Section 02
Repair and Adjustments
Contents
02
Page Page
Group 010—Engine Rebuild Guide, Break-In and
Remove Valve Assembly................02-020-24
Tune-Up
Inspect and Measure Valve Springs .......02-020-25
Engine Overhaul Guidelines ..............02-010-1
Inspect Valve Rotators .................02-020-26
Engine Repair Stand....................02-010-1
Clean, Inspect, and Measure Valves.......02-020-27
Safety Precautions .....................02-010-2
Grind Valves .........................02-020-28
Disconnect Turbocharger Oil Inlet Line ......02-010-3
Clean and Inspect Cylinder Head .........02-020-29
Install Engine Adapter Onto Repair Stand....02-010-3
Check Cylinder Head Flatness ...........02-020-30
Engine Lifting Procedure .................02-010-4
Measure Cylinder Head Thickness ........02-020-31
Mount Engine Onto Repair Stand ..........02-010-6
Resurface Cylinder Head Combustion
Clean Engine .........................02-010-7
Face .............................02-020-32
6105 and 6125 Engine Disassembly
Measure Valve Guide ID................02-020-33
Sequence ..........................02-010-8
Replace Valve Guides..................02-020-33
Sealant Application Guidelines ...........02-010-11
Clean and Inspect Valve Seats ...........02-020-34
6105 and 6125 Engine Assembly
Grind Valve Seats.....................02-020-35
Sequence .........................02-010-13
Remove Valve Seat Inserts..............02-020-36
Engine Break-In Guidelines..............02-010-15
Measure Valve Seat Bore in Cylinder
Perform Engine Break-In................02-010-16
Head .............................02-020-37
Check Crankcase Ventilation System ......02-010-17
Install Valve Seat Inserts................02-020-38
Check Air Intake System................02-010-18
Install Valves.........................02-020-38
Check Exhaust System .................02-010-18
Replace Unit Injector Sleeve in Cylinder
Check and Service Cooling System .......02-010-19
Head Using JDG981 .................02-020-40
Check Electrical System ................02-010-21
Replace Unit Injector Sleeve in Cylinder
Preliminary Engine Testing Before
Head Using JDG1184 ................02-020-45
Tune-Up ..........................02-010-22
Clean and Inspect Top Deck of Cylinder
General Tune-Up Recommendations ......02-010-23
Block .............................02-020-55
Measure Cylinder Liner Standout (Height
Above Block) .......................02-020-56
Group 020—Cylinder Head and Valves
Install Cylinder Head...................02-020-57
Remove and Install Rocker Arm Cover ......02-020-1
Torque-Turn Cylinder Head Cap Screws....02-020-59
Clean and Inspect Crankcase Ventilation
Install Rocker Arm Assembly.............02-020-61
Assembly...........................02-020-2
Complete Final Assembly for Cylinder Head
Replace Rocker Arm Cover Gasket.........02-020-3
Installation .........................02-020-68
Check and Adjust Valve Assembly
Clearances and Injector Preload .........02-020-4
Remove Rocker Arm Assembly...........02-020-10 Group 030—Cylinder Block, Liners, Pistons, and
RodsRemove Cylinder Head .................02-020-12
Diagnosing Head Gasket Joint Failures.....02-020-17 Remove and Install Cylinder Block Front
Plate ..............................02-030-1Head Gasket Inspection and Repair
Sequence .........................02-020-19 Preliminary Liner, Piston, and Rod Checks . . .02-030-5
Connecting Rods—General Information .....02-030-6Disassemble and Inspect Rocker Arms and
Shaft Assembly .....................02-020-21 Remove Pistons and Connecting Rods ......02-030-7
Measure Cylinder Liner Standout (HeightPreliminary Cylinder Head and Valve
Checks ...........................02-020-22 Above Block) .......................02-030-11
Remove Cylinder Liners Using D01062AAAssemble Rocker Arms and Shaft
Assembly..........................02-020-23 or D01073AA Cylinder Liner Puller ......02-030-12
Check Valve Height in Relation to Head
Surface (Valve Recess) ...............02-020-23
Continued on next page
CTM100 (06APR04)
02-1
P
OWER
T
ECH
10.5 L & 12.5 L Diesel Engines
040604
PN=1
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