Cummins Isx QSX Disassembly and Assembly Abby PDF

ßDC
Cummins ISX QSX Service Manual

Disassembly and Assembly
From the Library o f Barrington Diesel Club

for use by our members only
BDC
Index PI
□ Section PS - Engine Disassembly Group 00
(1Q-008-Q18-shQDdsi Cooling System

(10-007-037-shopdS; Lubricating Oil System
(1Q-QQQ-Q01-shopds) Engine Removal
(10-007-013-shopds) LuDricatina Oil Filter (Spin-On)
(10-008-QQ6-shopds) Coolant Filter
(10-006-015-shopds) Fuel Filter (Spin-On Type)
(10-003-011-shopds) Rocker Lever Cover
(10-013-020-shopds) Starting Motor
(10-008-002-shopds) Drive Belt. Cooling Fan
(10-008-080-shopds) BeltTensioner. Automatic (Water Pump)
(10-008-036-shopds) Fan Hub. Belt Driven
(10-008-088-shopds) Fan Support
(10-009-052-shopds) Drive Belt. Refrigerant C om pressor
(10-009-054-shopds) Idler Pullev. Refrigerant C om pressor
(10-009-053-shopds) BeltTensioner. Refrigerant Com pressor. Automatic
(10-009-051-shopds) Refrigerant C om pressor
(10-003-QQ1-shopds) Crankcase Breather (External)
(10-007-065-shopds) Lubricating Oil Fill Tube
(10-007-011-shopds) Lubricating Oil DiPStickTube
(10-011-021-shopds) EGR Mixer
(10-010-080-shopds) Air Intake Connection
(10-006-006-shopds) ECM Cooling Plate. Fuel Cooled
(101-011-051-shopds) Aftertreatment lmector Lines
(101-011-052-shopds) Aftertreatment Fuel Shutoff Manifold
(10-005-073-shopds) Integrated Fuel System Module (IFSM)
(10-010-114-shopds)TuroocharQer Air ShutoffValve Filter
(10-010-121-shopds)TurbocharQer. Variable Geometry Control Valve Air Supply Line
(10-010-115-shopds)TurbocharQer Control ShutoffValve Filter Head
(10-010-120-shopds)TurbocharQer. Variable Geometry Actuator Air Supply Line
(101-011-043-shopds) Aftertreatment Adapter Pice
(101-011-042-shopds) Aftertreatment Fuel Injector
D iesel Cl ll fa
BDC
Index P2
1 0 1 -0 1 1 -0 4 2 -sh o cq s. -ftertreatment Fuel Iniedor
10-010-113-shO D ds Turbocharaer. Variable Geometry Actuator
10 -010-041-shoD ds Turibocharger Coolant Hoses
10-010-033-shopds Turbocharaer
10-011-032-shopds Heat Shield
10-011-031-shopds EGR Cooler Coolant Lines
10-011-030-shopds EGR Valve Coolant Lines
10-011-022-shopds EGR Valve
10-011-044-shopds EGR Valve Mounting Bracket
10-011-027-shopds Exhaust Gas Pressure Sensor Tuoe
10-011-033-shopds Exhaust Gas Pressure Sensor Adapter
10-011-007-shopds Exhaust Manifold. Dry
10-011-025-shopds EGR Connection Tubes
10-011-019-shopds EGR Cooler
10-007-003-shopds Lubricating Oil Cooler
10-016-001-shopds Engine Lifting Brackets
10-008-014-shopds Coolant Thermostat Housing
10-008-013-shopds Coolant Thermostat
10-013-001-shopds Alternator
10-009-056-shopds Alternator/Refrioerant C om pressor Mountino Bracket
10-0 09-0 5 5-s hoods Refrigerant C om pressor Mounting Bracket
1Q-008-082-shopds Water Inlet Connection
10-008-062-shopds Water Pump
10-003-009-shopds Rocker Lever Assembly
10-006-026-shopds Injector
10-001-052-shopds Vibration Damper. Viscous
10-001-079-shopds Gear Cover. Upper
10-001-023-shocds Crankshaft Seal. Front
10-001-080-shopds Gear Cover. Lower
10-012-004-shopds Air C om pressor Coolant Lines
10-012-014-shopds Air Com pressor
È flP rih g to n D iesel C lub

BDC
Index P3
10-Q12-014-shopds Air Compressor
10-001-088-shODds Engine Base Timing
10-QQ2-024-shODds Overhead Camshaft. Valve
10-002-Q25-shODQS Overhead Camshaft. Injector
1Q-Q02-Q04-shopcs Cylinder Head
10-016-QQ2-shQDds Engine Support Bracket. Front
10-0Q1-Q76-shQDds Idler Gear. Lower Scissor
1Q-QQ7-Q25-shODds Lubricating Oil Pan
1Q-QQ7-Q35-shODds Lubricating Oil Suction Tube (Block-Mounted)
1Q-QQ1-Q89-shopds Block Stiffner Plate
1Q-QQ1-Q46-shopds Piston Cooling Nozzle
10-001-054-shopds Piston and Connecting Rod Assembly
1Q-QQ1-005-shopos Bearing. Connecting Rod
10-QQ1-047-shopds Piston Rings
10-Q16-005-shopqs Flywheel
10-001-024-shopds Crankshaft Seal. Rear
10-Q16-006-shopds Flywheel Housing
10-016-007-shopds Flywheel Housing. REPTO
10-001-033-shopds Gear Housing. Front
10-QQ7-031-shopds Lubricating Oil Pump
10-QQ1-016-shopqs Crankshaft
10-001-007-shopds Bearings. Thrust
10-QQ1-006-shopds Bearings. Main
10-001-028-shopds Cylinder Liner
Cooling System Page 1 of 3
008-018 Cooling System
Drain
Position the equipment on level ground

t ®
aB
m
iV lS 1 ^ \ A imv
A WARNING A
Do not remove the pressure cap
from a hot engine. Wait until the
coolant temperature is below 50°C
[120°F] before removing the
pressure cap. Heated coolant spray
or steam can cause personal injury.
NOTE: If the coolant is being

changed, or if the cooling system is
being flushed, leave the coolant flow
valves to the equipment heating
system s open, in order to
com pletely drain the system.
NOTE: Refer to the OEM service

manual fo r special coolant drain
requirements. Special instructions
may also be located near the cooling
system access point or fill door on
the vehicle.
Isolate the engine from the vehicle

cooling system by closing coolant flow
valves to the equipment heating
systems before starting the repair. This
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will prevent the heater circuit from

draining, minimizing the chance for air
pockets to be present during the fill
process.
This air can be very difficult to purge in

some applications that have several
feet of plumbing and multiple heater
cores.
Remove the radiator cap or expansion

tank fill cap to allow the coolant to drain
completely.
A WARNING A
■V
Coolant is toxic. Keep away from
children and pets. If not reused, Ç
dispose of in accordance with local
environmental regulations.
Do not allow the cooling system to dry

out.
If the coolant is to be reused, the

holding container m ust be free of oil
and dirt.
A drain pan with a capacity of 57 liters

[51 gal] is adequate for most
applications.
Before adding coolant back into the

engine, it m ust be tested for SCA
(Supplemental Coolant Additive)
concentration.
For automotive applications, use the

Signature™ and ISX Operation and
Maintenance Manual, Bulletin 3666251.
Refer to Procedure 018-004 in Section
V.
For industrial applications, use the

Industrial and Power Generation
QSX15 Engines Operation and
Maintenance Manual, Bulletin 3666423.
V.
Open the radiator drain valve(s).
Remove the lower radiator hose(s).
Do not remove the coolant filter.
Check for damaged hoses and loose or

damaged hose clamps. Replace as
required. ’I f j p )
>V *
f > r.
Check the radiator for leaks, damage,
and buildup of dirt. Clean and replace,
as needed.
Close the drain valve(s).
Install the lower radiator hose(s). Refer

to the OEM service manual.
Last Modified: 09-Jun-2010
C opyright © 2000-2010 C um m ins Inc. All rights reserved.
Lubricating Oil System Page 1 of 2
007-037 Lubricating Oil System
Drain
A WARNING A
To reduce the possibility of personal
injury, avoid direct contact of hot oil
with your skin.
A WARNING A
Some state and federal agencies
have determined that used engine
oil can be carcinogenic and cause
reproductive toxicity. Avoid
inhalation of vapors, ingestion, and
prolonged contact with used engine
oil. If not reused, dispose of in
accordance with local environmental
regulations.
Operate the engine until the water

temperature reaches 60°C [140°F],
Shut off the engine.
Remove the oil drain plug.
Drain the oil immediately to make sure

all the oil and suspended contaminants
are removed from the engine.
If lubricating oil element failure occurs

resulting in contamination of the
lubricating oil, the following is
recommended:
• Inspect the lubricating oil filter by

cutting it open and inspecting for
debris. Refer to Procedure 007
083.
• If debris is not found, drain the

lubricating oil and remove the
lubricating oil pan. Clean and
reinstall the lubricating oil pan.
Refer to Procedure 007-025.
• Remove the valve cover and
clean the contaminated
lubricating oil from the cylinder
head cavities. This can be done
using a siphoning device. Refer to
Procedure 003-011.
• If debris is found, refer to the
Cummins Warranty
Administration Manual, Bulletin
4021290.
Last Modified: 12-Apr-2005
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Engine Removal Page 1 of 6
000-001 Engine Removal
Remove
Autom otive and Industrial
Disconnect the intake and the exhaust

air pipes
Disconnect all chassis-mounted,

engine-driven accessories.
Disconnect the OEM wiring harness

from the electronic control module
(ECM). R eferto Procedure 019-071 in
the Troubleshooting and Repair Manual
CM870 Electronic Control Systems
Signature and ISX Engines, Bulletin
4021334.
NOTE: If the rear engine m ounts are
attached to the transm ission, it will

possibly be necessary to remove the
engine and the transm ission as an
assembly.
IIS -1 • WF
Most cab-over configuration vehicles will
have the Cummins® factory-installed rear
engine lifting bracket still installed.
A WARNING A
If a liquid refrigerant system (air
conditioning) is used, wear eye and
face protection, and wrap a cloth
around the fittings before removing.
Liquid refrigerant can cause serious
eye and skin injury.
A WARNING A
To protect the environment, liquid
refrigerant systems must be properly
emptied and filled using equipment
that prevents the release of
refrigerant gas into the atmosphere.
Federal law requires capturing and
recycling the refrigerant.
Remove all chassis components

necessary to remove the engine.
A WARNING A
The engine lifting equipment must
be designed to lift the engine and
the transmission as an assembly
without causing personal injury.
A WARNING A
This component weighs 23 kg [50 lb]
or more. To reduce the possibility of
personal injury, use a hoist or get
assistance to lift this component.
Use a correctly rated hoist, and attach

the engine lifting fixture, Part Number
3162871, to the engine-mounted lifting
brackets to remove the engine.
If the transmission is not removed,

place a support under the transmission
to prevent it from falling.
Remove the engine.
Cover all engine openings to prevent dirt

and debris from entering the engine.
Place the engine on suitable engine

support stands.
Remove and use all remaining

accessories and brackets with the
replacement engine.
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Power Generation
Disconnect the intake and the exhaust

air pipes.
Disconnect all chassis-mounted,

engine-driven accessories.
Disconnect the OEM wiring harness

from the electronic control module
(ECM). R eferto Procedure 019-071 in
Electronic Control System Signature,
ISX and QSX15 Engines, Bulletin
3666259.
Remove all chassis components

necessary to remove the engine.
'm □
LET .
© A
A WARNING A
A WARNING A

the engine lifting fixture, Part Number
brackets to remove the engine.
Remove the engine.
Cover all engine openings to prevent dirt

and debris from entering the engine.
Place the engine on suitable engine

support stands.
Last Modified: 14-Mar-2005

Lubricating Oil Filter (Spin-On) Page 1 of 1
007-013 Lubricating Oil Filter (Spin-On)
Remove
A WARNING A
To reduce the possibility of personal
injury, avoid direct contact of hot oil
with your skin.
A WARNING A
Some state and federal agencies
have determined that used engine
oil can be carcinogenic and cause
reproductive toxicity. Avoid
inhalation of vapors, ingestion, and
prolonged contact with used engine
oil. If not reused, dispose of in
regulations.
NOTE: If the lubricating oil filte r

head adapter comes o ff during the
removal o f the lubricating oil filter,
then reinstall the oil filte r head
adapter. Use a small am ount of
Loctite™ on the threads o f the oil
filte r head adapter and tighten. Refer
to Procedure 007-018 (Lubricating
Oil Filter Head Adaptor) in Section 7.
Use oil filter wrench, Part Number

3375049, 3397929, or 3400157 to
remove the oil filter.
Last M odified: 11-Jun-2009
Coolant Filter Page 1 of 1
008-006 Coolant Filter
Remove
A WARNING A
Remove the cooling system pressure

cap.
A WARNING A
Coolant is toxic. Keep away from
children and pets. If not reused,
dispose of in accordance with local
environmental regulations.
Turn the coolant on/off valve to the

OFF position.
Do not use force to open or close the

on/off valve. If the valve does not turn
freely, refer to Procedure 008-082.
Remove and discard the coolant filter.

