06DEC97
RG,RG34710,227 1917SEP021/2
UN26JUL99
RG8825
RG8261B
UN06DEC97
CTM100 (30AUG07)
02-070-8
PN=294
Cooling System
UN10DEC97
02
070
9
RG8467
RE38635,0000167 1915NOV061/1
CTM100 (30AUG07)
02-070-9
PN=295
Cooling System
RG8261A
02
070
10
CTM100 (30AUG07)
RE38635,0000168 1915NOV061/1
02-070-10
PN=296
Cooling System
Remove Thermostats
RG8239A
02
070
11
UN05DEC97
UN05DEC97
AThermostat Cover
BGasket
RG8242A
RG,RG34710,232 1917SEP021/1
CTM100 (30AUG07)
02-070-11
PN=297
Cooling System
Install Thermostats
UN05DEC97
RG8242B
Install Thermostats
UN05DEC97
RG8239B
02
070
12
Specification
Thermostat Cover/Housing
Assembly-to-Block Cap Screws
Torque ............................................................................. 50 Nm (37 lb-ft)
AWiggle Wire
BGasket
CM10 x 35 Cap Screw
RG,RG34710,233 1924SEP021/1
CTM100 (30AUG07)
02-070-12
PN=298
Cooling System
UN23NOV97
Specification
Thermostat TestRating ...................................................... 82C (180F)
Initial Opening (Range)
Temperature ......................................................... 8084C (175182F)
Full Open (Nominal) Temperature ........................................ 94C (202F)
RG5971
RG,RG34710,234 1930SEP971/1
CTM100 (30AUG07)
02-070-13
PN=299
Cooling System
UN05DEC97
RG8239C
RG8241
02
070
14
CTM100 (30AUG07)
02-070-14
RG,RG34710,235 1917SEP021/2
PN=300
Cooling System
Specification
Coolant Temperature Sensor
Torque ............................................................................ 10 Nm (7.5 lb-ft)
Thermostat Housing Pipe Plugs
Torque ............................................................................. 20 Nm (15 lb-ft)
RG,RG34710,235 1917SEP022/2
TS210
UN23AUG88
UN11AUG99
6. Install cord.
RG8472
AElectrical Cord
BHeater Element
CTM100 (30AUG07)
RG,RG34710,236 1930SEP971/1
02-070-15
PN=301
02
070
15
Cooling System
02
070
16
CTM100 (30AUG07)
02-070-16
PN=302
Group 080
Oil Contamination
CTM100 (30AUG07)
02-080-1
RG,RG34710,1256 1923AUG021/2
PN=303
02
080
1
02
080
2
RG,RG34710,1256 1923AUG022/2
CTM100 (30AUG07)
02-080-2
PN=304
Remove Turbocharger
CAUTION: After operating engine, allow exhaust
system to cool before removing turbocharger.
UN05DEC97
02
080
3
RG8187B
Removing Turbocharger
AOil Inlet Line
BOil Return Pipe
RG,RG34710,241 1930SEP971/1
CTM100 (30AUG07)
02-080-3
PN=305
Problem
Possible Cause
Suggested Remedy
Bearing failure.
Manufacturing defects.
Oil in Housing
CTM100 (30AUG07)
02-080-4
OUO1004,0000C21 1929NOV001/2
PN=306
Bearing failure.
Manufacturing defect.
Foreign Object Damage
Defective casting.
Defective gasket.
OUO1004,0000C21 1929NOV002/2
CTM100 (30AUG07)
02-080-5
PN=307
02
080
5
DPSG,OUO1004,945 1928JUL991/13
RG4523
02
080
6
ACompressor Wheel
CTM100 (30AUG07)
02-080-6
DPSG,OUO1004,945 1928JUL992/13
PN=308
RG4524
UN05DEC97
DPSG,OUO1004,945 1928JUL993/13
RG8539
CTM100 (30AUG07)
02-080-7
DPSG,OUO1004,945 1928JUL994/13
PN=309
02
080
7
UN05DEC97
RG4526
DPSG,OUO1004,945 1928JUL995/13
UN10DEC97
RG8540
02
080
8
CTM100 (30AUG07)
02-080-8
DPSG,OUO1004,945 1928JUL996/13
PN=310
RG4528
UN05DEC97
DPSG,OUO1004,945 1928JUL997/13
UN05DEC97
RG4529
CTM100 (30AUG07)
02-080-9
DPSG,OUO1004,945 1928JUL998/13
PN=311
02
080
9
UN10DEC97
RG8541
DPSG,OUO1004,945 1928JUL999/13
UN05DEC97
RG4531
02
080
10
CTM100 (30AUG07)
02-080-10
DPSG,OUO1004,945 1928JUL9910/13
PN=312
RG8498A
UN10DEC97
DPSG,OUO1004,945 1928JUL9911/13
UN10DEC97
RG8498B
CTM100 (30AUG07)
02-080-11
DPSG,OUO1004,945 1928JUL9912/13
PN=313
RG8542
02
080
12
UN10DEC97
DPSG,OUO1004,945 1928JUL9913/13
CTM100 (30AUG07)
02-080-12
PN=314
02
080
13
UN20AUG99
RG10284
DPSG,OUO1004,946 1903NOV001/1
CTM100 (30AUG07)
02-080-13
PN=315
RG8497
02
080
14
Specification
Garrett Turbocharger Axial
BearingEnd Play ........................................................ 0.0250.114 mm
(0.00100.0045 in.)
Borg Warner Turbocharger Axial
BearingEnd Play .................................................... 0.06350.1143 mm
(0.00250.0045 in.)
RG,RG34710,244 1903NOV001/1
Repair Turbocharger
Turbochargers used on the engines covered in this
manual are available through service parts as a complete
remanufactured assembly only. Individual components for
repair are not available.
RG,RG34710,245 1930SEP971/1
CTM100 (30AUG07)
02-080-14
PN=316
Prelube Turbocharger
IMPORTANT: DO NOT spin the rotor assembly with
compressed air. Damage to bearings
can occur when using compressed air.
UN20MAY98
02
080
15
Fill oil inlet or drain port with clean engine oil and spin
rotating assembly (by hand) to properly lubricate bearings.
RG8543
RG,RG34710,246 1930SEP971/1
CTM100 (30AUG07)
02-080-15
PN=317
Install Turbocharger
UN05DEC97
RG8172
RG8187C
02
080
16
Specification
Turbocharger-to-Exhaust
ManifoldTorque ............................................................ 50 Nm (37 lb-ft)
Installed Turbocharger
AGuide Pins
BGasket
COil Return Pipe
DOil Inlet Line
CTM100 (30AUG07)
02-080-16
RG,RG34710,247 1913AUG991/2
PN=318
02
080
17
RG,RG34710,247 1913AUG992/2
Turbocharger Break-In
IMPORTANT: A new or repaired turbocharger DOES
NOT have an adequate oil supply for
immediate start-up of engine. Perform
the steps below to prevent damage to
turbocharger bearings.
1. Remove ECU power fuse so engine does not start.
IMPORTANT: DO NOT crank engine longer than 30
seconds at a time to avoid damage to
starter motor.
2. Crank engine over with starter motor until oil pressure
gauge needle registers within the GREEN zone of
pressure gauge.
3. Install ECU power fuse. Start and run engine at low
idle while checking oil inlet and all piping connections
for leaks.
RG,RG34710,248 1930SEP971/1
CTM100 (30AUG07)
02-080-17
PN=319
RG8130
02
080
18
CTM100 (30AUG07)
02-080-18
RG,RG34710,249 1913AUG991/3
PN=320
RG8131
UN05DEC97
02
080
19
CTM100 (30AUG07)
02-080-19
RG,RG34710,249 1913AUG992/3
PN=321
RG8132
UN05DEC97
RG8133
02
080
20
CTM100 (30AUG07)
02-080-20
RG,RG34710,249 1913AUG993/3
PN=322
RG8184B
02
080
21
CTM100 (30AUG07)
02-080-21
RG,RG34710,250 1903NOV001/2
PN=323
02
080
22
CTM100 (30AUG07)
02-080-22
RG,RG34710,250 1903NOV002/2
PN=324
RG8439
UN09DEC97
02
080
23
3. Remove coolant inlet hose (A) and outlet hose (B) from
aftercooler end connections.
