Cylinder Block, Liners, Pistons, and Rods
02
030
55
RG,RG34710,138 –19–30AUG02–1/1
Complete Final Assembly
NOTE: Refer to the proper group for installation of
components.
1. Coat threads of oil gallery plugs with LOCTITE

242
Thread Lock and Sealant. Install plugs and tighten
to specifications.
Specification
Oil Gallery Plug—Torque 20 N•m (15 lb-ft)..........................................
Main Oil Gallery (Front)
Expansion Plug—Installed
Depth Flush—1.5 mm (0.059 in.)
Below Surface
.........................................................
2. Install oil pickup tube. (See REMOVE AND
INSTALL OIL PICKUP TUBE in Group 060.) Install
oil pan. (See INSTALL ENGINE OIL PAN in Group
060.)
3. Install the cylinder head using new head gasket.
(See INSTALL CYLINDER HEAD in Group 020.)
4. Install camshaft and valve train. (See REMOVE
AND INSTALL CAMSHAFT in Group 050.) Install
timing gear cover. (See INSTALL TIMING GEAR
COVER in Group 040.)
5. Install electronic unit injectors. Refer to the
appropriate fuel system repair manual.
Delphi/Lucas ECU controlled fuel systems:
• See REMOVE AND INSTALL ELECTRONIC
UNIT INJECTORS in CTM115, Section 02, Group
090.
John Deere Level 6 ECU controlled fuel systems:
• See REMOVE AND INSTALL ELECTRONIC
UNIT INJECTORS in CTM188, Section 02, Group
090. (Dual rail fuel systems)
• See REMOVE AND INSTALL ELECTRONIC
UNIT INJECTORS in CTM188, Section 02, Group
091. (Single rail fuel systems)
6. Adjust clearances, preloads, and gear backlash.
(Groups 020, 040, 050.)
7. Install remaining fuel injection system components.
(CTM115 Section 02, Group 090 or CTM188
Section 02 Group 090 and 091.)
8. Install the coolant pump and water piping. (See
INSTALL COOLANT PUMP in Group 070.)
9. Install lubrication system components. (Group 060.)
10. Install crankshaft pulley. (See INSTALL
CRANKSHAFT VIBRATION DAMPER AND
FRONT OIL SEAL in Group 040.)
11. Install the exhaust manifold. (See REMOVE,
INSPECT AND INSTALL EXHAUST MANIFOLD in
Group 080.) Install intake assembly. (See
REMOVE, INSPECT AND INSTALL INTAKE
MANIFOLD in Group 080.)
12. Install starter motor. (See REMOVE AND
INSTALL STARTER MOTOR in Group 100.)
13. Install alternator. (See REMOVE AND INSTALL
ALTERNATOR in Group 100.)
14. Install fan and fan belts. (See Machine Technical
Manual.)
15. Fill engine with clean oil. (See DIESEL ENGINE
OIL in Section 01, Group 002.) Service engine
with coolant. (See DIESEL ENGINE COOLANT
RECOMMENDATIONS in Section 01, Group 002.)
16. Perform engine break-in. (See PERFORM
ENGINE BREAK-IN in Group 010.)
LOCTITE is a registered trademark of Loctite Corp.
CTM100 (06APR04)
02-030-55
P
OWER
T
ECH
10.5 L & 12.5 L Diesel Engines
040604
PN=195
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