Clean the gasket surface on the filter
head.
Last M odified: 12-Apr-2005
Fuel Filter (Spin-On Type) Page 1 of 2
006-015 Fuel Filter (Spin-On Type)
Remove
With Pressurized Fuel Filtering
A WARNING A
Fuel is flammable. Keep all
cigarettes, flames, pilot lights, arcing
equipment, and switches out of the
work area and areas sharing
ventilation to reduce the possibility of
severe personal injury or death
when working on the fuel system.
Clean the area around the fuel filter

head and filter.
Remove the fuel filter with filter wrench,

Part Number 3400157.
With Vacuum Fuel Filtering
A WARNING A
Fuel is flammable. Keep all
cigarettes, flames, pilot lights, arcing
equipment, and switches out of the
work area and areas sharing
ventilation to reduce the possibility of
severe personal injury or death
when working on the fuel system.

head and filter.
Disconnect the wiring harness from the

water-in-fuel sensor, if equipped.

Rocker Lever Cover Page 1 of 1
View Related Topic
003-011 Rocker Lever Cover
Remove
NOTE: Enqines built before —■— —

September 7, 2006, and have a the tzS
separate cover and separate gasket.
Remove the eight capscrews and

isolator assemblies from the rocker
lever cover.
Remove the cover and gasket from the

head separately.
The rocker lever cover gasket is

reusable. Do not damage the gasket
when removing or cleaning.
NOTE: Engines built after September

7, 2006, or engines that have the
cover gasket embedded in the
rocker lever cover.
Completely loosen the eight capscrews

and isolator assemblies.
Remove the rocker lever cover, the

cover gasket and the isolators all
together as an assembly.
The cover gasket is reusable. Do not

damage the cover gasket when
removing the cover or when setting the
assembly aside during repair.
Last M odified: 31-0ct-2006
Starting Motor Page 1 of 1
013-020 Starting Motor
Remove
All Except 50MT With Alum inum Flywheel Housing
Remove the three mounting

capscrews, starting motor, and starting
motor spacer (if used), as well as the
necessary starting motor brackets.
Drive Belt, Cooling Fan Page 1 of 1
008-002 Drive Belt, Cooling Fan
Remove
Drives A lternator
A CAUTION A
The belt tensioner is spring loaded
and must be pivoted away from the
drive belt. Pivoting in the wrong
direction can result in damage to the
belt tensioner or cause personal
injury.
Pivot the automatic tensioner down to

relieve tension on the belt.
Remove the belt.
Belt Tensioner, Automatic (Water Pump) Page 1 of 3
008-080 Belt Tensioner, Automatic (Water Pump)
Remove
Drives A lternator
Remove the mounting capscrew and

the belt tensioner from the bracket
Autom otive Applications
NOTE: Different engine

configurations utilize different belt
tensioner bracket and belt tensioner
arrangements.
For the low-mount belt tensioner:
Remove the belt tensioner mounting

capscrew and belt tensioner from the
bracket.
Remove the belt tensioner bracket from

the water pump.
For the mid-mount belt tensioner:

capscrew and the belt tensioner from
the bracket.
The mid-mount aluminum belt

tensioner/idler bracket is part of the
water pump removal and installation
because of common capscrew usage.

For the low-mount (small version) belt

tensioner:

capscrew and belt tensioner from the
bracket.
Remove the belt tensioner bracket from

the front engine support
Fan Hub, Belt Driven Page 1 of 2
008-036 Fan Hub, Belt Driven
Remove
Autom otive w ith CM870
A WARNING A ■•¿I
This component weighs 23 kg [50 lb] r ; *

Remove the mounting capscrews and

the fan hub assembly.
A WARNING A
This assembly weighs 23 kg [50 lb] W : "a
assistance to lift this assembly.
Remove alternator belt tensioner and

bracket.
Remove the capscrews and the fan

hub assembly.
Industrial CM570 and Power Generation w ithout CM570
Remove the fan hub mounting

capscrews. @8
Remove the fan hub from the fan
support.

Fan Support Page 1 of 1
008-088 Fan Support
Remove
Copyright © 2000-2010 Cummins Inc. All rights reserved.
Drive Belt, Refrigerant Compressor Page 1of 1
009-052 Drive Belt, Refrigerant Compressor
Remove
With Water Pump and Refrigerant Com pressor Belt Routing
A CAUTION A
injury.
Pivot the automatic tensioner

counterclockw ise to relieve tension
on the belt.
Remove the belt.
Idler Pulley, Refrigerant Compressor Page 1 of 1
009-054 Idler Pulley, Refrigerant Compressor
Remove
Belt Tensioner, Refrigerant Compressor, Automatic Page 1 of 1
009-053 Belt Tensioner, Refrigerant Compressor,

Automatic
Remove
Remove the mounting capscrew and

the refrigerant compressor belt
tensioner from the bracket.
I f y -s
Refrigerant Compressor Page 1 of 1
009-051 Refrigerant Compressor
Remove
Sanden
Remove the four refrigerant

compressor mounting capscrews. »
Remove the refrigerant compressor.
Climate Control Incorporated
Crankcase Breather (External) Page 1 of 2
View Related Topic
003-001 Crankcase Breather (External)
Remove
Remove the breather tube and rubber

grommet from engine.
• i
~~ II 1\ V
Remove the four p-clips securing the * y*

hose to the front cover and block * a\ _r - \
< 1 ____
" \ \ . “4'
. J U -À J — '
Autom otive W ith CM871
Disconnect the wiring connector from

the breather pressure sensor.
Loosen the two hose clamps on the

inlet hose.
Disconnect hose from breather. Loosen * 1 %

outlet hose clamp. ' NAÍC ¡ W ^
Disconnect the outlet hose.
Disconnect the breather oil drain line.
Remove the drain line inline with the

connection nipple, do not bend.
Remove the four mounting capscrews

from the crankcase breather element
housing to the breather housing
bracket and remove the housing
assembly.
Lubricating Oil Fill Tube Page 1 of 3
007-065 Lubricating Oil Fill Tube
Remove
A CAUTION A
Removal of the oil fill tube without
loosening the tube brace capscrew
is likely to cause fill tube thread
breakage.
Loosen the tube brace capscrew (1).
Remove the tube brace capscrew from

the gear cover (2).

Remove the ring seals from the oil fill

connection, the oil fill tube, and the oil
fill tube cap.
»
Discard the ring seals.
Ring seals:
1. Oil fill connection ring seal

S' _
2. Oil fill tube ring seal

3. Oil fill cap ring seal.
A CAUTION A
Removal of the oil fill tube without
loosening the tube brace capscrew
is likely to cause fill tube thread
breakage
Remove the tube brace capscrews

from the gear cover.

Rotate the oil fill tube connection - # * #
counterclockw ise to remove. A

smooth, rounded end, bar can be used
for leverage to rotate the oil fill tube
connection.
* ß g U
Remove the ring seals from the oil fill

connection, the oil fill tube, and the oil
fill tube cap. o
Discard the ring seals. V
Ring seals:
1. Oil fill connection ring seal

2. Oil fill tube o-rings
3. Oil fill cap ring seal.
Last Modified: 21-Feb-2006

Lubricating Oil Dipstick Tube Page 1 of 1
007-011 Lubricating Oil Dipstick Tube
Remove

EGR Mixer Page 1 of 1
011-021 EGR Mixer
Remove
Do n o t remove the EGR inlet pipe into

the EGR mixer. This is a precision
interface and performance will be
affected if disturbed. There is no
service procedure for this and none is
required.
Remove the capscrews at the four-bolt

flange between the EGR mixer and the
air intake horn.
Last Modified: 25-Jul-2006
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Air Intake Connection Page 1 of 2
View Related Topic
010-080 Air Intake Connection
Remove
Cover all open points on the air intake ‘* dl * - J

connection and cylinder head with caps - <* A*‘ î ’^ Æ i
and heavy tape from the Air Handling
Clean Care Kit or heavy tape. ' f í ■V '
1 y ■*
Autom otive, Industrial w ith CM570 and Power Generation w ithout CM570
ECM Cooling Plate, Fuel Cooled Page 1 of 1
006-006 ECM Cooling Plate, Fuel Cooled
Remove
Disconnect the ECM cooling plate fuel

supply line (bottom) from the integrated
fuel system module and the ECM cooling
plate.
Disconnect the ECM cooling plate fuel

return line (top) from the fuel pump and
the ECM cooling plate.
Remove the five ECM mounting

capscrews and the ECM.
Remove the six cooling plate mounting

capscrews and washers.
Remove the cooling plate and gasket.
Remove five insulating washers and the

one ground washer from the cooling plate
mounting holes.
Copyright © 2 0 0 0 -2 0 1 0 Cum m ins Inc. All rights reserved.
Aftertreatment Injector Lines Page 1 of 5
011 -051 Aftertreatment Injector Lines
Remove
Disconnect the aftertreatment injector

coolant supply line at the inlet to the @i
aftertreatment injector.
/ s r f
coolant supply line at the EGR cooler.
Remove the aftertreatment injector

coolant supply line.
Disconnect the aftertreatment injector ' J j

coolant return line at the aftertreatment
injector.

V
coolant return line at the oil cooler. •<&

coolant return line.
A WARNING A
Depending on the circumstance,
diesel fuel is flammable. When
inspecting or performing service or
repairs in the fuel system, to reduce
the impossibility of fire and resulting
severe personal injury, death or
property damage, never smoke or
allow sparks or flames (such as pilot
lights, electrical switches, or welding
equipment) in the work area.

head and filter.

Disconnect the wiring harness from the < ' &

P a
shut off valve, fuel drain valve, and f if • ‘
pressure sensor.

fuel supply line from the supply outlet of
the fuel rifle.

fuel supply line at the inlet to the fuel
shutoff manifold.
Remove the aftertreatment injector fuel

supply line.
_ . «i f
For access lower the fuel shutoff A •
P
manifold by removing the two mounting v a
capscrews. -- . O-Ql t .•
1
I
'••sac
Disconnect the fuel return line from the

fuel shutoff manifold and the fuel
control module.

fuel supply line at the outlet of the fuel
shutoff manifold.
Disconnect the fuel lines from the union

fitting, located just above the EGR
valve.

fuel supply line at the inlet to the
aftertreatment injector, use a 9/16 inch
wrench. In some applications, access
to the aftertreatment injector is difficult
and requires removal of the exhaust
adapter pipe. Refer to Procedure 011
043 in Section 11.

coolant supply line at the inlet to the %
aftertreatment injector. 7
/ X t
Disconnect the aftertreatment injector o 7 - - / A ,
---- - !
coolant supply line at the coolant
$
heater housing.

coolant supply line.

coolant return line at the aftertreatment @8
injector.
coolant return line at the coolant return

manifold.

coolant return line.

fuel supply line from the supply outlet of 0 s
the fuel rifle.
x lu
fuel supply line at the inlet to the fuel
shutoff manifold.
a i
Remove the aftertreatment injector fuel
supply line.
Disconnect the fuel return line from the

fuel shutoff manifold and the fuel return
tee fitting, located in front of the engine 4
* r # i /
control module.
'¿ L : yJ
Remove the P-clips.
X

fuel supply line at the outlet of the fuel
shutoff manifold.

fuel supply line at the inlet to the
aftertreatment injector. In some
applications, access to the
aftertreatment injector is difficult and
requires removal of the exhaust
adapter pipe. Refer to Procedure 011
043 in Section 11.
Aftertreatment Fuel Shutoff Manifold Page 1 of 3
011-052 Aftertreatment Fuel Shutoff Manifold
Remove
A WARNING A X
Wear appropriate eye and face

protection when using compressed
air. Flying debris and dirt can cause
t
personal injury.
Fuel Shutoff Manifold - Make sure the

area around the fuel shutoff manifold is
clear of debris.
Use compressed air to clean the area

and remove any loose dirt particles.
A WARNING A
protection when using compressed
air. Flying debris and dirt can cause
personal injury.
Fuel Shutoff Manifold - Make sure the

area around the fuel shutoff manifold is
clear of debris.
Use compressed air to clean the area

and remove any loose dirt particles.
Remove the aftertreatment fuel shutoff

valve (1), aftertreatment fuel drain
valve (2), and aftertreatment pressure
sensor (3) with a 1-1/8 inch open end
wrench.
Integrateci Fuel System Module (IFSM) Page 1 of 1
005-073 Integrated Fuel System Module (IFSM)
Remove
A WARNING A
This component or assembly weighs
greater than 23 kg [50 lb]. To
prevent serious personal injury, be
sure to have assistance or use
appropriate lifting equipment to lift
this component or assembly.
Remove two mounting capscrews from

the IFSM.
Install two guide studs.
Remove the remaining capscrews,

IFSM, and gasket. Discard the gasket,
if damaged.
Turbocharger Air Shutoff Valve Filter Page 1 of 1
010-114 Turbocharger Air Shutoff Valve Filter
Remove
Variable Geometry
Use filter wrench and remove the air

filter from the turbocharger control
shutoff valve.
Turbocharger, Variable Geometry Control Valve Air Supply Line Page 1 of 2
010-121 Turbocharger, Variable Geometry

Control Valve Air Supply Line
Remove
A CAUTION A
The turbocharger control valve is
very sensitive to contamination.
Failure to prevent contamination
from entering the turbocharger
control valve air lines will cause
damage to the turbocharger control
valve.
Make sure the keyswitch is in the OFF

position.
Bleed the air from the control valve air

supply line.
Disconnect the air line at the

turbocharger control valve.
Mask the end of the air line and

turbocharger control valve to prevent
contamination.
Remove the p-clips holding the air line

to the engine.
Disconnect the air line from the

turbocharger control shutoff valve.
Remove the turbocharger control valve

air supply line.

turbocharger control shutoff valve to
prevent contamination.