RG8441
CTM100 (30AUG07)
02-080-23
RG,RG34710,251 1913AUG991/2
PN=325
Specification
Aftercooler Tube Clamp Cap
Screw (or Cap Screw with Nut)
Torque ............................................................................. 50 Nm (37 lb-ft)
RG,RG34710,251 1913AUG992/2
CTM100 (30AUG07)
02-080-24
PN=326
02
080
25
UN09DEC97
RG8446
AInlet Tube
BOutlet Tube
Specification
AftercoolerTest Pressure .......................... 140170 kPa (1.41.7 bar)
(2025 psi)
RG,RG34710,252 1913AUG991/1
CTM100 (30AUG07)
02-080-25
PN=327
02
080
26
CTM100 (30AUG07)
02-080-26
PN=328
Group 090
Fuel System
Fuel System
NOTE: Repair, operation, diagnostic, and testing
procedures on fuel systems and electronic
controls have been moved to the following
manuals:
02
090
1
OUO1004,0000C2D 1923AUG021/1
CTM100 (30AUG07)
02-090-1
PN=329
Fuel System
02
090
2
CTM100 (30AUG07)
02-090-2
PN=330
Group 100
02
100
1
UN20AUG99
RG10286
DPSG,OUO1004,1005 1923SEP021/1
CTM100 (30AUG07)
02-100-1
PN=331
RG10285
02
100
2
Starter Motor
AStarter Solenoid
Specification
Starter Motor Mounting
HardwareTorque ........................................................ 125 Nm (92 lb-ft)
DPSG,OUO1004,1006 1913AUG991/1
CTM100 (30AUG07)
02-100-2
PN=332
Section 03
Theory of Operation
Contents
Page
CTM100 (30AUG07)
03-1
03
PN=1
Contents
03
CTM100 (30AUG07)
03-2
PN=2
Group 120
RG12419
UN11SEP02
03
120
1
Engine Components
AOil Cooler
BOil Pump Drive Gear
CIdler Gear
DCamshaft Gear
ECrankshaft
FCylinder Liner
GCylinder Liner O-rings
HPiston
IPiston Rings
JConnecting Rod
CTM100 (30AUG07)
POil Filter
QCrankshaft Damper
RFlywheel
03-120-1
RG,RG34710,1518 1909SEP021/3
PN=335
03
120
2
CTM100 (30AUG07)
03-120-2
RG,RG34710,1518 1909SEP022/3
PN=336
RG,RG34710,1518 1909SEP023/3
CTM100 (30AUG07)
03-120-3
PN=337
03
120
3
L
U
N
J
K
O
I
G
C
X
CTM100 (30AUG07)
03-120-4
RG12421
UN11SEP02
RG,RG34710,1519 1916SEP021/3
PN=338
Oil is drawn from the sump via a pick-up tube (G) and
an internal passage in the cylinder block. The oil pump
sends the oil to the pressure regulating valve housing
and then to the oil cooler through an internal passage
in the cylinder block. An oil cooler relief valve (H)
protects the oil cooler during cold oil starting by
returning oil to sump. The cooler bypass valve allows
oil to bypass the cooler and flow to the filter if the oil
cooler is restricted. >From the oil cooler oil flows to the
oil filter housing and into the filter. If the filter becomes
restricted, the oil filter bypass valve will open sending
oil to the main oil galley.
CTM100 (30AUG07)
03-120-5
RG,RG34710,1519 1916SEP022/3
PN=339
03
120
5
03
120
6
RG,RG34710,1519 1916SEP023/3
CTM100 (30AUG07)
03-120-6
PN=340
03
120
7
CTM100 (30AUG07)
03-120-7
PN=341
O
P
G
I
M
F
H
G
UN11SEP02
N
K
RG12420
03
120
8
L
Cooling System
Continued on next page
CTM100 (30AUG07)
03-120-8
RG,RG34710,1521 1909SEP021/3
PN=342
IWater-to-Air Aftercooler
Supply
JWater-to-Air Aftercooler
Return
KLow Temperature Coolant
CTM100 (30AUG07)
03-120-9
RG,RG34710,1521 1909SEP022/3
PN=343
03
120
9
03
120
10
RG,RG34710,1521 1909SEP023/3
OUO1004,0000C29 1909SEP021/1
CTM100 (30AUG07)
03-120-10
PN=344
RG8428
UN09DEC97
03
120
11
DCylinder Liners
ECylinder Block
FSolid Steel Core
CTM100 (30AUG07)
03-120-11
RG,RG34710,67 1930SEP971/2
PN=345
03
120
12
RG,RG34710,67 1930SEP972/2
RG,RG34710,1522 1930SEP971/1
CTM100 (30AUG07)
03-120-12
PN=346
Turbocharger Operation
UN27MAR98
RG9098
Turbocharger Components
UN30AUG05
RG14466
RG,RG34710,1523 1930SEP971/1
CTM100 (30AUG07)
03-120-13
PN=347
03
120
13
RG8099
03
120
14
UN18NOV97
Turbocharger Lubrication
APressure Oil
BDischarge Oil
RG,RG34710,1524 1930SEP971/1
CTM100 (30AUG07)
03-120-14
PN=348
Section 04
Diagnostics
Contents
Page
CTM100 (30AUG07)
04-1
04
PN=1
Contents
04
CTM100 (30AUG07)
04-2
PN=2
Group 150
OUO1004,0000BE7 1906NOV001/1
CTM100 (30AUG07)
04-150-1
PN=351
04
150
1
DPSG,RG40854,345 1927NOV001/1
04
150
2
1/1
1/1
CTM100 (30AUG07)
04-150-2
PN=352
Check for excessive crankcase pressure. See CHECK FOR EXCESSIVE ENGINE
CRANKCASE PRESSURE (BLOW-BY) in this Group.
No fumes and no
dripping oil observed:
GO TO 3
Excessive fumes or
dripping oil observed;
appears to be caused
by boost pressure:
Check the turbocharger,
repair/replace as needed.
See TURBOCHARGER
FAILURE ANALYSIS in
Section 02, Group 080.
Excessive fumes or
dripping oil observed;
does not appear to be
caused by boost
pressure:
04
Excessive blow-by, not
caused by boost pressure 150
3
is most likely caused by
faulty piston rings/cylinder
liners not providing an
adequate combustion
seal.
Perform a compression
test to verify this. See
DST ENGINE TEST
INSTRUCTIONS RELATIVE
COMPRESSION TEST in
CTM115, Section 04,
Group 160. OR See DST
ENGINE TEST
INSTRUCTIONS RELATIVE
COMPRESSION TEST in
CTM188, Section 04,
Group 160
1/1
Check for turbocharger oil seal leaks. See CHECK FOR TURBOCHARGER OIL SEAL
LEAK in this Group.
1/1
CTM100 (30AUG07)
04-150-3
PN=353
At this point, the most likely cause of the excessive oil consumption is one of the
following failures in the pistons, rings, and/or cylinder liners or in the valve guides.
Check the most likely item as needed:
1/1
04
150
4
CTM100 (30AUG07)
04-150-4
PN=354
Problem
Solution
OUO1004,0000C30 1912DEC001/1
CTM100 (30AUG07)
04-150-5
PN=355
04
150
5
Problem
Solution
Incorrect oil
04
150
6
RG,RG34710,1542 1927NOV001/1
CTM100 (30AUG07)
04-150-6
PN=356
Problem
Solution
Engine overloaded
Defective thermostat(s)
RG,RG34710,1543 1927NOV001/1
CTM100 (30AUG07)
04-150-7
PN=357
04
150
7
Problem
Solution
Defective thermostat(s)
OUO1004,0000C4C 1921DEC001/1
Symptom
Problem
Solution
OUO1004,0000C4B 1921DEC001/1
CTM100 (30AUG07)
04-150-8
PN=358
Dynamometer Test
1. Connect engine to dynamometer using
manufacturers instructions.
04
150
9
RG,RG34710,1062 1913OCT001/1
CTM100 (30AUG07)
04-150-9
PN=359
CTM100 (30AUG07)
OUO1004,0000C2A 1905DEC001/1
04-150-10
PN=360
RG8531
Specification
Engine OilMinimum Pressure at
No Load (Idle)................................................. 138 kPa (1.38 bar) (20 psi)
Maximum Pressure at Full Load
(Rated Speed) .................................................. 310 kPa (3.1 bar) (45 psi)
UN30NOV99
04
150
11
RG10633
CTM100 (30AUG07)
04-150-11
PN=361
UN23MAR06
RG14810
04
150
12
CTM100 (30AUG07)
04-150-12
DPSG,RG40854,282 1927MAR061/2
PN=362
1. Attach one end of the hose to the crankcase outlet and the other end to a fixed panel,
brace or other surface. ( there must be at least 12 of vertical hose on each side of the
U tube)
2. Make sure both ends are not pinched closed restricting the pressure measurement.
3. Pour enough anti freeze or water into the tube to allow at least 3 in.of the liquid on
each vertical side of the U tube.
4. When the liquid has settled in the tube mark the high point on both sides.
Go to step # 2
2. Measure
crankcase
pressure
1. Start the engine, let it stabilize and mark the liquid level line.
2. Go to high idle, let it stabilize and mark the liquid level line.
3. Slowly load the engine if possible to approximately 25% load, let the liquid stabilize and
mark the level line. Did the liquid raise more then 2 inches on one side of the tube?
Yes: go to step # 3
No: The crank case
pressure meets John
Deere application
guidelines, return to the
previous diagnostic
procedure or the customer.
3. Turbo Test
1. Remove the Turbo oil drain line and install a long remote drain line.
2. Plug the opening where the turbo drain line entered the crank case. ( this will keep
crankcase pressure from escaping at this point)
3. Take a clean 5 gallon bucket, put about a gallon of oil in the bottom. Put the open end
of the long turbo drain line in the oil. If there is any combustion gas escaping from the
turbo charger it may show up as bubbles in the oil.
4. Check the engine oil level making sure it is at the full level. Then monitor the oil level in
the bucket to avoid oil spills.
5. Start the engine and go to fast idle slowly increase the load to about 25%. 5: when
stabilized check crankcase pressure. Was the liquid height increase still greater then 2
inches?
DPSG,RG40854,282 1927MAR062/2
CTM100 (30AUG07)
04-150-13
PN=363
04
150
13
UN30NOV99
RG10634
NOTE: The intake tube from the air cleaner (not included
in picture) would not have to be removed for this
test.
