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