Turbocharger Control Shutoff Valve Filter Head Page 1 of 1
010-115 Turbocharger Control Shutoff Valve

Filter Head
Remove
Variable Geometry
Turbocharger, Variable Geometry Actuator Air Supply Line Page 1 of 1

Actuator Air Supply Line
Remove
A CAUTION A
The turbocharger control valve is very
sensitive to contamination. Failure to
prevent contamination from entering
the turbocharger control valve air lines
will cause damage to the turbocharger
control valve.
Make sure the keyswitch is in the OFF

position.
Disconnect the air line at the turbocharger

actuator.

turbocharger actuator to prevent
contamination.
Remove the p-clip at the thermostat

housing.
Disconnect the air line from the


turbocharger control valve to prevent
contamination.
Remove the turbocharger control valve air

line.
C o p yrig h t© 2000-2010 Cum m ins Inc. All rights reserved.
http://127.0.0.1:5000/https@quickserve. cummins.com/qs2/pubsys2/xml/en/procedure... 2014/12/10

Aftertreatment Adapter Pipe Page 1 of 1
011-043 Aftertreatment Adapter Pipe
Remove
Remove the V-band clamp between the

exhaust adapter pipe and the
turbocharger.
Remove the V-band clamp between the

exhaust adapter pipe and the OEM
exhaust down-pipe.
Remove the adapter pipe assembly

from engine.
Remove the gasket from each end and

discard. Do not use a screwdriver or
other sharp tool to remove the gaskets.
This will damage the gasket seating
area.

from the adapter pipe. Refer to
Procedure 011-042 in Section 11.
Aftertreatment Fuel Injector Page 1 of 1
011-042 Aftertreatment Fuel Injector
Remove
Remove the adaptor tube gasket
Remove the capscrews holding the

injector.
Remove the injector assembly.
Cut the EZ tie holding the injector

harness to the heat shield.
Discard the metal gasket.
Discard the fibrous insulator.
Remove the capscrew spacers.

Turbocharger, Variable Geometry Actuator Page 1 of 2
View Related Topic

Actuator
Remove
Variable Geometry
A CAUTION ^
\ r^ y n l ilii
The keyswitch must be in the OFF
position to make sure no air
pressure is present at the actuator. y vV
\ i
. ...
Remove the capscrew holding the

actuator rod to the turbocharger cross
shaft.
Remove the snap ring from the cross

shaft.
A WARNING A
Keep fingers and hands away from
the actuator link to reduce the
possibility of personal injury as a
result of sudden movement when air
is supplied.
Loosen the two capscrews holding the

actuator to the turbocharger bearing
housing.
Use coupling, Part Number 3824843, to

apply 414 kPa [60 psi] regulated air
pressure to the actuator air inlet, to
reduce the spring load at the linkage.
Remove the two loosened capscrews

and actuator.
Turbocharger Coolant Hoses Page 1 of 2
View Related Topic
010-041 Turbocharger Coolant Hoses
Remove
A utom otive w ith CM870
Use a second wrench to hold the

coolant hose coupling while loosening
the line.
Remove the turbocharger coolant

supply line from the bottom of the
turbocharger and the lubricating oil filter
head.

the line.

return line from the top of the
turbocharger and the thermostat ft
housing.
Use a second wrench to hold the * -.¿r' ; j ?• . *

j I* »
the line.

supply hose from the lubricating oil filter
head (1).
’ V JS :
Remove the smaller banjo bolt from the
turbocharger electric actuator coolant

inlet port (2) and the large banjo bolt
from the turbocharger bearing housing
coolant inlet port (3).

t - " 1
the line.
Remove the turbocharger bearing ' • ....

housing coolant return hose from the
top of the turbocharger and the
thermostat housing (1). ...
Remove the turbocharger actuator

coolant return hose from the top of the
turbocharger and the thermostat
housing (2).
Last Modified: 18-May-2007
Turbocharger Page 1 of 11
010-033 Turbocharger
Remove
A WARNING A
Autom otive, Industrial, and Power

Generation with CM570
• Remove the oil supply, oil drain

tube, and brace (if equipped) from
the turbocharger.
Remove the intake and exhaust pipes

from the turbocharger.
Remove the charge-air cooler piping

from the discharge elbow.
NOTE: In some applications, the

turbocharger w ill not clear the
lubricating oil cooler assembly
during removal and installation. It
w ill, perhaps, be necessary to
remove the exhaust m anifold and
turbocharger together, and then
separate the two com ponents. If the
tw o com ponents must be removed
together fo r the removal and
installation o f the exhaust manifold.
Refer to Procedure 011-007 in
Section 11.
If the turbocharger mounting nuts do

not loosen freely, split the nuts to avoid
breaking a mounting stud.
Remove the four turbocharger

mounting nuts.
Remove the turbocharger and discard

the gasket.
Clean
Turbine Housing Cleaning fo r ISX
Autom otive with CM570, QSX15 with
CM570, and Power Generation with
CM570
• The turbocharger turbine housing

surface adjacent to the turbine
compressor wheels m ust be clean,
smooth, and free from deposits.
• Inspect the components to detect
signs of burning and other
conditions, in order to obtain as
much information as possible before
washing.
NOTE: This procedure applies ONLY to

Autom otive with CM570, QSX15 with
CM570, and Power Generation with
CM570. Do NOT disassemble variable

geometry turbochargers (VGT).

protection when using non-corrosive
metal cleaner.
Soak the turbocharger turbine housing in a

non-corrosive, low flash point metal
cleaner to loosen deposits.
A CAUTION A
protection when using compressed air.
Flying debris and dirt can cause
personal injury.
Scale-like deposits, if any, m ust be

removed by using a non-metallic bristle
brush. After removing the deposits, wash
and dry the components.
Dry the components with compressed air.
A CAUTION A
protection when using compressed air.
Flying debris and dirt can cause
personal injury.
NOTE: Do not bead blast alum inum and

cast iron com ponents together.
NOTE: To prevent bead spray

im pinging directly on the clamp plate
and turbine flange threads, mask and
plug off all items.

NOTE: Prevent the bead spray
im pinging directly on the wastegate
valve spindle, as beads can penetrate
the spindle bore, and lead to spindle
seizure.
It is permissible to bead blast the

turbocharger turbine housing if chemical
and brush cleaning is not effective.
Inspect for Reuse
ISX Autom otive w ith CM570, QSX15

w ith CM570 and Power Generation
w ith CM570
• Clean the retaining nut mating

surfaces of the turbocharger and
the exhaust manifold.
• Clean the mating surfaces with
Scotch-Brite™ 7448 abrasive
pad.
• The surface under the mounting
nuts m ust be free of dirt, rust, or
any other debris, before applying
anti-seize compound, Part
Number 3823097.
Inspect the wastegate actuator. Refer

to Procedure 010-050 in Section 10.
Inspect the turbocharger casings.
Replace the housing if through cracks

are found in the outer walls.
Cracking in the turbine housing inlet flange

c ____
and the inlet duct generally requires
replacement of the turbine housing.
Acceptance and rejection guidelines are
shown in these illustrations. If an exhaust
«
Ct&X
= = ^ (° j9
( fI ' O i m\ * .
gasket is available, always make certain .
that cracks do not exist within the sealing

area.
Check the turbine housing inlet flange

flatness. It m ust be within 0.1 mm [0.004
in] to be acceptable for reuse.
Flange Fasteners - Clearance Floles
Check the fastener hole diameter. It must

not be more than 1.5 mm [0.006 in] larger
than the maximum thread diameter of the
fastener.
A CAUTION A
If external cracks are found on the
turbine housing, the turbine housing
must be replaced.
A CAUTION ^

Turbine blades can be easily damaged

and care is required for the turbine
housing installation process.
Cracking of the internal wall at the entry to

the turbine wheel (tongue) is acceptable
as a service condition, and the turbine
housing can be re-used.
Inspect the turbocharger compressor v-

band outlet and the discharge elbow v-
band connection for dents or fretting.
Replace the turbocharger or discharge

elbow, if damaged, to prevent
compressed air leaks. 51
Use dial depth gauge, Part Number ST-

537.
Push the rotor assembly away from the

gauge.
Set the gauge to zero (0).
Push the rotor assembly toward the

gauge and record the reading.
Turbocharger Axial Clearance

mm____________________in
0.025 MIN 0.001
0.127 MAX 0.005
If the turbocharger axial clearance is

not within specifications, the
turbocharger m ust be replaced.
i---------------------------------------------------------------------------- 1---------------- 1-----------------------------------------------------------1
Use a dial indicator to check radial

movement at the compressor impeller
nose.
Push the impeller away from the gauge

and set the indicator to zero. Push the
impeller toward the gauge and record
the reading.
Turbocharger Radial Bearing

Clearance________________________
mm____________________in
0.406 MIN 0.016
0.610 MAX 0.024
If the turbocharger radial clearance is

not within specifications, the
turbocharger m ust be replaced.
If the engine experiences a

turbocharger malfunction or any other ©
occasion where oil or debris is put into
the charge-air system, the charge-air I" iw a fe l
system m ust be inspected and
cleaned. Refer to Procedure 010-027 in H frs
Section 10. if ram
Inspect for cracks in the turbocharger

and compressor casings. ©
Replace the turbocharger if through
cracks in the outer walls are found.
Inspect for cracks on the turbine inlet I N I

and exhaust mounting flanges. Replace
the turbocharger if any cracks are
found.
Clean the retaining nut mating surfaces

of the turbocharger and the exhaust
manifold.
\ . « jV /
Clean the mating surfaces with Scotch )>V.-
Brite™ 7448 abrasive pad.
\\ ^
The surface under the mounting nuts
& |1
m ust be free of dirt, rust, or any other
debris before applying anti-seize \\ «MW»
compound, Part Number 3823097.

band outlet and the discharge elbow v- w 1

compressed air leaks.
Inspect the compressor wheel for signs

of rubbing against the compressor
cover. Replace the turbocharger if
rubbing evidence is seen.
Use light finger pressure to push the

compressor wheel. If the compressor
wheel contacts the cover, replace the
turbocharger.

turbocharger malfunction or any other
the charge-air system, the charge-air
cleaned. Refer to Procedure 010-027 in
Section 10.

turbocharger must be replaced.
Check the radial movement of the

turbocharger wheels and shaft. ©
compressor wheel toward the side of
the compressor housing.
Repeat the procedure for the turbine

wheel and housing.
Replace the turbocharger if either

wheel contacts the housing.
Inspect the variable geometry actuator

and mechanism for proper operation.
10 .
Inspect for cracks in the turbocharger

and compressor casings.
Replace the turbocharger if through

cracks in the outer walls are found.
Inspect for cracks on the turbine inlet

and exhaust mounting flanges. Replace
the turbocharger if any cracks are
found.
NOTE: All openings on the

turbocharger, including the turbine
inlet connection, m ust be plugged
w ith caps from the A ir Handling and
Vehicle A ir Plumbing Clean Care I ■, /

Kits, Part Numbers 4919403, and
4919425 respectively, during flange > iw r\[
cleaning.
Clean the turbocharger and exhaust

L ^ £ l \
manifold where the retaining nut it ir
contacts the turbocharger and exhaust \\ \
manifold.
Clean the mating surfaces with Scotch

Brite™ 7448 abrasive pad.
After abrasive cleaning, wipe debris

from both surfaces with a clean shop
towel.
The surface under the mounting nuts

must be free of dirt, rust, or any other
debris, before applying anti-seize
compound, Part Number 3823097.
Replace turbocharger if any leaks are

found.
Check for evidence of coolant in the oil

supply and oil drain fittings.

band outlet and the discharge elbow v-

compressed air leaks.
Inspect the compressor wheel for signs

of rubbing against the compressor
cover. Replace the turbocharger if
rubbing evidence is seen.

compressor wheel. If the compressor
wheel contacts the cover, replace the

turbocharger.

turbocharger malfunction or any other
the charge-air system, the charge-air
cleaned. Refer to Procedure 010-027 in
Section 10.
Check the axial movement of the

turbocharger wheels and shaft.
Turbocharger Axial Clearance________

mm_____________________ in
0.051 MIN 0.002
0.152 MAX 0.006
If the turbocharger axial clearance is not

within specifications, the turbocharger
must be replaced.
Check the radial movement of the

turbocharger wheels and shaft.
Use light finger pressure to push the ÆS,\ \

compressor wheel toward the side of the
compressor housing.
Repeat the procedure for the turbine

wheel and housing.
WW
Replace the turbocharger if either wheel
contacts the housing.
Last Modified: 18-Nov-2009
Heat Shield Page 1 of 1
011-032 Heat Shield
Remove_________
Remove the three mounting

from the EGR valve
Remove the heat shield
Autom otive With CM871
Remove the four EGR valve heat shield

mounting capscrews from the EGR
valve
Remove the heat shield
EGR Cooler Coolant Lines Page 1 of 3
011 -031 EGR Cooler Coolant Lines
Remove
Remove the two mounting capscrews

from the EGR cooler coolant return
line.
Disconnect the EGR cooler coolant

return line from the EGR cooler and the
elbow connection on the thermostat
housing.
A CAUTION A
Be sure all the components are
clean and free of debris that can
cause damage to o-ring seals.
Disconnect the EGR cooler coolant

vent line from the thermostat housing
and the EGR cooler.
Remove the two EGR cooler coolant

return tube mounting capscrews.
*
&
Remove the EGR cooler coolant return

jumper tube from the EGR cooler. ©
o
9
K
-q
b
Remove the EGR cooler coolant supply

tube mounting capscrew
Slide the EGR cooler coolant supply

jumper tube all the way rearward inside
the EGR cooler coolant supply tube.

tube retaining clamp capscrew from the
water pump housing.