AIntake Hose
BExhaust Flange
COil Return Line
DPSG,RG40854,283 1910AUG991/1
CTM100 (30AUG07)
04-150-14
PN=364
UN23NOV97
RG5971
Rating
71C (160F)
77C (170F)
82C (180F)
89C (192F)
90C (195F)
92C (197F)
96C (205F)
99C (210F)
Full Open
(Nominal)
84C (182F)
89C (192F)
94C (202F)
101C (214F)
103C (218F)
105C (221F)
100C (213F)
111C (232F)
RG,RG34710,1548 1924SEP021/1
CTM100 (30AUG07)
04-150-15
PN=365
04
150
15
UN20JAN93
RG6557
UN20JAN93
RG6558
04
150
16
CTM100 (30AUG07)
04-150-16
DPSG,RG40854,284 1924SEP021/2
PN=366
04
150
17
Test pressures recommended are for all Deere OEM cooling systems.
On specific vehicle applications, test cooling system and pressure cap
according to the recommended pressure for that vehicle.
DPSG,RG40854,284 1924SEP022/2
CTM100 (30AUG07)
04-150-17
PN=367
RG8429
UN19MAY98
Head Gasket
04
150
18
ACombustion Seals
(Flanges)
BGasket Body
CFront of Engine
CTM100 (30AUG07)
04-150-18
DPSG,RG40854,281 1927NOV001/2
PN=368
Engine overheating.
Power loss.
Engine runs rough.
White exhaust smoke.
Loss of cab heat.
Gasket section dislodged, missing (blown).
Coolant in cylinder.
Coolant in crankcase oil.
Low coolant level.
Possible Causes:
Insufficient liner standout.
Excessive liner standout differential between
cylinders.
Low head bolt clamping loads.
Rough/damaged liner flange surface.
Cracked/deformed gasket combustion flange.
Out-of-flat/damaged/rough cylinder head surface.
Missing/mislocated gasket firing ring.
Block cracked in liner support area.
Excessive fuel delivery.
Hydraulic or mechanical disturbance or combustion
seal.
NOTE: Cracked cylinder head or liners may also allow
combustion gas leakage into coolant.
Symptoms:
Possible Causes:
Excessive liner standout
Excessive liner standout differential between
cylinders.
Low head bolt clamping loads
Out-of-flat/damaged/rough block surface.
Out-of-flat/damaged/rough cylinder head surface.
Oil or coolant overheating.
Cracks/creases in gasket body surfaces.
Damage/voids in elastomer beading.
Damaged/missing O-ring seal at oil port to rocker
arms.
If above symptoms are found, see HEAD GASKET
INSPECTION AND REPAIR SEQUENCE in Section
02, Group 020.
NOTE: Defective oil cooler may also allow oil leakage
into coolant.
Possible Causes:
DPSG,RG40854,281 1927NOV002/2
CTM100 (30AUG07)
04-150-19
PN=369
04
150
20
RG8800
UN26NOV97
RG,RG34710,1549 1924SEP021/1
CTM100 (30AUG07)
04-150-20
PN=370
RG10660
UN14DEC99
04
150
21
BMuffler
CRain Cap
DIntake Piping
DPSG,RG40854,285 1910AUG991/1
CTM100 (30AUG07)
04-150-21
PN=371
T5906AP
UN23FEB89
UN14DEC99
RG10664
04
150
22
Air Filter
Intake Plug
AIntake Plug
Specification
Intake ManifoldTest Pressure ............. 13.820.8 kPa (0.130.21 bar)
(23 psi)
DPSG,RG40854,286 1907NOV001/1
CTM100 (30AUG07)
04-150-22
PN=372
RG10651
UN30NOV99
04
150
23
BExhaust Manifold
CTurbocharger Gasket
DPSG,RG40854,287 1910AUG991/1
CTM100 (30AUG07)
04-150-23
PN=373
RG8228A
UN05DEC97
UN05DEC97
RG8227D
ATiming Pin
BFlywheel Turning Tool
CTiming Pin
DSingle Timing Slot
EDouble Timing Slot
RG11165
04
150
24
CTM100 (30AUG07)
04-150-24
DPSG,RG40854,357 1906NOV001/2
PN=374
RG10290
UN24AUG99
RG10380
UN19OCT99
DPSG,RG40854,466 1907NOV001/1
CTM100 (30AUG07)
04-150-25
PN=375
04
150
25
04
150
26
CTM100 (30AUG07)
04-150-26
PN=376
Section 05
Page
05
05-1
PN=1
Contents
05
CTM100 (30AUG07)
05-2
PN=2
Group 170
Name
Use
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
OUO1082,0000251 1919SEP021/1
OUO1004,0000BC3 1901NOV001/16
RG7056 UN17JUN05
JDG820
OUO1004,0000BC3 1901NOV002/16
RG8519
UN20MAY98
JDG971
Continued on next page
CTM100 (30AUG07)
05-170-1
OUO1004,0000BC3 1901NOV003/16
PN=379
OUO1004,0000BC3 1901NOV004/16
RG8502A
05
170
2
UN10MAR04
JDG970A
OUO1004,0000BC3 1901NOV005/16
RG6246 UN05DEC97
CTM100 (30AUG07)
05-170-2
OUO1004,0000BC3 1901NOV006/16
PN=380
OUO1004,0000BC3 1901NOV007/16
RG5061 UN05DEC97
D01168AA
05
170
3
OUO1004,0000BC3 1901NOV008/16
RG5065 UN05DEC97
OUO1004,0000BC3 1901NOV009/16
RG5067 UN06APR89
CTM100 (30AUG07)
05-170-3
OUO1004,0000BC3 1901NOV0010/16
PN=381
JDE41296
OUO1004,0000BC3 1901NOV0011/16
RG5066 UN23AUG88
OUO1004,0000BC3 1901NOV0012/16
RG8507
UN15SEP99
CTM100 (30AUG07)
05-170-4
OUO1004,0000BC3 1901NOV0013/16
PN=382
RG10265
UN29JUL99
JDG1184
05
170
5
OUO1004,0000BC3 1901NOV0014/16
RG8508 UN20MAY98
Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG978
Used to restore threaded holes in cylinder block for
cylinder head cap screws.
JDG978
OUO1004,0000BC3 1901NOV0015/16
RG7029 UN05DEC97
OUO1004,0000BC3 1901NOV0016/16
CTM100 (30AUG07)
05-170-5
PN=383
OUO1004,0000BC4 1901NOV001/9
OUO1004,0000BC4 1901NOV002/9
05
170
6
Plastic Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean valve guides.
OUO1004,0000BC4 1901NOV003/9
OUO1004,0000BC4 1901NOV004/9
OUO1004,0000BC4 1901NOV005/9
OUO1004,0000BC4 1901NOV006/9
Eccentrimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measure valve seat runout.
CTM100 (30AUG07)
05-170-6
OUO1004,0000BC4 1901NOV007/9
PN=384
OUO1004,0000BC4 1901NOV009/9
Name
Use
T43514 (U.S.)
TY9475 (Canadian)
277 (LOCTITE)
Plastic Gasket
AR44402 (U.S.)
JDT405 (U.S.)
TY24311 (U.S.)
CXTY24311 (Canadian)
222 (LOCTITE)
CTM100 (30AUG07)
OUO1004,0000BC5 1901NOV001/1
05-170-7
PN=385
05
170
7
OUO1004,0000BCC 1902NOV001/16
RG7029 UN05DEC97
JDG451
05
170
8
1
A dial indicator is not supplied with JDG451. Use D17526CI (English,
in.) or D17527CI (Metric, mm) Dial Indicator with JDG451.
OUO1004,0000BCC 1902NOV002/16
RG6246 UN05DEC97
OUO1004,0000BCC 1902NOV003/16
RG5019 UN05DEC97
D01073AA
CTM100 (30AUG07)
05-170-8
OUO1004,0000BCC 1902NOV004/16
PN=386
RG10280
UN13AUG99
JDG1145
OUO1004,0000BCC 1902NOV005/16
RG5074 UN07NOV97
D17006BR
05
170
9
OUO1004,0000BCC 1902NOV006/16
RG7406
UN21MAY98
JDG967
CTM100 (30AUG07)
05-170-9
OUO1004,0000BCC 1902NOV007/16
PN=387
OUO1004,0000BCC 1902NOV008/16
RG8516 UN20MAY98
OUO1004,0000BCC 1902NOV009/16
RG8517 UN20MAY98
CTM100 (30AUG07)
05-170-10
OUO1004,0000BCC 1902NOV0010/16
PN=388
5
36104
7
4
10
RG5078
UN25APR02
JDE98A
OUO1004,0000BCC 1902NOV0011/16
UN29JAN93
RG6612
JDG782
OUO1004,0000BCC 1902NOV0012/16
RG5075
UN07NOV97
D17015BR
CTM100 (30AUG07)
05-170-11
OUO1004,0000BCC 1902NOV0013/16
PN=389
05
170
11
Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG978
Used to restore threaded holes in cylinder block for
cylinder head cap screws.
JDG978
OUO1004,0000BCC 1902NOV0014/16
UN20MAY98
RG8515
05
170
12
JDG1017
OUO1004,0000BCC 1902NOV0015/16
RG5698
UN05DEC97
JT05993
OUO1004,0000BCC 1902NOV0016/16
CTM100 (30AUG07)
05-170-12
PN=390
OUO1004,0000BC9 1901NOV001/4
OUO1004,0000BC9 1901NOV002/4
05
170
13
OUO1004,0000BC9 1901NOV003/4
OUO1004,0000BC9 1901NOV004/4
CTM100 (30AUG07)
05-170-13
PN=391
Name
Use
PLASTIGAGE
AR54749 (U.S.)
