Introduction
RG,RG34710,1 –19–11OCT00–1/1
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:
•CTM115—Delphi/Lucas Electronic Fuel Systems
With Delphi/Lucas EUIs
•CTM188—Level 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
listing in Section 01, Group 001 identifies
product-model/component type-model relationship.
Information is organized in sections and groups for the
various components requiring service instruction. At
the end of this manual are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Before beginning repair on an engine, clean the engine
and mount on a repair stand. (See Section 2, Group
010.)
This manual contains SI Metric units of measure
followed immediately by the U.S. customary units of
measure. Most hardware on these engines is metric.
Some components of this engine may be serviced
without removing the engine from the machine. Refer
to the specific machine technical manual for
information on this and for engine removal and
installation procedures.
Read each block of material completely before
performing service to check for differences in
procedures or specifications. Follow only the
procedures that apply to the engine model number you
are working on. If only one procedure is given, that
procedure applies to all the engines in the manual.
CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects and other reproductive harm.
CTM100 (06APR04) P
OWER
T
ECH
10.5 L & 12.5 L Diesel Engines
040604
PN=2