tube rearward until the EGR cooler
coolant supply tube is disengaged from
the water pump outlet. X aA

tube from the engine.
jß
Remove and discard all three o-rings.
Remove the nuts from the EGR cooler £> é ^ ti.'

coolant supply tube mounting bracket.
EGR Valve Coolant Lines Page 1 of 1
011-030 EGR Valve Coolant Lines
Remove
EGR Valve Page 1 of 2
011-022 EGR Valve
Remove
Loosen the v-band clamp connecting

the EGR valve to the exhaust manifold.
Loosen the v-band clamp connecting

the EGR valve to the EGR cooler
connection.
Disconnect the EGR valve electrical

connector
Make sure to support the EGR valve by

hand before removing the mounting
capscrews. If the EGR valve is no t
supported, it can fall off of the engine,
causing damage to the EGR valve and
actuator.
Loosen and remove the four EGR valve

mounting capscrews.
Remove the EGR valve from the EGR

valve support bracket.
The EGR valve will need to be moved

at an angle forward and downward in
order to disengage it from the EGR
valve support bracket.
Use protective caps from the Air

Handling Clear Care Kit to cover open
points on the EGR valve and bracket.
EGR Valve Mounting Bracket Page 1 of 1
View Related Topic
011-044 EGR Valve Mounting Bracket
Remove
Remove one of the EGR valve bracket

rear support mounting capscrews (2)
9
from the EGR valve mounting bracket
and cylinder head. &
Remove the remaining two EGR valve
mounting bracket capscrews (1).
> fî' 'f.*
Exhaust Gas Pressure Sensor Tube Page 1 of 1
011-027 Exhaust Gas Pressure Sensor Tube
Remove
Exhaust Gas Pressure Sensor Adapter Page 1 of 1
011 -033 Exhaust Gas Pressure Sensor Adapter
Remove
All Applications
Exhaust Manifold, Dry Page 1 of 1
View Related Topic
011-007 Exhaust Manifold, Dry
Remove
A WARNING A
Remove two mounting capscrews and

install two guide studs.
Remove the remaining mounting

capscrews, the spacers, the exhaust
manifold assembly and the gaskets.
Discard the gaskets.
Cover open points on the exhaust

manifold and cylinder head using heavy
tape.
EGR Connection Tubes Page 1 of 4
011-025 EGR Connection Tubes
Remove
A WARNING A
The EGR connection tubes can be
hot. To reduce the possibility of
personal injury, allow the engine to
cool before removing.
Loosen all hose clamps on the EGR

connection tubes and remove the two
p-clip mounting capscrews or nuts
(depending on the vintage of the
engine) on the front EGR connection
tube.
If the M10 stud comes out upon

removal of the nut, install the M10 stud
into the block until the stud bottoms
out.
Remove the one capscrew and one nut

or the two nuts that attach the rear
section of the connection tube to the
cylinder block.
If the M10 stud comes out upon

removal of the nut, install the M10 stud
into the block until the stud bottoms
out.
Remove the front EGR connection

tube.
Remove the one capscrew and one nut

that attach the rear section of the @8
connection tube to the cylinder block.
Remove the rear EGR connection tube
from the EGR cooler.
Autom otive With CM871
A WARNING A
— vdJ
The EGR connection tubes can be
hot. To reduce the possibility of
personal injury, allow the engine to
cool before removing.
Loosen the hose clamps on the front

EGR connection tube and remove the
hose.
Remove the two retaining capscrews

on the lower portion of the tube at the
EGR valve housing outlet.
Remove the front EGR connection tube

and hose.
Discard the hose.
Use protective caps from the Air Handling

Clean Care Kit, Part Number 4919403 and
Q fc .
Part Number 4919425, to cover the open
points on all components. ® c r ••••
• *\ , % ^
6 :V 1
•
Remove the three EGR venturi

mounting capscrews. IS
Remove the EGR venturi. /✓
C j
Cover the irregular openings on the // x

venturi and air intake connections with
I
protective caps from the Air Handling
Clean Care Kit, Part Number 4919403 and 'A
~cc _
Remove the two rear EGR connection

capscrews from the EGR cooler.
1 8 ^
Loosen the hose clamp on the rear
EGR connection tube.
Pull the EGR cooler outlet connection

tube from the EGR cooler. <^‘) .
Use protective caps from the Air Handling

Clean Care Kit, Part Number 4919403 and
Part Number 4919425, to cover the open
points on all components.
Last M odified: 08-Dec-2009

EGR Cooler Page 1 of 3
011-019 EGR Cooler
Remove
Loosen the hose clamps at the rear

EGR connection tube.
Remove and discard the EGR hose.
A CAUTION A
The straps on the EGR cooler are
not serviceable. Adjusting or
removing the straps can damage the
EGR cooler.
Remove the four capscrews that attach

the EGR cooler to the block.
Remove the four nuts that attach the

EGR cooler to the lubricating oil cooler
assembly.
Remove the EGR cooler assembly

from the engine.
Remove the coolant supply and vent

jumper tubes if they remain in the block
after the cooler is removed.
Loosen the v-band clamp between the

EGR cooler and the exhaust manifold.
In order to prevent damage to the EGR
cooler bellows, place the v-band clamp
over the exhaust manifold flange.
Loosen the rear EGR connection tube

/ V
retaining capscrews at the EGR cooler
9
gas outlet.
Remove and discard the gasket.

Handling Clean Care Kit, Part Number w ar
4919403, to cover the open points on
both the EGR cooler and EGR
plumbing.

the EGR cooler to the block.
V. k
Remove the four nuts that attach the
EGR cooler to the lubricating oil cooler
assembly.
Remove the EGR cooler bracket

clamping plates from the EGR cooler.
Remove the EGR cooler assembly

from the engine.

Lubricating Oil Cooler Page 1 of 2
View Related Topic
007-003 Lubricating Oil Cooler
Remove
All A pplications
Remove two oil cooler mounting

capscrews and install the guide pins.
T
Clean the area above the oil cooler to if*
prevent debris entry into the oil
passages. <■,<> ,
A WARNING A <s>
Remove the remaining 18 capscrews,

oil cooler, and gasket. Discard the
gasket.
■i
A CAUTION A . & '

\ v
.A y f\\
Immediately upon removal of the /* \

lubricating oil cooler assembly, a - 1/ js b s i
«
plug must be inserted into the v •m
housing and cylinder block oil

passage drillings. Failure to insert
the oil passage plug can result in a
bearing failure, crankshaft failure, or
both.
The reusable plugs, Part Numbers

4918322, 4918324, and 4918340, are
included in protective plug kit, Part
Number 4918319. These plugs are
necessary to prevent debris from
entering the lubrication system during
the repair.
Plug the oil cooler housing filtered oil

passage with plug, Part Number
4918323, the block filtered oil passage
with plug, Part Number 4918340, and
the block oil pump passage with plug,
Firmly push the plugs into the oil

passages to prevent all debris from
entering the lubrication system when
cleaning the gasket surface.
Engine Lifting Brackets Page 1 of 1
016-001 Engine Lifting Brackets
Remove
NOTE: Newer models use three

m ounting capscrews.
Remove the four capscrews and the

rear lifting bracket.
Remove the four capscrews and the

front lifting bracket
Coolant Thermostat Housing Page 1 of 3
008-014 Coolant Thermostat Housing
Remove
Single Thermostat
Remove the four thermostat housing

cover capscrews.
Remove the thermostat cover and

gasket.
Discard the gasket.

.S O k .* •
Remove the thermostat from the

thermostat housing cover.
c p
Remove the three thermostat housing

capscrews.
Remove the thermostat housing and

gasket.
Discard the gasket.
Dual Thermostat
Remove the upper radiator hose from

the thermostat housing cover.

the thermostat housing cover to the
thermostat housing.
Remove the thermostat housing cover

and gasket from the thermostat
housing.
Discard the gasket.
Remove the two capscrews that attach

the thermostat housing to the cylinder
head.
Remove the thermostat housing and

gasket from the cylinder head.
Discard the gasket.
Coolant Thermostat Page 1 of 2
008-013 Coolant Thermostat
Remove
Remove the upper radiator hose from

the thermostat housing cover.

the thermostat housing cover to the
thermostat housing.
Remove the thermostat housing cover

and gasket from the thermostat
housing. Discard the gasket.
Alternator Page 1 of 2
013-001 Alternator
Remove
Driven by Cooling Fan Drive Belt
Remove the four alternator mounting

capscrews.
Remove the alternator from the

alternator spacers.
Alternator/Refrigerant Compressor Mounting Bracket Page 1 of 1
009-056 Alternator/Refrigerant Compressor

Mounting Bracket
Remove
Disconnect the wire harness jumper from the

EGR valve motor, EGR valve position sensor
and the main engine wire harness.
Remove the five mounting capscrews from the

alternator/refrigerant compressor mounting
bracket.
Gently pry out the bracket from the gear

housing.
The split washers will create a slight friction fit

between the bracket and the gear housing.
Remove the wire harness jumper from the

bracket.
Remove the six mounting capscrews from the

bracket.
Gently pry out the bracket from the gear i f /

housing.
The split washers will create a slight friction

between the bracket and the gear housing.
Refrigerant Compressor Mounting Bracket Page 1 of 2
009-055 Refrigerant Compressor Mounting

Bracket
Remove
Sanden
Remove the four mounting capscrews

from the refrigerant compressor
bracket.
Remove the refrigerant compressor

bracket from the refrigerant
compressor.
Water Inlet Connection Page 1 of 1
008-082 Water Inlet Connection
Remove
Remove the coolant hoses.
Remove the four capscrews, water inlet

connection, gasket, and o-ring.
Water Pump Page 1 of 2
008-062 Water Pump
Remove
Remove two water pump mounting

capscrews and install two guide studs.
Remove the remaining three

capscrews, the water pump, and the o-
ring seal.
Discard the o-ring seal.
Remove two water pump capscrews

and install guide studs.
Remove remaining three capscrews,

water pump, and water inlet o-ring seal.
Discard the o-ring seal.
Rocker Lever Assembly Page 1 of 2
003-009 Rocker Lever Assembly
Remove
There are four rocker lever shafts:
• Front - valve and brake rocker lever

shaft
• Rear - valve and brake rocker lever
shaft
• Front - injector rocker lever shaft
• Rear - injector rocker lever shaft.
A CAUTION A
Some valves will not be loose. Do not
tighten or bottom adjusting screw
against lever. Engine damage can
occur.
Loosen the valve and injector adjusting

screw locknuts on each rocker lever.
Turn the adjusting screws

counterclockw ise until the rocker levers
are loose.
A CAUTION A
Use care when handling shafts.
Rocker levers can fall off the shaft
during removal and damage the
levers.
Remove the valve and brake, rocker

lever shaft capscrews, and the rocker
lever shaft assemblies.
Remove the injector, rocker lever shaft

capscrews, and the rocker lever shaft
assemblies.
Remove the valve crossheads.
To prevent increased wear, mark each

crosshead and rocker lever shaft
assembly as it is removed so it can be
installed back in its original location.
Remove the rocker levers and brake

levers from the shafts.
Remove the rocker lever spacers from

the shaft.
Remove the locknuts and the adjusting

screws from the rocker levers. v*""
To prevent increased wear, mark each
adjusting screw as it is removed so it
can be installed back in its original
rocker lever.
Inj ector Page 1 of 3
006-026 Injector
Remove
Do not bottom out adjusting screws.

Engine damage can occur if
adjusting screws are bottomed out.
Remove only the valve and injector

shaft for the injector(s) being removed.
Loosen the injector rocker lever

adjusting screws.
Remove the six capscrews and injector

rocker lever shaft.
Do not let the rocker levers come off of

the shaft during removal.
Rotate the engine to the valve set mark

for the injector being removed Refer to
Procedure 003-004 in Section 3
Loosen and turn the valve lash

adjusting screws counterclockw ise to
allow the intake and exhaust valve
crossheads to be removed.
Remove the intake crosshead.
Mark the crossheads to make certain

they are installed in the same position.
Position the exhaust valve crosshead

toward the exhaust side of the engine
to allow the injector to be removed.
Loosen the injector clamp capscrew.
Use a small magnet to remove the

injector clamp capscrew and washer.
Remove the injector clamp capscrew

and washer.
Do not use a heel bar to pry the

injector loose from the cylinder head.
Damage to the injector can occur.
Use injector puller, Part Number

3823579, to remove the injectors.
If the injector spring does come loose

from the spring retainer, it can be
reassembled by using a screwdriver to
compress the spring back under the
retainer.
Last M odified: 15-Sep-2010
Vibration Damper, Viscous Page 1 of 3
View Related Topic
001-052 Vibration Damper, Viscous
Remove
Autom otive A pplications
A CAUTION A
Do not use a hammer or a
screwdriver to remove the vibration
damper(s). These tools can damage
the vibration damper(s).
Remove two of the vibration damper(s)

and crankshaft pulley retaining
capscrews.
Install two guide studs into the holes.
Remove the remaining 10 capscrews.
Remove the pulley and vibration

damper(s).
Industrial and Power Generation with Crank-Driven Fan or PTO
Remove the crankshaft adapter (1)

from the pulley (2).
Remove two pulley capscrews
Install two guide studs into the holes.
A CAUTION A
damper. These tools can damage
the vibration damper.
Remove the remaining four capscrews.
Remove the pulley (4), vibration

damper (3), mounting spacer (2) and
second vibration damper (1).
« t >
A CAUTION A
damper. These tools can damage
the vibration damper.
Remove the remaining 10 capscrews.
Remove the pulley (4), vibration

damper (3), mounting spacer (2), and
second vibration damper (1).
Gear Cover, Upper Page 1 of 2
001-079 Gear Cover, Upper
Remove
A WARNING A
The component weighs 23 kg [50 lb]
injury, use a hoist or get assistance
to lift the component.
Remove 16 capscrews and the upper

gear cover.
Discard the strip seal.
Some industrial applications use a

stamped steel cover with a clamping plate.
Remove two capscrews and install two

guide pins.
Remove the 14 vibration isolator capscrew

assemblies.
A WARNING A
assistance to lift the component.
Remove the clamping plate and upper

gear cover.
Discard the strip seal.
Crankshaft Seal, Front Page 1 of 2
View Related Topic
001-023 Crankshaft Seal, Front
Remove
Position the replacer plate (1) over the

crankshaft end and against the
crankshaft seal. The large notch
between the teeth needs to bridge the
raised gear cover surface.
Make certain that the alignment of the

three welded nuts on the crankshaft
seal are positioned into the counterbore
slots of the replacer plate (1).
Install a capscrew (4) with a flat washer