Soap Lubricant
JDT405 (U.S.)
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
(U.S.)
05
170
14
CTM100 (30AUG07)
OUO1004,0000BCA 1901NOV001/1
05-170-14
PN=392
OUO1004,0000BD0 1902NOV001/9
RG6246 UN05DEC97
05
170
15
OUO1004,0000BD0 1902NOV002/9
RG7056 UN17JUN05
RG8513
UN13AUG99
JDG1020
CTM100 (30AUG07)
05-170-15
OUO1004,0000BD0 1902NOV004/9
PN=393
RG8521
UN20MAY98
JDG996
OUO1004,0000BD0 1902NOV005/9
RG8510 UN20MAY98
JDG977
OUO1004,0000BD0 1902NOV006/9
UN20MAY98
RG8511
05
170
16
JDG975
CTM100 (30AUG07)
05-170-16
OUO1004,0000BD0 1902NOV007/9
PN=394
UN13AUG99
RG8512
JDG974A
OUO1004,0000BD0 1902NOV008/9
RG8509 UN13AUG99
OUO1004,0000BD0 1902NOV009/9
OUO1004,0000BD1 1902NOV001/4
CTM100 (30AUG07)
05-170-17
OUO1004,0000BD1 1902NOV003/4
PN=395
OUO1004,0000BD1 1902NOV004/4
05
170
18
Name
Use
(U.S.)
(U.S.)
PLASTIGAGE
TY15969 (U.S.)
TY9479 (Canadian)
680 (LOCTITE)
TY16285 (U.S.)
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
TY6304 (U.S.)
TY9484 (Canadian)
515 (LOCTITE)
Flexible Sealant
CTM100 (30AUG07)
OUO1004,0000BD2 1902NOV001/1
05-170-18
PN=396
OUO1004,0000BD4 1902NOV001/8
RG7056 UN17JUN05
JDG820
05
170
19
OUO1004,0000BD4 1902NOV002/8
RG8519
UN20MAY98
JDG971
OUO1004,0000BD4 1902NOV003/8
RG8520
UN20MAY98
JDG993
Continued on next page
CTM100 (30AUG07)
05-170-19
OUO1004,0000BD4 1902NOV004/8
PN=397
OUO1004,0000BD4 1902NOV005/8
RG8504 UN20MAY98
OUO1004,0000BD4 1902NOV006/8
RG8505
UN13AUG99
JDG968
CTM100 (30AUG07)
05-170-20
OUO1004,0000BD4 1902NOV007/8
PN=398
RG9040
UN21MAY98
JDG1144
OUO1004,0000BD4 1902NOV008/8
05
170
21
OUO1004,0000BD5 1902NOV001/2
OUO1004,0000BD5 1902NOV002/2
CTM100 (30AUG07)
05-170-21
PN=399
Name
Use
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
OUO1004,0000BD6 1902NOV001/1
05
170
22
CTM100 (30AUG07)
05-170-22
PN=400
OUO1022,0000008 1925OCT001/2
RG5061 UN05DEC97
D01168AA
05
170
23
OUO1022,0000008 1925OCT002/2
CTM100 (30AUG07)
05-170-23
PN=401
05
170
24
Number
Name
Use
T43513 (U.S.)
TY9474 (Canadian)
271 (LOCTITE)
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
TY16285 (U.S.)
CXTY16285 (Canadian)
7649 (LOCTITE)
TY16021 (U.S.)
TY9484 (Canadian)
17430 (LOCTITE)
TY9375 (U.S.)
TY9480 (Canadian)
592 (LOCTITE)
Pipe Sealant
OUO1022,0000009 1925OCT001/1
CTM100 (30AUG07)
05-170-24
PN=402
OUO1022,000000B 1926OCT001/2
RG6219
UN06MAR92
JDG743A
OUO1022,000000B 1926OCT002/2
Name
Use
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
TY9375 (U.S.)
TY9480 (Canadian)
592 (LOCTITE)
Pipe Sealant
CTM100 (30AUG07)
OUO1022,000000C 1918SEP021/1
05-170-25
PN=403
05
170
25
OUO1004,0000C2C 1906DEC001/2
RG6246 UN05DEC97
05
170
26
OUO1004,0000C2C 1906DEC002/2
Name
Use
PT569 (U.S.)
NEVER-SEEZ Compound
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
CTM100 (30AUG07)
05-170-26
DPSG,OUO1004,954 1929JUL991/1
PN=404
DPSG,OUO1004,861 1928APR991/2
RW17441 UN16NOV89
JDE80
05
170
27
DPSG,OUO1004,861 1928APR992/2
CTM100 (30AUG07)
05-170-27
PN=405
05
170
28
CTM100 (30AUG07)
05-170-28
PN=406
Group 180
OUO1004,0000C1D 1927NOV001/6
UN29JAN93
RG6612
05
180
1
JDG782
OUO1004,0000C1D 1927NOV002/6
R26406N
UN29NOV88
D05104ST
CTM100 (30AUG07)
05-180-1
OUO1004,0000C1D 1927NOV003/6
PN=407
JDG820
OUO1004,0000C1D 1927NOV004/6
UN20MAY98
RG8519
JDG971
OUO1004,0000C1D 1927NOV005/6
UN21OCT99
RG10381
05
180
2
JDG1334
OUO1004,0000C1D 1927NOV006/6
CTM100 (30AUG07)
05-180-2
PN=408
Group 190
RG8534
UN10DEC97
05
190
1
RG,RG34710,276 1915NOV061/1
CTM100 (30AUG07)
05-190-1
PN=409
T36748N
UN24OCT88
05
190
2
RG,RG34710,277 1930SEP971/1
CTM100 (30AUG07)
05-190-2
PN=410
Section 06
Specifications
Contents
Page
06
CTM100 (30AUG07)
06-1
PN=1
Contents
06
CTM100 (30AUG07)
06-2
PN=2
Group 200
UNIT OF
MEASURE
6105AF
6105HF
6125AF
6125HF (
29999)
6125HF
(30000 )
Number of Cylinders
Fuel
Diesel
Diesel
Diesel
Diesel
Diesel
Stroke
mm
(in.)
138
(5.43)
138
(5.43)
165
(6.50)
165
(6.50)
165
(6.50)
Bore
mm
(in.)
127
(5.00)
127
(5.00)
127
(5.00)
127
(5.00)
127
(5.00)
Displacement
L
(cu in.)
10.5
(640)
10.5
(640)
12.5
(766)
12.5
(766)
12.5
(766)
Compression Ratio
16:1
16:1
16:1
16:1
17:1
Width
mm
(in.)
741
(29.2)
808
(31.8)
741
(29.2)
808
(31.8)
808
(31.8)
Height
mm
(in.)
1224
(48.2)
1239
(48.8)
1224
(48.2)
1239
(48.8)
1239
(48.8)
Length
mm
(in.)
1326
(52.2)
1326
(52.2)
1326
(52.2)
1326
(52.2)
1326
(52.2)
kg
(lb)
1211
(2665)
1200
(2640)
1216
(2675)
1205
(2650)
1205
(2650)
Physical Dimensions:
06
200
1
RG,RG34710,7615 1930OCT001/1
CTM100 (30AUG07)
06-200-1
PN=413
Bolt or
SAE Grade 2a
SAE Grade 1
b
Screw
Lubricated
Size
1/4
Lubricated
Dry
Lubricated
Dry
Lubricatedb
Nm
Dry
Nm
lb-in
Nm
lb-in
Nm
lb-in
Nm
lb-in
Nm
lb-in
Nm
lb-in
3.7
33
4.7
42
53
7.5
66
9.5
84
12
106
13.5
Nm
5/16
7.7
68
9.8
86
12
106
15.5
137
3/8
13.5
120
17.5
155
22
194
27
240
7/16
22
194
19.5
Nm
Nm
Nm
06
200
2
lb-ft
Nm
lb-ft
Nm
172
lb-ft
25
Nm
221
lb-in
120
lb-ft
Dryc
Nm
17
Nm
lb-in
150
lb-ft
28
20.5
35
26
lb-ft
35
26
44
32.5
49
36
63
46
lb-ft
28
20.5
35
26
44
32.5
56
41
70
52
80
59
100
74
53
39
67
49
85
63
110
80
120
88
155
115
lb-ft
1/2
34
25
42
31
9/16
48
35.5
60
45
76
56
95
70
125
92
155
115
175
130
220
165
5/8
67
49
85
63
105
77
135
100
170
125
215
160
240
175
305
225
3/4
120
88
150
110
190
140
240
175
300
220
380
280
425
315
540
400
7/8
190
140
240
175
190
140
240
175
490
360
615
455
690
510
870
640
285
210
360
265
285
210
360
265
730
540
920
680
1030
760
1300
960
1-1/8
400
300
510
375
400
300
510
375
910
670
1150
850
1450
1075
1850
1350
1-1/4
570
420
725
535
570
420
725
535
1280
945
1630
1200
2050
1500
2600
1920
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2140
1580
2700
2000
3400
2500
1-1/2
990
730
1250
930
990
730
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
Torque values listed are for general use only, based on the strength of the
bolt or screw. DO NOT use these values if a different torque value or
tightening procedure is given for a specific application. For plastic insert or
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on
U-bolts, see the tightening instructions for the specific application. Shear
bolts are designed to fail under predetermined loads. Always replace shear
bolts with identical grade.