(5) in the upper slot of the replacer
plate to hold it in position
A CAUTION A
Tighten the capscrews by hand until
a slight resistance is felt. Do not
overtighten the capscrews or the
seal nuts can break off causing
damage to the seal and leading to
front cover damage.
Use a small alien wrench to thread the

removal tool capscrews (2) through the
replacer plate and into the seal nuts.
Tighten the socket head capscrews (2)

clockw ise into the three seal removal
nuts that are welded on the crankshaft
seal until a slight resistance is felt.
Remove the capscrew in the upper slot

of the replacer plate (1 ).
Install the replacer screw (3) into the

replacer plate (1).
Turn the screw (3) clockw ise until the

crankshaft seal is removed from the
crankshaft.
* O T \V If -
Last Modified: 10-Dec-2007
Gear Cover, Lower Page 1 of 1
View Related Topic
001-080 Gear Cover, Lower
Remove
NOTE: If the gear cover contains an

o-ring seal groove fo r the crankshaft
seal and the seal needs to be
replaced, the lower gear cover must
also be replaced. The new
crankshaft seal has the o-ring
incorporated into the seal.
Remove the 15 capscrews and the

lower gear cover. Discard the strip seal.
Air Compressor Coolant Lines Page 1 of 1
012-004 Air Compressor Coolant Lines
Remove
Finishing Steps
Air Compressor Page 1 of 1
012-014 Air Compressor
Remove
Engine Base Timing Page 1 of 7
001-088 Engine Base Timing
Remove
Valve Camshaft Gear
The injector camshaft scissor gear

m ust be unloaded during removal of
the valve camshaft gear. To unload the
gear, two of the gear screws m ust be
backed out far enough to allow the
teeth on the scissor gear to be aligned.
Unload the injector camshaft scissor

gear.
Remove the valve camshaft gear

mounting capscrew and washer.
Early production engines were not

equipped with puller holes in the valve
camshaft gear. A 3-jaw gear puller
m ust be used for gears that do not
have puller holes. The injector and
valve gear puller, Part Number
3163069, can be used for gears that
have puller holes.
Install the gear puller, Part Number

3163069.
Install the valve camshaft gear

mounting capscrew completely.
Loosen the capscrew two turns.
Use the gear puller to remove the valve

camshaft gear from the camshaft nose.
Remove the puller.
Do not completely remove the

camshaft gear mounting capscrew
when the 3-jaw puller is used. The

capscrew serves as a safety catch by
preventing the gear from shooting off of
the camshaft nose.
Remove the valve camshaft gear

mounting capscrew, spacer, and valve
camshaft gear.
A WARNING A
When using solvents, acids, or
alkaline materials for cleaning, follow
the manufacturer's
recommendations for use. Wear
goggles and protective clothing to
reduce the possibility of personal
injury.
A WARNING A
Some solvents are flammable and
toxic. Read the manufacturer's
instructions before using.
Use a lint free cloth and solvent to

clean the Loctite™ residue from the
nose of the camshaft.
Injector Camshaft Scissor Gear
A CAUTION A
Remove the rear injector camshaft

cover plate before removal of the
injector camshaft gear or camshaft.
The force required to remove the
camshaft gear creates sufficient
backwards movement of the
camshaft to crack the rear cover
plate.
Remove the injector camshaft rear

cover plate.
Remove the injector camshaft scissor

gear mounting capscrew and washer.
Install gear puller, Part Number

3163069.
Install the injector camshaft scissor

gear mounting capscrew. Loosen the
capscrew one turn.
Use the gear puller to force the injector

camshaft scissor gear off the camshaft
taper.
Remove the gear puller.
Remove the capscrew.
Remove the injector camshaft scissor

gear.
A WARNING A
the manufacturer's
injury.
A WARNING A

Injector Camshaft Non-Scissor Gear
A CAUTION A
Remove the rear injector camshaft
cover plate before removal of the
injector camshaft gear or camshaft
The force required to remove the
camshaft gear creates sufficient
backwards movement of the
camshaft to crack the rear cover
plate.
Remove the injector camshaft rear

cover plate.
Remove the injector camshaft gear

mounting capscrew and washer.
Install gear puller, Part Number

3163069.
Install the injector camshaft gear

mounting capscrew. Loosen the
capscrew one turn.
I---------------------------------------------------------1
A WARNING A
the manufacturer's
injury.
A WARNING A

Adjustable Idler Gear
The adjustable idler gear shaft can fall

out when the adjustable idler gear is
removed.
Remove the retainer capscrews,

retainer, gear, and adjustable idler gear
shaft.
Lower Idler Scissor Gear
The lower idler scissor gear m ust be

unloaded during removal. To unload
the gear, two of the gear screws must
be backed out far enough to allow the
teeth on the scissor gear to be aligned
Unload the lower idler scissor gear.
Remove the idler scissor gear

capscrews.
Lower Idler Non-Scissor Gear
Remove the gear, shaft, and thrust

bearing.

Overhead Camshaft, Valve Page 1 of 1
002-024 Overhead Camshaft, Valve
Remove
Remove the retainer capscrews,

retainer, seal, and o-ring
Discard the seal and o-nng
A CAUTION A
Use caution when removing the
camshaft to avoid damaging the
camshaft bushings.
r - ' l
Remove the valve camshaft.
Overhead Camshaft, Injector Page 1 of 1
002-025 Overhead Camshaft, Injector
Remove
Remove the injector camshaft cover plate

capscrews.
Remove the injector cover plate and

gasket.
Discard the gasket.
Remove the two capscrews and the

injector camshaft retainer plate and o-
rings.
Discard the o-rings.
A CAUTION A
Use caution when removing the
camshaft bushings.
Remove the injector camshaft.
Cylinder Head Page 1 of 2
002-004 Cylinder Head
Remove
A WARNING A
Use a chip vacuum to remove the

excess oil from the top of the cylinder
head.
Remove the cylinder head capscrews.
Use engine lifting fixture, Part Number

4919360 or equivalent, to lift the
cylinder head.
Remove the cylinder head. Remove

and discard the gasket.
Remove the fire rings from the cylinder

liners, if equipped.
NOTE: This step is not applicable if

the engine has flat-top liners and a
single-piece head gasket, or when
upgrading from grooved-top liners
and a 13-piece gasket to flat-top
liners and a single-piece gasket.
Prior to removing the cylinder head

gasket and sealing rings (if installed),
examine the gasket for carbon tracks
across the sealing ring.
The pressure of carbon indicates a

combustion leak.
Remove the cylinder head gasket.
Make sure the cylinder liner recession

or protrusion (based on liner style) is
within specification.
Refer to Procedure 001 -028 in Section

1.
Engine Support Bracket, Front Page 1 of 1
View Related Topic
016-002 Engine Support Bracket, Front
Remove
A WARNING A
This assembly weighs 23 kg [50 lb]
Remove the two capscrews that attach

the support to the equipment frame.
Use the hoist to lift the weight of the

engine off the front support.
Idler Gear, Lower Scissor Page 1 of 1
001-076 Idler Gear, Lower Scissor
General Information
Before installation or removal of any .'Ie (Its |Vh / A1

gears, read Engine Base Timing. Refer
if
I f
Last Modified: 11-Sep-2009

Lubricating Oil Pan Page 1 of 1
View Related Topic
007-025 Lubricating Oil Pan
Remove
Remove the oil pan mounting

capscrews, oil pan, and gasket. ® i
Discard the oil pan gasket.
Lubricating Oil Suction Tube (Block-Mounted) Page 1 of 1
007-035 Lubricating Oil Suction Tube (Block-

Mounted)
Remove
Remove the lubricating oil suction tube J ç r ~tt— —• • • . .
capscrews, suction tube, and o-ring

Discard o-ring

Block Stiffener Plate Page 1 of 1
001-089 Block Stiffener Plate
Remove
Piston Cooling Nozzle Page 1 of 1
001-046 Piston Cooling Nozzle
Remove
Piston and Connecting Rod Assembly Page 1 of 3
001-054 Piston and Connecting Rod Assembly
Remove
A WARNING A
alkaline materials for cleaning,
following the manufacturer's
injury.
A WARNING A
A CAUTION A
Do not use emery cloth or
sandpaper to remove carbon from
the cylinder liners. Aluminum oxide
or silicon particles from emery cloth
or sandpaper can cause serious
engine damage. Do not use any
abrasives in the ring travel area. The
cylinder liner can be damaged.
Use a fine fibrous, abrasive pad such

as Scotch-Brite™ 7448, Part Number
3823258, or equivalent, and solvent to
remove the carbon.
Install two connecting rod guide pins,

Use a T-handle piston pusher to push
the connecting rod away from the

crankshaft.
Push the connecting rod until the piston

rings are outside of the top of the
cylinder liner.
Remove the upper connecting rod

bearing. I
v \
Mark the cylinder number and the letter
U (upper) on the flat surface of the ------ v
/T W
bearing tang.
K ~ y —
Use both hands to remove the piston

and connecting rod assembly.
The piston and connecting rod

assemblies m u st be installed in the ?
same cylinder they were removed from
to provide for proper fit of worn mating
f C
surfaces if parts are reused. ¡ n n u
Use a tag to mark the cylinder number

from which each piston and connecting
rod assembly was removed.
A CAUTION A
To reduce the possibility of engine
damage all pistons within a given
engine must be of the same design - all
are to be either the articulated design
or the single-piece design. Do not mix
piston designs in the same engine.
Single-piece pistons must have drilled
rods and connecting rod bearings.

Articulated pistons can use either
drilled or non-drilled rods and bearings.
Place the connecting rod and piston

assemblies in a container to protect them
from damage.
A unique number (not cylinder number)

(£ )
is stamped on the connecting rod and Æ )
matching connecting rod cap. When the
connecting rods and connecting rod
cap are installed in the engine, the
numbers on the connecting rod and cap
must match and be installed on the
same side (the exhaust side) of the
engine.
Bearings, Connecting Rod Page 1 of 2
View Related Topic
001-005 Bearings, Connecting Rod
Remove
Rotate the crankshaft so that two of the

connecting rods are at bottom dead
center.
Do not remove the capscrews at this time.
Loosen the connecting rod capscrews.
Hit the connecting rod capscrews with a

rubber hammer to loosen the rod caps
from the dowels.
X -
Remove the capscrews and the rod

cap.
Remove the bearing shell from the rod

cap and mark the cylinder number and
the letter "L” on the flat surface of the Wn/
bearing tangs.
§ fs !
\
Install two guide pins, Part Number

3163097, in the connecting rod. 0 »
Push the rod up far enough to allow the
upper bearing shell to be removed. Use
a T-handle piston pusher.
Remove the bearing shell and mark the

cylinder number and the letter "U" on
N K - y
the flat surface of the bearing tangs.
Piston Rings Page 1 of 2
001-047 Piston Rings
Remove
Articulated Piston
Place a tag on the rings, and record the

cylinder number of the piston on the tag
for future reference, if required.
SO
Single-Piece Piston
A CAUTION A
Do not over-expand the second
piston ring on single-piece pistons.
n
Use a universal ring expander to
remove the second piston ring on
single-piece pistons.
Place a tag on the rings, and record the

cylinder number of the piston on the tag
for future reference, if required.
[IT O
Flywheel Page 1 of 1
View Related Topic
016-005 Flywheel
Remove
A WARNING A
This component weighs 23 kg [50 lb] or
more. To reduce the possibility of personal
injury, use a hoist or get assistance to lift
the component.
Use two M6 x 1.5 guide studs to prevent the

flywheel from rotating. Remove two capscrews
and install the guide studs.
Use a hoist, two t-handles, and a lifting sling.

Install the tee-handles. Remove the remaining
ten capscrews. Remove the flywheel.
Use a soft faced mallet to tap the flywheel

from the crankshaft, if necessary. Damage to
the clutch surface can occur if a hard faced
hammer is used.
Remove the pilot bearing spacer from the rear

of the crankshaft. 0
c
Use a mandrel and hammer to remove the
pilot bearing from the flywheel.
\
Crankshaft Seal, Rear Page 1 of 2
001-024 Crankshaft Seal, Rear
Remove
The rear crankshaft seal requires the rear

crankshaft seal replacer kit, Part Number
3164780, for the seal removal and
installation.
i V s
V
1.
2.
3.
Replacer plate
Pilot drill
Replacer screw
w
4. Self-tapping screw x 10
5. Stud x 3
6. Hex nut x 3.
Use three flywheel mounting

capscrews to secure the replacer plate
(1) to the crankshaft.
Install a pilot drill (2) into one of the

holes in the rear crankshaft seal tool
and drill a hole through the seal casing.
%
§ § ||
Remove the pilot drill (2) and repeat the
procedure for at least two more evenly
spaced holes of the rear crankshaft
seal tool. As many as six holes may be
drilled to assist in removing the rear
crankshaft seal.
NOTE: Three stud screws (3) and

three hex nuts (4) are required fo r
some engines w ith flywheel
m ounting capscrews that are too
short to m ount the replacer plate (1)
to the crankshaft.
NOTE: Three quide pins. Part

Number 3164765, are required on
REPTO applications to support the
REPTO crankshaft gear and the
replacer plate.
Install at least three self-tapping screws

(1) into the replacer plate (2).
Remove the flywheel capscrews from

the rear crankshaft seal tool.
Install the replacer screw (3) into the

center hole of the replacer plate and
turn clockw ise to remove the seal.
Measure
Measure the protrusion of the outer

rubber portion (A) of the seal relative to
the inner metal portion of the seal (B).
Set the dial indicator to zero on the

inner metal portion of the seal.
Measure and record the protrusion of

the outer rubber portion of the seal.
Repeat the measurement in four
locations equally spaced around the
crankshaft seal.
The protrusion measurement at each

location m ust be within +/-1 mm [+/-
0.04 in]. The difference between any of
the four protrusion measurements
m ust be within +/- 0.5 mm [0.02 in].
If either of these conditions are not

met, the rear crankshaft seal m ust be
removed and a new seal installed.
Flywheel Housing Page 1 of 2
View Related Topic
016-006 Flywheel Housing
Remove
A WARNING A
or more. To avoid personal injury,
use a hoist or get assistance.
Use a hoist and lifting sling. Install the

ill
lifting sling around both sides of the
upper housing. Adjust the hoist until
there is tension in the lifting sling.
Remove the remaining capscrews.
A CAUTION A
Immediately upon removal of the
flywheel housing assembly, a plug must
be inserted into the cylinder block oil
passage drillings. Failure to insert the
oil passage plug can result in a bearing
failure, crankshaft failure, or both.
The reusable plug, Part Number 4918321,

is included in Protective Plug Kit, Part
Number 4918319. This plug is necessary
to prevent debris from entering the
lubrication system during the repair.
Plug the block oil passage with plug Part

Number 4918321.
Firmly push plug into oil passage to

prevent all debris from entering the
lubricating system when cleaning the
gasket surface.
Flywheel Housing, REPTO Page 1 of 4
View Related Topic
016-007 Flywheel Housing, REPTO
Remove
A WARNING A
Remove the 10 10-mm capscrews from

the hydraulic housing.
Remove the hydraulic housing from the

REPTO flywheel housing.
Remove the spray nozzle from the oil

supply line hole.
Remove the 12 capscrews (1) from the

seal carrier.
Remove the seal carrier (2) from the

Remove oil seal (4) and discard. Refer

Procedure 001-024 (Crankshaft Seal,
Rear) in Section 1.
Remove the o-ring (3) from the groove

on the REPTO flywheel housing.
Remove the crankshaft gear.

sZ>
Remove the idler gear shaft capscrew
and washer.
Remove the three guide pins.
If the idler gear shaft can not be

removed with the handle, a slide
hammer similar to Snap-On, Part
Number CJ114, can be used.
|f\
Position the replacer idler plate, Part
Number 3164762, on the idler gear
shaft. Install and tighten the two idler
gear capscrews. Install the handle, Part
Number 3163089.
Torque Value: 14 n.m [124 in-lb]
Remove the idler shaft, idler gear, and

bearing from the REPTO flywheel
housing.
Remove two capscrews from the

Install the two guide pins, Part Number

3164764.
Install the two eye bolts, Part Number

3164767, on the top of the REPTO
flywheel housing. Install the lifting
slings to the eye hooks. Adjust the hoist
until there is tension in the lifting sling. •
Remove the remaining capscrews.
' \ .
A WARNING A
Use a mallet to tap the REPTO

flywheel housing off the two locating
dowels. Remove and discard the
gasket.
A CAUTION A
6
Immediately upon removal of the
flywheel housing assembly, a plug must
be inserted into the cylinder block oil
passage drillings. Failure to insert the w m
oil passage plug can result in a bearing
failure, crankshaft failure, or both.
The reusable plug, Part Number 4918321,

is included in Protective Plug Kit, Part
Number 4918319. This plug is necessary
to prevent debris from entering the
lubrication system during the repair.
Plug the block oil passage with plug Part

Number 4918321.
Firmly push the plug into the oil passage

to prevent all debris from entering the
lubricating system when cleaning the
gasket surface.
Gear Housing, Front Page 1 of 1
View Related Topic
001-033 Gear Housing, Front
Remove
A WARNING A
injury, use a hoist or get assistance
to lift the component.
Remove two capscrews and install two

guides.
Lubricating Oil Pump Page 1 of 1
007-031 Lubricating Oil Pump
Remove
A CAUTION A
Do not discard shims, if equipped.
They must be installed in the original
location. Failure to do so can result
in engine damage.
Remove four capscrews, oil pump, and

shims if equipped.
When installing a new oil pump, new

shims will possibly be needed to
acquire acceptable lash.
Last Modified: 04-Aug-2009
Crankshaft Page 1 of 1
001-016 Crankshaft
Remove
A WARNING A
This component or assembly weighs w
J U
to ítiD
greater than 23 kg [50 lb]. To ;
b r\

sure to have assistance or use B u c o cB R L
Use a lifting strap that will not damage

the crankshaft.
Use a hoist and a sling that to remove

the crankshaft.
Bearings, Thrust Page 1 of 1
001-007 Bearings, Thrust
Remove
Remove the thrust bearings from the

number four main bearing cap.
Mark the thrust bearings as being

lower, and front or rear bearings.
A CAUTION A
To reduce the possibility of damage
to the crankshaft, use care when
removing the upper thrust bearings.
Use a blunt tool to remove the upper

thrust bearings.
Mark these bearings as being upper,

and front or rear bearings.
Bearings, Main Page 1 of 2
View Related Topic
001-006 Bearings, Main
Remove
A CAUTION A
Mark any unmarked bearing caps
before removing them from the
cylinder block. Do not remove main
bearing capscrews until the main
bearing cap is pulled, or the cap
could fall out, causing personal
injury and parts damage.
If the crankshaft is not going to be

removed, replace the main bearings
one at a time.
Loosen the main bearing cap

capscrews.
Use the main bearing cap puller, Part

Number ST-1178, to remove the cap.
The tool m ust be centered on the cap
Remove the main bearing capscrews

and cap.
Rotate the crankshaft with the air

compressor drive or a barring device to
remove the main bearing shell.
Mark each main bearing for location if

they are to be installed again in the
engine.
Cylinder Liner Page 1 of 2
001-028 Cylinder Liner
Remove
The cylinder liners can be removed by

using either: 1
• Cylinder liner puller (universal), ». ».
Part Number 3163745, and puller

plate (S600), Part Number 1 _____
t
1
3162462.
• Cylinder liner puller (universal),
A CAUTION A
The cylinder puller must be installed
and used as described to reduce the
possibility of damage to the cylinder
block. The puller plate must be
parallel to the main bearing saddles
and must not overlap the cylinder
liner outside diameter.
Insert the cylinder liner puller onto the

top of the cylinder block.
The cylinder liner puller m ust be

centered on the top of the cylinder
block.
Turn the puller jackscrew clockw ise to

loosen the cylinder liner from the
cylinder block.
Use both hands to remove the cylinder

liner.
Remove and discard the o-ring seals.
Use Dykem™, or equivalent, to place a

mark on the intake air side of the cylinder
liner to show cylinder liner orientation.
» IÂ
Use Dykem™, or equivalent, to mark the

cylinder number on each cylinder liner.
, j* ï
A ^ /

BDC
E Section AS - Engine Assembly - Group 00
10-0Q1-Q28-shoDas :' Cylinder Liner
10-001-006-shopas) Bearings. Main
10-Q01-QQ7-shopas; Bearing. Thrust
1 0-001-016-shopasi Crankshaft
1 0 - 0 0 7 - 0 3 1 - s h Q D a s ) Lubricating Oil Pump
1Q-Q01-Q33-shopas) Gear Housing. Front
lO-Oie-OOe-shopas’; Flywheel H ousing
1 0-016-007-shopasi Flywheel Housing. REPTO
10-001-024-shopas Crankshaft Seal. Rear
10-016-005-shopas Flywheel
10-001-047-shopas Piston Rinas
10-001-005-shopas Bearings, Connecting Rod
10-001-054-shopas Piston and Connecting Rod Assem bly
10-001-046-shopas Piston Cooling Nozzle
10-001-089-shopas Block Stiffener Plate
10-007-035-shopas Lubricating Oil Suction Tube (Block-Mounted)
10-007-025-shopas Lubricating Oil Pan
10-001-076-shopas Idle Gear. Lower Scissor
10-016-002-shopas Engine Support Bracket. Front
10-002-004-shopas Cylinder Head
10-002-025-shopas Overhead Camshaft. Injector
10-002-024-shopas Overhead Camshaft. Valve
10-001-088-shopas Engine Base Tim ing
10-012-014-shopas Air C o m p re s so r
10-012-004-shopas Air C o m p re s so r Coolant Lines
10-001-080-shopas Gear Cover. Lower
10-001-023-shopas Crankshaft Seal. Front
10-001-079-shopas Gear Cover. Upper
10-001-052-shopas Vibration Damper. Viscous
10-006-026-shopas Injector
10-003-009-shopas Rocker Lever Assem bly
10-003-004-shopas Overhead Set
10-008-062-shopas Water Pump
10-008-082-shopas Water Inlet Connection
10-009-055-shopas Refrigerant C o m p re s so r Mounting Bracket
10-009-056-shopas Alternator/Refrigerant C o m p re s so r Mounting Bracket
10-013-001-shopas) Alternator
0 -0 1 3 -0 0 1 -s h o p a s ) A lternator
0 -0 0 8 -0 1 3 -s h o p a s ) C o o la n t T h e rm o s ta t
0 -0 0 8 -0 1 4 -s h o p a s ) C o o la n t T h e rm o s ta t H o u sin g
0 -0 1 6 -0 0 1 -s h o p a s ) E ngine Lifting Brackets
0 -0 0 7 -0 0 3 -s h o p a s ) L ubricating Oil C o o ler
0 -0 1 1 -0 1 9 -s h o p a s ) EGR C o o le r
0 -0 1 1 -0 2 5 -s h o p a s ) EGR C onnection Tubes
0 -0 1 1 -0 0 7 -s h o p a s ) E xhaust Manifold. Dry
0 -0 1 1 -0 3 3 -s h o p a s ) E xhaust Gas P re ssu re S e n so r Adapter
0 -0 1 1 -0 4 4 -s h o p a s ) EGR Valve M ounting Bracket
0 -0 1 1 -0 2 7 -s h o p a s ) E xhaust Gas P re s s u re S e n so r Tube
0 -0 1 1 -0 2 2 -s h o p a s ) EGR Valve
0 -0 1 1 -0 3 0 -s h o p a s ) EGR Valve C o o la n t L in es
0 -0 1 1 -0 3 1 -s h o p a s ) EGR C o o le r C o o la n t Lines
0 -01 1 -0 3 2 -s h o p a s ) H eat S hield
0 -0 1 0 -0 3 3 -s h o p a s ) T u rb o ch a ra e r
0 -0 1 0 -0 4 1 -s h o p a s ) T u rb o ch a ra e r C o o la n t H o se s
0 -0 1 0 -1 1 3 -s h o p a s ) Turbocharaer. V ariable Geom etry Actuator
0 1 -0 1 1 -0 4 2 -s h o p a s ) A ftertreatm ent Fuel Im ector
0 1 -0 1 1 -0 4 3 -s h o p a s ) A ftertreatm ent A dapter Pipe
0 -0 1 0 -1 2 0 -s h o p a s ) Turbocharaer. V ariable G eom etry Actuator Air Supply Line
0 -0 1 0 -1 1 5 -s h o p a s ) T urbocharaer. C ontrol S hutoff Valve Filter H ead
0 -0 1 0 -1 2 1 -s h o p a s ) Turbocharaer. V ariable Geometry C ontrol Valve Air Supply Line
0 -0 1 0 -1 1 4 -s h o p a s ) T u rb o ch a ra e r Air S hutoff Valve Filter
0 -0 0 5 -0 7 3 -s h o p a s ) Integrated Fuel System M odule (IFSM )
0 1 -0 1 1 -0 5 2 -s h o p a s ) A ftertreatm ent Fuel S hutoff M anifold
0 1 -0 1 1 -0 5 1 -s h o p a s ) Aftertreatm ent Im ector L ine s
0 -0 0 6 -0 0 6 -s h o p a s ) ECM C o o lin g Plate. Fuel C ooled
0 -0 1 0 -0 8 0 -s h o p a s ) Air Intake C onnection
0 -0 1 1 -0 2 1 -s h o p a s ) EGR Mixer
0 -0 0 7 -0 1 1 -s h o p a s ) Lu b rica tin g Oil D ip s tic k T u b e
0 -0 0 7 -0 6 5 -s h o p a s ) L ubricating Oil Fill Tube
0 -0 0 3 -0 0 1 -s h o p a s ) C ra n kcase B reather .External)
0 -0 0 9 -0 5 1 -s h o p a s ) R e frig era n t C o m p re s s o r
0 -0 0 9 -0 5 3 -s h o p a s ) Belt T e n sio n e r. R efrigerant C o m p re sso r. Autom atic
0 -0 0 9 -0 5 4 -s h o p a s ) Idler Pulley. R e frig era nt C o m p re s s o r
0 -0 0 9 -0 5 2 -s h o p a s ) Drive Belt. R e frig era nt C o m p re s s o r
0 -0 0 8 -0 8 8 -s h o p a s ) Fan S upport
0-008-035-shODas) Fan Hub. Belt Driven
0-008-080-shopas) Belt Tensioner. Automatic (Water Pump)
0-008-002-shoDas'j Drive Belt. Cooling Fan
0-013-020-shoDas) Starting Motor
0-003-011-shopas) Rocker Lever Cover
0-006-015-shopas) Fuel Filter (Spin-On Type)
0-008-006-shODas'i Coolant Filter
0-007-013-shopas) Lubricating Oil Filter (Spin-On)
0-000-002-shoDas i Engine Installation
0-007-037-shoDas) Lubricating Oil System
0-008-018-shoDas) Cooling System
001-028 Cylinder Liner
Install
A CAUTION A
Cylinder liners of different design can
not be mixed within an engine. All six
cylinder liners must be of the same
design.
There are two different designs of cylinder

liners used. The design used in a
particular engine is dependent on the
engine's production vintage.
Engines assembled prior to engine serial

number 14022615 have groove-top
cylinder liners. They are characterized by
a groove machined into the top surface of
the cylinder liner flange.
Engines with serial number 14022615,

and after, are assembled with flat-top
cylinder liners. They are characterized by
a cylinder liner flange that is flat, except
for the fire dam.
Make sure the cylinder block and all

parts are clean before assembly.
Lubricate the two cylinder liner o-ring

seals with vegetable oil prior to
assembly.
Install the two o-ring seals onto the

cylinder liner.
A CAUTION A
Cylinder liners of different design
can not be mixed within an engine.
All six cylinder liners must be of the
same design.
Install the cylinder liner into the cylinder

block.
When acceptable and used cylinder

liners are installed, rotate the cylinder
liner 90 degrees from its original
position in the engine. The thrust and
anti-thrust surfaces m ust face the front
and back of the cylinder block.
Use cylinder liner installation kit, Part