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with
JDM F13C zinc flake coating.
c
Dry means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
DX,TORQ1 1924APR031/1
CTM100 (30AUG07)
06-200-2
PN=414
8.8
9.8
10.9
12.9
12.9
4.8
8.8
9.8
10.9
12.9
12.9
TS1670
4.8
UN01MAY03
Bolt or
Screw
Class 4.8
Lubricateda
Lubricateda
Class 10.9
Dryb
Lubricateda
Size
Nm
lb-in
Nm
lb-in
Nm
lb-in
Nm
lb-in
M6
4.7
42
53
8.9
79
11.3
100
Nm
13
Nm
M8
11.5
102
14.5
Nm
M10
23
Nm
204
128
lb-ft
29
21
22
Nm
194
lb-ft
43
32
27.5
Nm
55
243
lb-in
115
lb-ft
Class 12.9
Dryb
Nm
16.5
Nm
Lubricateda
lb-in
146
lb-ft
Nm
15.5
Nm
lb-in
137
lb-ft
Dryb
Nm
lb-in
19.5
172
Nm
lb-ft
32
23.5
40
29.5
37
27.5
47
35
40
63
46
80
59
75
55
95
70
lb-ft
lb-ft
M12
40
29.5
50
37
75
55
95
70
110
80
140
105
130
95
165
120
M14
63
46
80
59
120
88
150
110
175
130
220
165
205
150
260
190
M16
100
74
125
92
190
140
240
175
275
200
350
255
320
235
400
300
M18
135
100
170
125
265
195
330
245
375
275
475
350
440
325
560
410
M20
190
140
245
180
375
275
475
350
530
390
675
500
625
460
790
580
M22
265
195
330
245
510
375
650
480
725
535
920
680
850
625
1080
800
M24
330
245
425
315
650
480
820
600
920
680
1150
850
1080
800
1350
1000
M27
490
360
625
460
950
700
1200
885
1350
1000
1700
1250
1580
1160
2000
1475
M30
660
490
850
625
1290
950
1630
1200
1850
1350
2300
1700
2140
1580
2700
2000
M33
900
665
1150
850
1750
1300
2200
1625
2500
1850
3150
2325
2900
2150
3700
2730
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2770
4750
3500
Torque values listed are for general use only, based on the strength
of the bolt or screw. DO NOT use these values if a different torque
value or tightening procedure is given for a specific application. For
stainless steel fasteners or for nuts on U-bolts, see the tightening
instructions for the specific application. Tighten plastic insert or
crimped steel type lock nuts by turning the nut to the dry torque
shown in the chart, unless different instructions are given for the
specific application.
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with
JDM F13C zinc flake coating.
b
Dry means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 1924APR031/1
CTM100 (30AUG07)
06-200-3
PN=415
06
200
3
Measurement
Specification
Torque
Torque
90 Nm (66 lb-ft)
Torque
OUO1082,0000252 1919SEP021/1
06
200
4
CTM100 (30AUG07)
06-200-4
PN=416
Measurement
Specification
Torque
30 Nm (22 lb-ft)
Torque
Intake Valve
Clearance
Exhaust Valve
Clearance
Torque
50 Nm (37 lb-ft)
Preload
Torque
65 Nm (48 lb-ft)
Torque
33 Nm (24 lb-ft)
ID
OD
Oil Clearance
OD
39.99540.045 mm (1.5746
1.5766 in.)
37.99538.045 mm (1.4959
1.4978 in.)
Recess
06
200
5
CTM100 (30AUG07)
06-200-5
OUO1004,0000BC6 1919SEP021/4
PN=417
06
200
6
Item
Measurement
Specification
OD
Maximum Runout
OD
Angle
29.25 0.25
Cylinder Head
124.975125.025 mm (4.9203
4.9222 in.)
124.840 mm (4.9150 in.)
Surface Finish
CTM100 (30AUG07)
06-200-6
OUO1004,0000BC6 1919SEP022/4
PN=418
Item
Measurement
Specification
Cylinder Head
Valve Guide
ID
Valve Stem
OD
Valve Stem-to-Guide
Clearance
0.0770.129 mm (0.00300.0050
in.)
ID
Valve Guide
Installed Height
Contact Angle
Width
Maximum Runout
30
1.502.00 mm (0.0590.079 in.)
0.16 mm (0.006 in.)
ID
Bore Depth
Radius at Lower Bore
Standard Intake and Exhaust Valve
Seat
OD
49.48749.513 mm (1.9483
1.9493 in.)
Torque
10 Nm (7.5 lb-ft)
Fuel Lines
Torque
24 Nm (18 lb-ft)
Cylinder Liner
0.0300.117 mm (0.00120.0046
in.)
Cylinder Liner
Initial Torque
Cylinder Head4
Step 1No. 17 Cap Screw
See INSTALL CYLINDER HEAD later in this group for proper torque
sequence.
Continued on next page
CTM100 (30AUG07)
06-200-7
OUO1004,0000BC6 1919SEP023/4
PN=419
06
200
7
Item
06
200
8
Measurement
Specification
Initial Torque
Torque
Initial Torque-Turn
90
Final Torque-Turn
90
Initial Torque
30 Nm (22 lb-ft)
Final Torque-Turn
60 5
Final Torque-Turn
90 + 10 0
Torque
25 Nm (18 lb-ft)
Torque
35 Nm (26 lb-ft)
Apply LOCTITE 222 (TY24311) Thread Lock and Sealer (Low Strength)
to nut only.
OUO1004,0000BC6 1919SEP024/4
CTM100 (30AUG07)
06-200-8
PN=420
Measurement
Specification
Torque
50 Nm (37 lb-ft)
Torque
33 Nm (24 lb-ft)
Torque
68 Nm (50 lb-ft)
0.0300.117 mm (0.00120.0046
in.)
0.05 mm (0.002 in.)
Thickness
Thickness
Thickness
Dimension
Cylinder Liners
Flange Area
OD
151.565151.615 mm (5.9671
5.9691 in.)
OD
145.795145.845 mm (5.7400
5.7419 in.)
OD
144.73144.99 mm (5.6985.708
in.)
OD
140.397140.447 mm (5.5274
5.5294 in.)
End Gap
End Gap
CTM100 (30AUG07)
06-200-9
06
200
9
OUO1004,0000BCF 1902NOV001/5
PN=421
06
200
10
Item
Measurement
Specification
End Gap
End Gap
Clearance
0.0640.114 mm (0.00250.0045
in.)
0.165 mm (0.0065 in.)
Clearance
Piston Pin
OD
50.77250.787 mm (1.9989
1.9995 in.)
ID
50.79550.805 mm (1.9998
2.0002 in.)
ID
50.79850.808 mm (1.9999
2.0003 in.)
ID
50.81050.825 mm (2.0004
2.0010 in.)
126.872126.898 mm (4.9950
4.9960 in.)
126.910126.930 mm (4.9965
4.9972 in.)
Cylinder Liner
ID
126.990127.010 mm (4.9996
5.0004 in.)
0.020 mm (0.0008 in.)
0.030 mm (0.0012 in.)
Maximum Clearance
0.0410.091 mm (0.00160.0036
in.)
0.132 mm (0.0052 in.)
Maximum Clearance
Clearance
0.0920.138 mm (0.00360.0054
in.)
0.152 mm (0.0060 in.)
Clearance
0.0600.100 mm (0.00240.0039
in.)
0.152 mm (0.0060 in.)
CTM100 (30AUG07)
06-200-10
OUO1004,0000BCF 1902NOV002/5
PN=422
Item
Measurement
Specification
Thickness
9.5259.575 mm (0.37500.3770
in.)
Initial Torque
27 Nm (20 lb-ft)
Final Torque
Torque
OD
88.84488.874 mm (3.4980
3.4990 in.)
ID
Oil Clearance
Max. Oil Clearance
ID
93.7693.79 mm (3.69153.6925
in.)
Dimension
263.95264.05 mm (10.392
10.396 in.)
ID
55.52955.555 mm (2.1862
2.1872 in.)
ID
50.72950.781 mm (1.9972
1.9992 in.)
ID
50.80550.830 mm (2.0002
2.0012 in.)
Out-of-Round
Piston Pin-to-Bushing
Oil Clearance
0.0170.059 mm (0.00070.0023
in.)
0.076 mm (0.0030 in.)
Press Fit
CTM100 (30AUG07)
06
200
11
0.1000.163 mm (0.00390.0064
in.)
06-200-11
OUO1004,0000BCF 1902NOV003/5
PN=423
Item
Measurement
Specification
ID
55.52955.555 mm (2.1862
2.1872 in.)
0.1000.163 mm (0.00390.0064
in.)
ID
50.80550.830 mm (2.0002
2.0012 in.)
Piston Pin
OD
50.77250.787 mm (1.9989
1.9995 in.)
Piston Pin-to-Bushing
Clearance
0.0170.059 mm (0.00070.0023
in.)
Depth in Block
9.4619.512 mm (0.37250.3745
in.)
Thickness
9.5259.575 mm (0.37500.3770
in.)
133.097133.123 mm (5.2400
5.2410 in.)
37.7738.03 mm (1.4871.497 in.)
37.5138.29 mm (1.4761.507 in.)
06
200
12
Minimum Distance
429.92430.07 mm (16.926
16.932 in.)
ID
153.57153.77 mm (6.0466.054
in.)
145.845145.895 mm (5.7419
5.7439 in.)
140.465140.515 mm (5.5301
5.5321 in.)
CTM100 (30AUG07)
06-200-12
OUO1004,0000BCF 1902NOV004/5
PN=424
Item
Measurement
Specification
0.0300.117 mm (0.00120.0046
in.)
Thickness
Thickness
Torque
15 Nm (11 lb-ft)
Torque
20 Nm (15 lb-ft)
Installed Depth
OUO1004,0000BCF 1902NOV005/5
CTM100 (30AUG07)
06-200-13
PN=425
06
200
13
06
200
14
Item
Measurement
Specification
Vibration Damper
Crankshaft
End Play
0.0380.380 mm (0.00150.0150
in.)
Maximum Variation
Maximum Variation per 25 mm (1.0
in.) of Travel
Torque
Torque
50 Nm (37 lb-ft)
5 Nm (44 lb-in.)
Torque
Torque
0.0460.122 mm (0.00180.0048
in.)
0.152 mm (0.0060 in.)
ID With Bearing
125.071125.127 mm (4.9241
4.9263 in.)
133.097133.123 mm (5.2400
5.2411 in.)
ID Without Bearing
CTM100 (30AUG07)
06-200-14
OUO1004,0000BD3 1923JUN061/3
PN=426
Item
Measurement
Specification
OD
124.983125.017 mm (4.9206
4.9219 in.)
Max. Out-of-Round
Max. Taper per 25.4 mm (1.0 in.) of
Journal Length
ID Without Bearings
133.097133.123
5.2411 in.)
0.013 mm (0.0005
0.005 mm (0.0002
0.038 mm (0.0015
mm (5.2400
in.)
in.)
in.)
Surface Width
Undersize
Thickness
162.24163.76 mm (6.3876.447
in.)
42.0542.12 mm (1.6561.658 in.)
45
43.46 mm (1.711 in.)
0.025 mm (0.0010 in.)
Initial Torque
68 Nm (50 lb-ft)
Final Torque
Torque
25 Nm (18 lb-ft)
Torque
15 Nm (11 lb-ft)
CTM100 (30AUG07)
06-200-15
OUO1004,0000BD3 1923JUN062/3
PN=427
06
200
15
Item
Measurement
Specification
Initial Torque
45 Nm (33 lb-ft)
Final Torque
63 Nm (46 lb-ft)
Initial Torque
50 Nm (37 lb-ft)
Final Torque
68 Nm (50 lb-ft)
Torque
90 Nm (66 lb-ft)
Torque
Torque
Torque
15 Nm (11 lb-ft)
06
200
16
1
Initial torque is required only on early timing gear covers using Fel-Pro
gaskets with sealant.
OUO1004,0000BD3 1923JUN063/3
CTM100 (30AUG07)
06-200-16
PN=428
Measurement
Specification
Initial Torque
Second Torque
Final Retorque
Backlash
Backlash
Torque
85 Nm (63 lb-ft)
Initial Torque
35 Nm (26 lb-ft)
Final Torque
35 Nm (26 lb-ft)
Torque
4 Nm (3 lb-ft)
Torque
50 Nm (37 lb-ft)
Torque
35 Nm (26 lb-ft)
Torque
14 Nm (10 lb-ft)
Camshaft Journal
OD
101.987102.013 mm (4.0152
4.0162 in.)
Camshaft Bushing
ID
102.091102.167 mm (4.0193
4.0223 in.)
Camshaft Journal-to-Bushing
Oil Clearance
0.0780.180 mm (0.00310.0071
in.)
Camshaft Bushing
Bore in Head
105.987106.013 mm (4.1727
4.1737 in.)
Intake Lobe
Lift
Exhaust Lobe
Lift
06
200
17
Camshaft Lobe:
CTM100 (30AUG07)
06-200-17
OUO1004,0000BD7 1902NOV001/2
PN=429
Item
Measurement
Specification
Lift
Torque
50 Nm (37 lb-ft)
Torque
50 Nm (37 lb-ft)
Torque
OUO1004,0000BD7 1902NOV002/2
06
200
18
CTM100 (30AUG07)
06-200-18
PN=430
Measurement
Specification
Free Length
Working Load at 7684 N (1719
lb-force)
Torque
Free Length
Working Load @ 6478 N (1418
lb-force)
Free Length
Working Load @ 6478 N (1418
lb-force)
Torque
Torque
Free Length
Working Load @ 196222 N (44
50 lb-force)
Oil Cooler
Test Pressure
Torque
50 Nm (37 lb-ft)
Torque
3 Nm (25 lb-in.)
Installed Depth
Torque
68 Nm (50 lb-ft)
Retorque
68 Nm (50 lb-ft)
Torque
68 Nm (50 lb-ft)
06
200
19
CTM100 (30AUG07)
06-200-19
OUO1022,000000A 1919SEP021/2
PN=431
06
200
20
Item
Measurement
Specification
Torque
Torque
Torque
35 Nm (26 lb-ft)
ID
135.70135.80 mm (5.3435.346
in.)
Initial Torque
20 Nm (177 lb-in.)
Torque Turn
90 (1/4 Turn)
Backlash
Torque
35 Nm (26 lb-ft)
Torque
25 Nm (18 lb-ft)
Torque
Torque
Torque
Torque
46 Nm (34 lb-ft)
Torque
64 Nm (47 lb-ft)
OUO1022,000000A 1919SEP022/2
CTM100 (30AUG07)
06-200-20
PN=432
Measurement
Specification
Housing ID
71.99972.025
2.8356 in.)
35.00135.017
1.3786 in.)
34.98735.013
1.3785 in.)
71.98772.013
2.8351 in.)
Shaft OD
Bearing ID
Bearing OD
mm (2.8346
mm (1.3780
mm (1.3774
mm (2.8341
End Play
Torque
75 Nm (56 lb-ft)
Torque
61 Nm (45 lb-ft)
Torque
90 Nm (66 lb-ft)
Tension
Tension
Torque
50 Nm (37 lb-ft)
Torque
68 Nm (50 lb-ft)
Torque
10 Nm (7.5 lb-ft)
Torque
50 Nm (37 lb-ft)
Torque
41 Nm (30 lb-ft)
Torque
6 Nm (4.5 lb-ft)
Torque
9 Nm (7 lb-ft)
Torque
35 Nm (26 lb-ft)
CTM100 (30AUG07)
06-200-21
06
200
21
OUO1022,000000D 1926OCT001/2
PN=433
Item
Measurement
Specification
Thermostat Cover/Housing
Assembly-to-Block Cap Screws
Torque
50 Nm (37 lb-ft)
Thermostat Test
Rating
Initial Opening (Range) Temperature
Full Open (Nominal) Temperature
82C (180F)
8084C (175182F)
94C (202F)
Torque
10 Nm (7.5 lb-ft)
Torque
20 Nm (15 lb-ft)
OUO1022,000000D 1926OCT002/2
06
200
22
CTM100 (30AUG07)
06-200-22
PN=434
Measurement
Specification
0.0760.165 mm (0.0030.0065
in.) (measured on center of shaft)
End Play
0.0250.114 mm (0.00100.0045
in.)
End Play
0.06350.1143 mm (0.0025
0.0045 in.)