Number 3162461, to seat the liner.
If the cylinder liner does not seat

properly, remove it and inspect the
cylinder liner bore seat and cylinder
liner for nicks, burrs, or dirt.
Install the cylinder liner again.
Measure
Liner Protrusion
Because of design differences, the

o
cylinder liner's position (relative to the
cylinder top deck) will be different. 1 i l 1A
For groove-top cylinder liners, a recession

measurement is taken. This measures the
depth of the groove relative to the cylinder
block deck regardless of the flange or fire
dam height.
For flat-top cylinder liners, a cylinder liner

protrusion measurement is taken which is
the height of the cylinder liner flange
above the cylinder block surface
regardless of the flange or fire dam height.
Regardless of the cylinder liner design, the

measurement technique will be the same.
The cylinder liner measurement must

be checked before installing the pistons
and connecting rods.
The cylinder liner measurement must

be made with the cylinder liners in the
clamped state.
Install and tighten the cylinder liner

installation tool.
Torque Value: 68 n.m [50 ft-lb]
Use depth gauge, Part Number

3823495, to measure the clamped
state at the intake side three times and
average the readings.
Measure the clamped state of the

exhaust side three times and average
the readings.
Cylinder Liner Recession (Groove

Top Cylinder Liners)
mm in
0.36 MIN 0.014
0.51 MAX 0.019
Cylinder Liner Protrusion (Flat-Top
Cylinder Liners)
mm in
0.18 MIN 0.007
0.33 MAX 0.014
If the cylinder liner measurement on
either the intake or exhaust side is not

within specifications, the cylinder liner
must be replaced.
For flat-top cylinder liners only:
• The difference between the lowest

cylinder liner and the highest
cylinder liner can not be greater than
0.102 mm [0.004 in],
• The maximum allowable difference
between adjacent cylinders is 0.051
mm [0.002 in],
• The protrusion must be within
0.0381 mm [0.0015 in] around any
cylinder.
Before installing the piston and

connecting rod assemblies, wipe the
inside of the cylinder liners.Use a clean
cloth with 15W-40 oil.
View Related Topic
001-006 Bearings, Main
Install
A CAUTION A Ù-*
The cylinder block saddle and the

cap mating surfaces must be clean
and dry when the bearing shells are
installed. Used bearings must be
installed in their original location or
engine damage can occur.
A CAUTION A
The bearing tang must fit into the slot
in the bearing saddle or engine
damage can occur.
A CAUTION A
Do not use a capscrew or any hard
metal object to install bearings, as
this can damage the crankshaft and
cause an engine failure.
Use clean Lubriplate™ 105 multi

purpose lubricant, or its equivalent, to
lubricate the upper main bearing shell
to crankshaft journal mating surface.
Start the bearing into the upper saddle

by hand. Slide the bearing into position.
Take care to not damage the
crankshaft journal while installing the
bearing.

purpose lubricant, or its equivalent, to «
lubricate the inside diameter of the
bearing shells and the liner side of the
upper thrust bearings.
Align the lower main bearing shell and

push it into place.
' iksxmr
A CAUTION A Ò-*
Make sure the bevel side is toward

the crankshaft journal. Incorrect
thrust bearing installation will result
in engine damage.

purpose lubricant, or its equivalent, to
lubricate the liner side of the lower
thrust bearings.
Install the lower thrust bearings in the

number four main bearing cap as
shown.
A CAUTION A
Make sure the bevel side is toward
the crankshaft journal. Incorrect

thrust bearing installation will result
in engine damage.
Install the upper thrust bearings in the

number four main bearing saddle.
Push the crankshaft toward the rear of

the engine to install the front thrust
bearing and toward the front of the
engine to install the rear thrust bearing.
A CAUTION A
Only use Loctite™ 518 thread sealant
on the main cap joint mating surface.
Other sealants can become hard,
brittle, and allow oil and debris into the
main bearing/block joint, causing
engine damage.
A CAUTION A
The bead must be 3 to 5 mm [0.12 to
0.20 in] wide and must not enter the
main bearing shell inside the main
bearing shell inside diameter. Sealant
in the main bearing can cause engine
damage.
Apply a bead of Loctite™ 518 thread

sealant to the two main bearing cap
surfaces on each main bearing cap as
shown.
Use clean 15W-40 engine oil to

D-
lubricate the capscrew threads and flat
washers (or the underside of the
capscrew heads if washers are not
used).
Drain the excess oil from the capscrews

before installing them.
A CAUTION A
The main bearing caps are marked
with a 'V.' Position the 'V mark so
that it points to the front of the
engine. Incorrect positioning will
result in severe engine damage.
Align the capscrew holes in the cap

with the holes in the cylinder block.
Make sure the lower bearing shell is in
position.
Install the capscrews through the cap

and into the cylinder block.
To reduce the possibility of bore size

issues, clearance issues, or both, the main
bearing capscrews m u st be tightened
within 15 minutes of the Loctite™ 518
thread sealant application.
Make sure the bearing shell does not ,4 k

move.
Tighten the capscrews in far enough to

use a heel bar to pry the caps into
place.
Tighten both of the capscrews on a

main bearing cap to 203 N*m [150 ft-
lb].
Loosen both capscrews completely.
The remaining main bearings do not

have thrust bearings.
It is recommended to use an air impact

wrench and socket, Tool Numbers
3163059 and 3163060, to rotate the
capscrews an additional 180 degrees.
Use the torque plus angle method to

tighten the main bearing capscrews in
the sequence shown.
Torque Q. 1 149 n.m [110 ft-

Value: btep ' lb]
Rotate
Step 2 180
degrees.
To measure the end clearance of the

crankshaft, install a dial indicator onto
the oil pan flange.
Place the tip of the gauge against the

crankshaft counterweight.
Push the crankshaft toward the rear of
the cylinder block.
Crankshafts that have been reground

on the thrust bearing surfaces are
marked for oversize thrust bearings on
the rear crankshaft counterweight. If the
crankshaft counterweight is marked,
check the thrust ring part number to
make sure the correct thrust ring size is
used. ® • 9
Example: F0.010 = front 0.25 mm

[0.010 in]
Example: R0.020 = rear 0.51 mm

[0.020 in]
If the crankshaft end play is more than

0.50 mm [0.020 in], the engine m ust be
removed to allow for replacement of the
crankshaft. Refer to Procedure 000-001
(Engine Removal) in Section 0.
Bearings, Thrust Page 1 of 1
001-007 Bearings, Thrust
Install
Use Lubriplate™ 105, or equivalent, to

coat the upper thrust bearings.
Push the crankshaft toward the rear of the

engine to install the rear thrust bearing,
and to the front of the engine to install the
front thrust bearing.
Install the upper thrust bearings in the

number four main bearing saddle.
The bevel must be toward the crankshaft.
Use Lubriplate™ 105, or equivalent, to

coat the lower thrust bearings.
Install the lower thrust bearings in the

number four main bearing cap as shown.
The bevel of the thrust bearing must be

toward the crankshaft.
http://127.0.0.1:5000/https@quickserve. cummins.com/qs2/pubsys2/xml/en/procedure... 2014/12/08

Crankshaft Page 1 of 1
001-016 Crankshaft
Install
A WARNING A
£ 5 -u b BbSL
A CAUTION A
Use a lifting strap that will not
damage the crankshaft. Do not drop
the crankshaft on the bearings.
Install the main bearings. Refer to

The end of the crankshaft with the

smallest diameter m ust point toward
the front of the cylinder block.
Install the crankshaft.
007-031 Lubricating Oil Pump
Install
Align dowels on oil pump with mounting

holes in the cylinder block.
Install the oil pump, shims (if they were

removed), and the four capscrews.
Tighten the capscrews.
Use a dial indicator, check the oil pump

idler gear back lash.
Oil Pump Idler Gear Backlash

mm in
0.18 MIN 0.008
0.32 NOM 0.013
0.46 MAX 0.018
A CAUTION A
Improper gear lash can cause
damage to the gear train and the
lubricating oil pump.
Shims will be available in six different

thicknesses in order to provide correct
lash. The various thicknesses are
identified by the color of the shim.
Identify the number stamped on the
pump (1) and the letter on the block (2).
Use the following table to determine
which shim should be used according
to the stamped number and letter.
If a lube pump or cylinder block is replaced, the block and pump will not be stamped.
In that instance, a shim m ust be chosen and installed. The oil pump idler gear
backlash m ust be checked. If the backlash is not within the specification, choose
another size shim and recheck the backlash. Do this until the backlash is within
specification.
Block
Pump A B C D
0.000 mm [0.000 0.45 mm [0.018 0.55 mm [0.022 0.35 mm [0.014
1
in]-None- in]-Black- in]-Purple- in]-Yellow-
0.45 mm [0.018 0.65 mm [0.026 0.75 mm [0.030 0.55 mm [0.022
2
in]-Black- in]-Red- in]-Blue- in]-Purple-
0.55 mm [0.022 0.75 mm [0.030 0.85 mm [0.033 0.65 mm [0.026
3
in]-Purple- in]-Blue- in]-Green- in]-Red-
0.35 mm [0.014 0.55 mm [0.022 0.65 mm [0.026 0.45 mm [0.018
4
in]-Yellow- in]-Purple- in]-Red- in]-Black-
If the lubricating oil pump is not within

specifications, the shims m ust be
changed to proper thickness to give
proper backlash.
'^ ‘ " ' mm
View Related Topic
001-033 Gear Housing, Front
Install
Remove the protective plug from the

cylinder block oil passage. Make sure
no debris enters the lubrication system.
Use a clean shop towel, carefully wipe
out the oil passage and inspect to
make sure no debris is left in the
passages.
Install two guide studs.
Install a new gear housing mounting

gasket.
The gear housing has the words

“Special Capscrew” cast into the
housing at the number 1 mounting
location (see illustration). This
capscrew m ust be the short head
capscrew to prevent contact between *4* ax
the capscrew and the idler gear. - _
J* r %
* L
i---------------------------------------------------------1
A WARNING A
Install the gear housing.
Install the 18 mounting capscrews.
Four different length capscrews are

utilized on the front gear housing. Use
the table below to identify the
capscrews and their mounting
locations.
Capscrew Mounting Location

Location Size Quantity
14 M 1 0 x 1 .5 x 9 3 1
18, 19, 20 M 1 0 x 1 .5 x 7 0 3
M10 x 1.5 x
1 21.8 (Special 1
Short Head)
All
M 1 0 x 1 .5 x 2 .5 15
remaining
Remove the guide studs and install two

capscrews.
Tighten the capscrews in the sequence

shown.
All Capscrews Except (1)
20 n.m [15 ft-

Step 2
Ib]
72 n.m [53 ft-

Step 3
Ib]
Capscrew (1)
View Related Topic
016-006 Flywheel Housing
Install

block oil passages. Make sure debris
does not enter the lubrication system.
Use a clean shop towel to carefully

wipe out the oil passage and inspect to
passage.
All
Install two guide studs into the cylinder

block to help support and align the
housing during installation.
Position the flywheel housing gasket to

the rear of the engine block using the
guide pins.
Install the flywheel housing over the

guide studs.
Lubricate the threads and underneath

the heads of the capscrews with clean
15W-40 lubricating oil.
Install capscrews 1, 2, 3, and 4, and

tighten in the sequence shown.
The flywheel housing is located on the

block by two ring dowels from the factory.
If a flywheel housing is removed, it can be
reinstalled with the ring dowels in place,
but alignment m ust be checked with the
following alignment procedure.
If the alignment does not meet

specification, the ring dowels m ust be
removed and the housing m ust be
realigned without the ring dowels.
A CAUTION A
The flywheel housing bore and
surface must be in alignment with
the crankshaft to prevent possible
damage to the engine, the clutch, or
the transmission.
Measure the flywheel housing

alignment.
Measure
Bore Alignm ent
Attach a dial indicator to the crankshaft.