Turbocharger-to-Exhaust Manifold
Torque
50 Nm (37 lb-ft)
Torque
50 Nm (37 lb-ft)
Torque
50 Nm (37 lb-ft)
Torque
35 Nm (26 lb-ft)
Torque
70 Nm (52 lb-ft)
Torque
35 Nm (26 lb-ft)
Torque
35 Nm (26 lb-ft)
Torque
50 Nm (37 lb-ft)
Aftercooler
Test Pressure
06
200
23
OUO1004,0000BDA 1903NOV001/1
CTM100 (30AUG07)
06-200-23
PN=435
Measurement
Specification
M8 Cap Screw
Torque
25 Nm (18 lb-ft)
Torque
50 Nm (37 lb-ft)
Torque
61 Nm (45 lb-ft)
Torque
70 Nm (52 lb-ft)
Torque
60 Nm (44 lb-ft)
Torque
DPSG,OUO1004,959 1929JUL991/1
06
200
24
CTM100 (30AUG07)
06-200-24
PN=436
Group 210
Diagnostic Specifications
Observable Diagnostics and Test
Specifications
Item
Measurement
Specification
Engine Oil
Intake Manifold
Test Pressure
Torque
14 Nm (10 lb-ft)
OUO1004,0000C20 1927NOV001/1
06
210
1
CTM100 (30AUG07)
06-210-1
PN=437
Diagnostic Specifications
ENGINE
MODEL
FUEL SYSTEM
OPTION CODES
INTERMITTENT POWER
RATING @ RATED
SPEED WITHOUT FAN
kW (hp)
6105AF
224 (300)
6105HF
6125AF
6125HF ( 29999)
06
210
2
6125HF (30000)
6125AFM (Marine)
RATED SPEED
(rpm)
SLOW IDLE
(rpm)
FAST IDLE
(rpm)
2100
850
2225
242 (325)
2100
850
2225
261 (350)
2100
850
2225
242 (325)
2100
850
2225
261 (350)
2100
850
2225
280 (375)
2100
850
2225
298 (400)
2100
850
2225
317 (425)
2100
850
2225
336 (450)
2100
850
2225
354 (475)
2100
850
2225
373 (500)
2100
850
2225
224 (300)
2100
900
2225
242 (325)
2100
900
2225
261 (350)
2100
900
2225
280 (375)
2100
900
2225
298 (400)
2100
900
2225
317 (425)
2100
900
2225
336 (450)
2100
900
2225
354 (475)
2100
900
2225
373 (500)
2100
900
2225
410 (550)
2100
M1
254 (340)
1800
650
1950
M2
280 (375)
1900
650
2225
M3
298 (400)
2000
650
2225
336 (450)
2100
650
2225
CTM100 (30AUG07)
06-210-2
DPSG,OUO1004,924 1913SEP021/2
PN=438
Diagnostic Specifications
GENERATOR SET (STANDBY) APPLICATIONS
ENGINE
MODEL
6125AF
6125HF ( 29999)
6125HF (30000 )
FUEL SYSTEM
OPTION CODES
STANDBY
POWER RATING
@ RATED SPEED
WITHOUT FAN
kW (hp)
RATED SPEED
(rpm)
SLOW IDLE
(rpm)
FAST IDLE
(rpm)
233 (312)
1500
900
1550
254 (341)
1500
900
1550
277 (371)
1500
900
1550
280 (375)
1800
900
1850
300 (402)
1800
900
1850
330 (442)
1800
900
1850
302 (405)
1500
900
1550
352 (472)
1500
900
1550
360 (483)
1800
900
1850
420 (563)
1800
900
1850
460 (616)
1800
900
1850
300 (402)
1500
900
1550
330 (442)
1800
900
1850
350 (469)
1500
900
1550
360 (483)
1800
900
1850
387 (519)
1500
900
1550
420 (563)
1800
900
1850
460 (617)
1800
900
1850
06
210
3
6125AFM
1606, 1616
300 (402)
1800
900
1850
1609, 1619
252 (338)
1500
900
1550
DPSG,OUO1004,924 1913SEP022/2
CTM100 (30AUG07)
06-210-3
PN=439
Diagnostic Specifications
Rated
Speed
(rpm)
224 (300)
2100
6105HF
1609,1610, 1620,1621
242 (325)
2100
261 (350)
2100
6125AF
242 (325)
2100
261 (350)
2100
280 (375)
2100
298 (399)
2100
317 (425)
2100
336 (450)
2100
354 (474)
2100
6125HF ( 29999)
6125HF (30000 )
06
210
4
373 (500)
2100
224 (300)
2100
242 (325)
2100
261 (350)
2100
280 (375)
2100
298 (400)
2100
317 (425)
2100
336 (450)
2100
354 (475)
2100
373 (500)
2100
6125HF ( 29999)
6125HF (30000
233 (312)
1500
254 (341)
1500
277 (371)
1500
280 (375)
1800
300 (402)
1800
330 (442)
1800
302 (405)
1500
352 (472)
1500
360 (483)
1800
420 (563)
1800
460 (616)
1800
300 (402)
1500
330 (442)
1800
350 (469)
1500
360 (483)
1800
387 (519)
1500
CTM100 (30AUG07)
06-210-4
RG,RG34710,1610 1913SEP021/4
PN=440
Diagnostic Specifications
Engine Model
Rated
Speed
(rpm)
420 (563)
1800
460 (617)
1800
Rated
Speed
(rpm)
Pressure Specification
6125AFM
M1
254 (340)
1800
M2
280 (375)
1900
M3
298 (400)
2000
336 (450)
2100
300 (402)
1800
252 (338)
1500
RG,RG34710,1610 1913SEP022/4
06
210
5
CTM100 (30AUG07)
06-210-5
PN=441
Diagnostic Specifications
Engine Model
Deere Model
Pressure Specification
6125ADW01
2000
6125HDW01 (30000 )
2000
06
210
6
6125ADW70
230LC Excavator
2000
6125HT001 (30000 )
450C LC Excavator
1800
6105HRW01
2100
6125HRW05 (30000 )
2100
6125HRW01
2100
6125HRW07 (30000 )
2100
6125HRW11
6125HRW02
2100
6125HRW09 (30000 )
2100
6125HRW12
6125HRW03
2100
6125HRW06 (30000 )
2100
6125HRW04
2100
6125HRW08 (30000 )
2100
6125HZ001
2100
6125HZ005
6125HZ002
2100
6125HZ006
6125AT801
2100
6125HRW10
2100
6125HRW13
2100
6125HRW16
6125HRW13
6125HRW16
6125HRW14
6125HRW15
6125HRW17
6125HRW15
6125HRW17
6125HT001
6125HT004
844H Loader
2100
CTM100 (30AUG07)
06-210-6
RG,RG34710,1610 1913SEP023/4
PN=442
Diagnostic Specifications
Engine Model
Deere Model
6125HH003
Pressure Specification
RG,RG34710,1610 1913SEP024/4
06
210
7
CTM100 (30AUG07)
06-210-7
PN=443
Diagnostic Specifications
06
210
8
CTM100 (30AUG07)
06-210-8
PN=444
Index
Page
A
Aftercooler
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .02-080-25
Remove and install . . . . . . . . . . . . . . . . .02-080-23
Air intake and exhaust system
specifications . . . . . . . . . . . . . . . . . . . . .06-200-23
Air intake system, check. . . . . . . . . . . . . . .02-010-18
Alternator, remove and install . . . . . . . . . . . .02-100-1
Auxiliary drive
SAE "A" and "B" . . . . . . . . . . . . . . . . . . .02-050-26
SAE "A", align front adapter . . . . . . . . . .02-050-28
SAE "B" . . . . . . . . . . . . . . . . . . . . . . . . .02-050-27
B
Backlash, gear train, check and adjust . . . . .02-050-4
Belt tensioner
Check spring tension . . . . . . . . . . . . . . . .02-070-5
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-070-7
Block, cylinder
Complete disassembly . . . . . . . . . . . . . .02-030-38
Install main bearings . . . . . . . . . . . . . . . .02-040-28
Remove crankshaft . . . . . . . . . . . . . . . . .02-040-19
Break-in engine oil . . . . . . . . . . . . . . . . . . . .01-002-4
C
Camshaft
Inspect camshaft and roller followers . . .02-050-18
Inspect sensor lobe. . . . . . . . . . . . . . . . .02-050-20
Measure bushing ID and journal OD . . . .02-050-19
Measure lobe lift height. . . . . . . . . . . . . .02-050-20
Remove and install . . . . . . . . . . . . . . . . . .02-050-9
Camshaft and timing gear train
specifications . . . . . . . . . . . . . . . . . . . . .06-200-17
Camshaft gear
Access cover torque sequence . . . . . . . . .02-050-1
Camshaft gear access cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-34
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-6
Camshaft-to-crankshaft timing . . . . . . . . . . .02-050-2
Camshaft-to-crankshaft timing check . . . . .04-150-24
Check
Camshaft-to-crankshaft timing. . . . . . . . .04-150-24
Crankshaft position sensor depth . . . . . .04-150-25
Engine crankcase pressure (blow-by) . . .04-150-12
Engine oil pressure . . . . . . . . . . . . . . . . .04-150-11
Exhaust air leaks . . . . . . . . . . . . . . . . . .04-150-23
Exhaust restrictions. . . . . . . . . . . . . . . . .04-150-21
CTM100 (30AUG07)
Page
Index-1
PN=1
Indx
1
Index
Indx
2
Page
Page
CTM100 (30AUG07)
D
Damper, vibration
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-2
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-39
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-4
Torque sequence . . . . . . . . . . . . . . . . . . .02-040-1
Dealer fabricated tool
Camshaft locking tool . . . . . . . . . . . . . . . .05-190-1
Cylinder liner holding fixture . . . . . . . . . . .05-190-2
Diagnostics
Coolant system malfunctions
Coolant in oil or oil in coolant . . . . . . . .04-150-8
Engine coolant temperature above
normal . . . . . . . . . . . . . . . . . . . . . . . .04-150-7
Engine coolant temperature below
normal . . . . . . . . . . . . . . . . . . . . . . . .04-150-8
Lubrication system malfunctions
Engine oil pressure high . . . . . . . . . . . .04-150-5
Engine oil pressure low . . . . . . . . . . . . .04-150-6
Execessive oil consumption. . . . . . . . . .04-150-2
Diesel engine oil. . . . . . . . . . . . . .01-002-5, 01-002-6
Diesel fuel . . . . . . . . . . . . . . . . . .01-002-1, 01-002-2
Dynamometer test . . . . . . . . . . . . . . . . . . . .04-150-9
Dynamometer test specifications . . . . . . . . .06-210-2
E
Electrical system
Check . . . . . . . . . . . . . . . . . . . . . . . . . . .02-010-21
Engine
Application chart . . . . . . . . . . . . . . . . . . . .01-001-4
Assembly checks . . . . . . . . . . . . . . . . . .02-030-54
Assembly sequence . . . . . . . . . . . . . . . .02-010-13
Break-in guidelines . . . . . . . . . . . . . . . . .02-010-15
Break-in, perform . . . . . . . . . . . . . . . . . .02-010-16
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .02-010-7
Disassembly sequence . . . . . . . . . . . . . . .02-010-8
Dynamometer test. . . . . . . . . . . . . . . . . . .04-150-9
Index-2
PN=2
Index
Page
Page
F
Fan drive bearings, replace . . . . . . . . . . . . .02-070-1
Flywheel
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-12
Measure flatness. . . . . . . . . . . . . . . . . . . .02-040-8
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-8
Replace ring gear . . . . . . . . . . . . . . . . . .02-040-10
Flywheel housing
Measure face runout . . . . . . . . . . . . . . . . .02-040-7
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-040-11
Front crankshaft oil seal
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-39
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-5
Front plate
Remove and install . . . . . . . . . . . . . . . . . .02-030-1
Front timing gear backlash, adjust . . . . . . . .02-050-4
Fuel
Diesel . . . . . . . . . . . . . . . . . . . .01-002-1, 01-002-2
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3
Fuel supply pump drive pin, replace . . . . . .02-050-18
CTM100 (30AUG07)
G
Grease
Extreme pressure and multipurpose . . . . .01-002-9
H
Head gasket
Check for failure . . . . . . . . . . . . . . . . . . .04-150-18
Construction . . . . . . . . . . . . . . . . . . . . . .03-120-11
Failure analysis . . . . . . . . . . . . . . . . . . . .02-020-17
I
Injector
Adjust preload. . . . . . . . . . . . . . . . . . . . . .02-020-4
Intake air leak check . . . . . . . . . . . . . . . . .04-150-22
Intake and exhaust system
Check for restrictions . . . . . . . . . . . . . . .04-150-21
Operation, theory of . . . . . . . . . . . . . . . .03-120-12
Intake manifold
Remove, inspect and install . . . . . . . . . .02-080-21
Intake manifold pressure (turbo boost)
Measure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-20
Intake restrictions check . . . . . . . . . . . . . . .04-150-21
L
Lubricant
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-8
Lubrication system
Diagnostics
Engine oil pressure high . . . . . . . . . . . .04-150-5
Engine oil pressure low . . . . . . . . . . . . .04-150-6
Excessive oil Consumption . . . . . . . . . .04-150-2
Flow diagram . . . . . . . . . . . . . . . . . . . . . .03-120-4
Operation, theory of . . . . . . . . . . . . . . . . .03-120-4
Specifications . . . . . . . . . . . . . . . . . . . . .06-200-19
Lubricity of diesel fuel. . . . . . . . . . . . . . . . . .01-002-3
Index-3
PN=3
Indx
3
Index
Page
Page
Main bearings
Failure analysis . . . . . . . . . . . . . . . . . . . .02-040-15
Inspect thrust bearings . . . . . . . . . . . . . .02-040-27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-28
Measure . . . . . . . . . . . . . . . . . . . . . . . . .02-040-22
Measure caps . . . . . . . . . . . . . . . . . . . . .02-040-23
Oil clearance. . . . . . . . . . . . . . . . . . . . . .02-040-18
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-040-16
Thrust bearing new part
specifications . . . . . . . . . . . . . . . . . . . .02-040-27
Mixing lubricants. . . . . . . . . . . . . . . . . . . . . .01-002-8
Pistons
Disassemble pistons and rods . . . . . . . .02-030-20
Inspect compression ring groove
(6105) . . . . . . . . . . . . . . . . . . . . . . . . .02-030-22
Inspect compression ring groove
(6125) . . . . . . . . . . . . . . . . . . . . . . . . .02-030-23
Inspect oil control ring groove . . . . . . . . .02-030-24
Inspect pin and bore . . . . . . . . . . . . . . . .02-030-25
Measure protrusion . . . . . . . . . . . . . . . . .02-030-54
Pins and bushings, inspect . . . . . . . . . . .02-030-34
Piston pin bushing, install . . . . . . . . . . . .02-030-37
Piston-to-liner clearance, measure . . . . .02-030-26
Preliminary checks . . . . . . . . . . . . . . . . . .02-030-5
Remove piston pin bushings and clean
bore. . . . . . . . . . . . . . . . . . . . . . . . . . .02-030-36
Indx
4
P
Piston pins and bushings
Remove bushings and clean bore . . . . . .02-030-36
Piston spray jets, remove and install . . . . .02-030-55
CTM100 (30AUG07)
R
Rear oil seal and housing
Install housing. . . . . . . . . . . . . . . . . . . . .02-040-32
Install oil seal and wear sleeve . . . . . . . .02-040-33
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-040-13
Rocker arm assembly
Assemble . . . . . . . . . . . . . . . . . . . . . . . .02-020-23
Check and adjust clearance and
preload . . . . . . . . . . . . . . . . . . . . . . . . .02-020-4
Disassemble and inspect . . . . . . . . . . . .02-020-21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-020-63
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-020-10
Rocker arm cover
Gasket replace . . . . . . . . . . . . . . . . . . . . .02-020-3
Remove and install . . . . . . . . . . . . . . . . . .02-020-1
S
Safety precautions, repair stand
mounting . . . . . . . . . . . . . . . . . . . . . . . . . .02-010-2
Sensor
Crankshaft position sensor depth
check. . . . . . . . . . . . . . . . . . . . . . . . . .04-150-25
Specifications
Air intake and exhaust system . . . . . . . .06-200-23
Camshaft and timing gear train . . . . . . . .06-200-17
Cooling system . . . . . . . . . . . . . . . . . . . .06-200-21
Crankshaft, main bearings and
flywheel . . . . . . . . . . . . . . . . . . . . . . . .06-200-14
Cylinder block, liners, pistons and rods . . .06-200-9
Cylinder head and valves . . . . . . . . . . . . .06-200-5
Dynamometer test. . . . . . . . . . . . . . . . . . .06-210-2
Engine diagnostic and test . . . . . . . . . . . .06-210-1
Index-4
PN=4
Index
Page
Page
T
Test
Radiator cap . . . . . . . . . . . . . . . . . . . . . .04-150-16
Thermostat opening temperature . . . . . .04-150-15
Thermostat
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-15
Test opening temperature . . . . . . . . . . . .04-150-15
Thermostat housing, remove and install . . .02-070-14
Thermostats
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-070-12
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-070-11
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-070-13
Timing adjustment,
camshaft-to-crankshaft . . . . . . . . . . . . . . .02-050-2
Timing gear cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-34
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-6
Tune-up recommendations . . . . . . . . . . . . .02-010-23
Turbo boost
Measure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-20
Specifications . . . . . . . . . . . . . . . . . . . . . .06-210-4
Turbocharger
Axial bearing end play test . . . . . . . . . . .02-080-14
Break-in . . . . . . . . . . . . . . . . . . . . . . . . .02-080-17
Disconnect oil inlet line . . . . . . . . . . . . . . .02-010-3
Extending life . . . . . . . . . . . . . . . . . . . . . .02-080-1
Failure analysis . . . . . . . . . . . . . . . . . . . . .02-080-4
How lubricated . . . . . . . . . . . . . . . . . . . .03-120-14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-080-16
Oil seal check . . . . . . . . . . . . . . . . . . . . .04-150-14
Operation, theory of . . . . . . . . . . . . . . . .03-120-13
Prelube . . . . . . . . . . . . . . . . . . . . . . . . . .02-080-15
Radial bearing clearance test . . . . . . . . .02-080-13
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-080-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-080-14
Seven-step inspection . . . . . . . . . . . . . . . .02-080-6
V
V-belt tensioner
Check spring tension . . . . . . . . . . . . . . . .02-070-5
Valve
Oil cooler bypass . . . . . . . . . . . . . . . . . . .02-060-4
Oil filter bypass . . . . . . . . . . . . . . . . . . . . .02-060-4
Oil pressure regulating . . . . . . . . . . . . . . .02-060-3
Oil pressure relief . . . . . . . . . . . . . . . . . . .02-060-5
Valve clearance, check and adjust . . . . . . . .02-020-4
Valve guide
Measure ID . . . . . . . . . . . . . . . . . . . . . . .02-020-33
Replace . . . . . . . . . . . . . . . . . . . . . . . . .02-020-33
Valve rotators, inspect . . . . . . . . . . . . . . . .02-020-26
Valve seats
Clean and inspect . . . . . . . . . . . . . . . . . .02-020-34
Grind. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-020-35
Install inserts. . . . . . . . . . . . . . . . . . . . . .02-020-38
Measure bores in head . . . . . . . . . . . . . .02-020-37
Remove inserts . . . . . . . . . . . . . . . . . . . .02-020-36
Valve springs
Inspect and measure . . . . . . . . . . . . . . .02-020-25
Valves, intake and exhaust
Clean, inspect and measure . . . . . . . . . .02-020-27
Grind. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-020-28
Height (recess), measure . . . . . . . . . . . .02-020-23
Install valves . . . . . . . . . . . . . . . . . . . . . .02-020-38
Remove valves . . . . . . . . . . . . . . . . . . . .02-020-24
Ventilation assembly, crankcase, clean and
inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .02-020-2
Vibration damper
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-2
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-040-4
Torque sequence . . . . . . . . . . . . . . . . . . .02-040-1
W
Water pump
Clean and inspect . . . . . . . . . . . . . . . . . . .02-070-9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-070-10
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-070-8
U
Unit injector
Replace sleeve (using JDG1184) . . . . . .02-020-45
CTM100 (30AUG07)
Index-5
PN=5
Indx
5
Index
Indx
6
CTM100 (30AUG07)
Index-6
PN=6