Use mounting tool Part Number ST-
1325 and indicator Part Number
3376050.
The dial indicator can be mounted by

any method that holds the extension
bar of the indicator rigid so it does not
sag. If the bar sags or the indicator
slips, the readings obtained will be
inaccurate.
Position the indicator in the 6:00 o'clock

position and the gauge at zero.
Slowly rotate the crankshaft. Record

the readings obtained at the 9:00
o'clock, 12:00 o'clock, and 3:00 o'clock
positions as (a), (b), and (c) in the
concentricity work sheet. Recheck zero
at the 6:00 o'clock position.
The values for (a), (b), and (c) can be

positive or negative. Refer to the
accompanying figure to determine the
correct sign when recording these
values.
A CAUTION A
Do not force the crankshaft beyond
the point where the bearing
clearance has been removed. Do not
pry against the flywheel housing.
These actions can cause false
bearing clearance reading.
Rotate the crankshaft until the dial

indicator is at the 12-o'clock position
and zero the gauge.
Use a pry bar to raise the rear of the

crankshaft to its upper limit. Record the
value as (d) in the concentricity work
sheet. This is the vertical bearing
clearance adjustment and will always
be positive.
Use the concentricity work sheet (see C o n c ^ i n t H y WOrftfrhMl
the accompanying illustration) to 9 n'ctOCir. 1 n 0 Btìd
determine the total vertical and 3 o 'e la i* e - -O & U
horizontal values. T o d jl H m u m ili ■ a - o ■ DM
■3 a 'cln ck b - .00 3
The total horizontal is equal to the 9:00 n » i n q C 4Hnxicfl d m Bùi
o'clock reading (1) minus the 3 :00 T o d i VirilcflJ fa + d 1 ME

o'clock reading (c).
The total vertical is equal to the 12:00

o'clock reading (b) plus the bearing
clearance (d).
Example:
6:00 o'clock = reference = 0

9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Using the work sheet and the numbers

from the example, the total horizontal
value equals 0.006, and the total
vertical value equals 0.005.
Mark the total horizontal value on the

horizontal side of the chart and the total
vertical on the vertical side of the chart.
Use a straightedge to find the

intersection point of the total horizontal
and total vertical values. The
intersection point m ust fall within the TOTAL M O f lC r m r A l
shaded area for the flywheel housing

concentricity to be within specification.
Using the total horizontal and total

vertical values from the previous
example, the intersection point falls
within the shaded area. Therefore, the
flywheel housing concentricity is within
specification.
Use the accompanying chart for SAE 1,

2, and 3 flywheel housings.
Use the accompanying chart for SAE 0

and % flywheel housings.
OKI
.’.a us is ;ts m
TOTAL l HEADING

flywheel housings.
ok)
• .fs i\X :7 5 a s :* /-
T O T A L H O M S O K T A i. H E A D IN G
If the intersection point falls outside the

shaded area, the ring dowels m ust be
removed and the housing repositioned.
The ring dowels are not required to

maintain concentricity of the housing;
the clamping force of the capscrews
holds the housing in place.
After the ring dowels are discarded,

install the flywheel housing on the
engine.
To position the housing, tighten the

capscrews enough to hold the flywheel
housing in place, but loose enough to
enable small movement when struck
lightly with a mallet.
Recheck the concentricity. When

concentricity is within specification,
tighten the capscrews to the specified
value.
Face Alignm ent
The dial indicator tip must not enter

XT
the capscrew holes, or the gauge
will be damaged.
Install a dial indicator as illustrated.
The extension bar for the indicator

must be rigid for an accurate reading.
It m ust not sag. Position the indicator
at the 12:00 o'clock position. Adjust the
dial until the needle points to zero.
Slowly rotate the crankshaft. Record 6 . 6

the readings at the 3:00 o'clock, 6:00
o'clock, and 9:00 o'clock positions.
The crankshaft m ust be pushed toward

the front of the engine to remove the *
crankshaft end clearance each time a
position is measured.
Continue to rotate the crankshaft until

the indicator is at the 12:00 o'clock
position. Check the indicator to make
sure that the needle points to zero. If it
does not, the readings will be incorrect.
0.00 mm [0.000
12:00 o'clock
in]
+0.08 mm
3:00 o'clock
[+0.003 in]
-0.05 mm [-0.002
6:00 o'clock
in]
+0.08 mm
9:00 o'clock
[+0.003 in]
Total Indicator 0.13 mm [0.005
Runout = in]
The maximum allowable total indicator

reading is determined by the diameter
of the housing bore. If out of
specifications, replace the housing.
Total
SAE Bore Indicator
Number Diameter Runout
Maximum
787.40 to
787.65 mm 0.30 mm
00
[30.88 to [0.012 in]
31.00 in]
647.70 to
647.95 mm 0.25 mm
0
[25.50 to [0.010 in]
25.51 in]
584.2 to
584.4 mm 0.25 mm
1/2
[23.000 to [0.010 in]
23.008 in]
511.18 to
511.30 mm 0.20 mm
1
[20.125 to [0.008 in]
20.130 in]
447.68 to
447.80 mm 0.20 mm
2
[17.652 to [0.008 in]
17.630 in]
409.58 to 0.20 mm
3 409.70 mm [0.008 in]
[16.125 to
16.130 in]
Install the remaining capscrews. (X —b ‘o — ^ 5 ^ °

Tighten all capscrews in two steps
using the sequence shown.
Torque
Value:
Q. 1
btep '
100 n.m
lb]
[74 ft- ©
S te p 2 ¡ f nm I 14 5« '
ICJ

View Related Topic
016-007 Flywheel Housing, REPTO
Install

block oil passages. Make sure no
debris enters the lubrication system.
Use a clean shop towel to carefully

wipe out the oil passage and inspect to
passage.
Install the two guide pins (3), Part

Number 3164764, into the cylinder
block.
Position the flywheel housing gasket to

the rear of the cylinder block using
guide pins.
A WARNING A
Install the two eye hooks (4) in the top

of the REPTO flywheel housing. Install
the lifting slings to the eye hooks and

push the REPTO flywheel housing onto
the two guides pins (3).
Install the six short capscrews (2) and

four long capscrews (1) in the locations
shown.
Remove the two guide pins and install

the two other long capscrews.
Tighten capscrews (1), (2), (9) and

|T \
( 10 ).
Tighten the remaining capscrews in the

sequence shown.
A CAUTION A
The REPTO flywheel housing bore
and face must be in alignment with
the crankshaft to prevent possible
damage to the engine, the clutch, or
the transmission.
Use the measure step in this procedure

to align the housing.
Torque Q. 1 100 n.m [74 ft-

©
Value: btep ' lb]
Install the three oil pan capscrews.
Assemble the replacer idler shaft plate

and handle.
Install the two capscrews in the idler

shaft holes and tighten.
Use clean 15W-40 oil to lubricate the

idler shaft.
The two cones (2) are loose and will fall

out if not contained.
Make sure the gear (4), two bearing

snap rings (1), and the two cups (3) are
pressed in place before inserting the
assemblies through the center or sides
of the REPTO flywheel housing
openings.

bearing snap rings, cones, cups, idler
shaft, and gear.
Make sure the idler shaft plug (1) is

facing upward when installing it into the
bore.
Install the gear and bearing assembly

through the center or sides of the
REPTO flywheel housing holes.
Position the bearing races together and
insert the idler shaft with the tool
through the first bear bore. The running
clearance is 0 to 0.025 mm [0.000 to
0.001 in].
Make sure the idler shaft is properly

aligned and seated against the
shoulder of the internal bore.
Repeat the procedure if installing a

second gear.
Remove the two capscrews, replacer

X
idler plate, and handle from the idler
shaft.
Lubricate the threads and under the

capscrew head with clean 15W-40 oil.
Install the washer and capscrew and

tighten capscrew.
A second idler gear can be installed or
an insert shaft can be used without the

idler gear and roller.
Install the o-rings onto the insert shaft.

Lubricate the o-rings with clean 15W-
40 oil.
Install the insert shaft into the flywheel i? \

housing hole where the cover plate will
be installed (opposite pump location).
Align the hole with the tapped hole in
the block.
Lubricate the threads and under the

capscrew head with clean 15W-40 oil.
Install the washer and capscrew and

tighten capscrew.
Install the three guide pins, Part

Number 3164765, equally spaced
through the crankshaft gear and into
the crankshaft.
Rotate the idler gears, as necessary, to

mesh the crankshaft gear with the idler
gear(s).
Install the crankshaft gear.
Make sure the o-rings are properly

seated into the groove before
installation.
Use clean 15W40 oil to lubricate the o-

rings.
Install four plugs (1) with o-rings (2) into

the REPTO flywheel housing holes.
Install the o-ring in the REPTO flywheel

housing groove.
Install the three flywheel mounting *• / ilt f ' >J v \
capscrews and spacers. Tighten the

flywheel mounting capscrews.
Cl r_:-
Torque Value: 60 n.m [44 ft-lb] C = ^5 ® —
Remove the three flywheel mounting

capscrews and spacers.
✓/ \sM Ci
A CAUTION A
The rear crankshaft seal must be
pressed evenly into the bore. If the
crankshaft and crankshaft seal is not
~Q 0 %
pressed evenly into the bore, the oil
seal can cause equipment damage.
Install the rear crankshaft oil seal over

the rear crankshaft seal replacer, Part

Number 3164780, and onto the three

guide pins.
Install three flywheel mounting

capscrews (without the washers)
through the three holes in the rear
crankshaft seal replacer.
A CAUTION A
To reduce the possibility of damage C Ê
to the oil seal and crankshaft, never
use a hammer or mallet to install the
rear crankshaft oil seal.
Do not use lubricants during the

installation process. Apply a 10 percent
soap solution to the outer ribbed
surface of the rear crankshaft oil seal.
Tighten the flywheel mounting

capscrews no more than % revolution
at a time, alternating capscrews in a
clockw ise pattern, until the rear
crankshaft seal replacer, Part Number
3164780, seats against the REPTO
flywheel housing.
Remove the rear crankshaft seal

replacer and the three flywheel
mounting capscrews.
Install the flywheel. Refer to Procedure

016-005 (Flywheel) in Section 16.
If one side of the REPTO flywheel

housing cover access hole does not
use a hydraulic housing, the opening
m ust be covered in conjunction with

the oil supply line hole and plugging the
straight thread plug hole.
Install the 1/8-inch pipe plug (1) into the

oil supply line hole. Make sure the pipe
plug is flush with the mounting surface.
Install the straight thread plug (2) into

the flywheel housing hole. Make sure
pipe plug is flush with the mounting
surface.
Install the diamond seal (1) on the

REPTO flywheel housing cover access
hole.
Apply a small amount of RTV on the D-

two ends (2) where the diamond seal
comes together and a small amount of
15W-40 oil on the diamond seal. ft?
Install the cover plate to the REPTO

flywheel housing cover access hole.
Install the 10 capscrews and tighten.
Make sure the idler gear is locked in

position. Use a dial gauge to check the
backlash.
Idler Gear to Crankshaft Gear

Backlash
mm in
0.15 MIN 0.006
0.28 MAX 0.011
If the backlash is not within

specifications, replace the idler gear,
REPTO hub gear, or both.
NOTE: The spray nozzle and

diamond seal are only installed if a
hydraulic housing is used.
Install the spray nozzle (1) into the oil

supply line hole. Tighten the spray
nozzle.
Install the diamond seal (2) on the

REPTO flywheel housing cover access
hole.
Apply a small amount of RTV on the

two ends (3) where the diamond seal
comes together and a small amount of
clean 15W-40 oil on the diamond seal.
Apply clean 15W-40 oil on the gear

teeth and bearings.
Install the hydraulic housing over the

dowel pins. The gear inside the
hydraulic housing is free to rotate and
will locate the position of the idler gear
as the hydraulic housing is being
installed over the dowel pins.
Install the 10 capscrews and tighten in

the sequence shown.
Verify that backlash exists between the

Hydrive housing gear and idler gear by
inserting a tool into the spline to help
rotate the gear.
A small amount of backlash must be

present, although obtaining a
measurement is not required.
If no backlash is present, disassemble the

Hydrive housing from the flywheel
housing, and assemble the Hydrive
housing to the opposite flywheel housing
mounting pad and check for backlash.
If no backlash is present when assembled

on either flywheel housing mounting pad,
the Hydrive housing must be replaced.
If backlash is present on only one side,

the flywheel housing m ust be replaced.
Install the threaded plug (1) in the

bottom hole of the hydraulic housing.
Tighten the threaded plug.
Install the oil line hose on the straight

connectors. Tighten the hose and
check for leaks.
Measure
Bore Alignm ent
Attach a dial indicator to the crankshaft.

Use mounting tool, Part Number ST-
1325, and indicator Part Number
3376050.
The dial indicator can be mounted by

any method that holds the extension
bar of the indicator rigid so it does not
sag. If the bar sags or the indicator
slips, the readings obtained will not be
accurate.
Position the indicator in the 6:00 o'clock

position and the gauge at zero.
Slowly rotate the crankshaft. Record

the readings obtained at the 9:00
o'clock, 12:00 o'clock, and 3:00 o'clock
© " r .,
LB
_>>
>4
positions as (a), (b), and (c) in the ' '1

A<■V f iC v S
concentricity work sheet. Recheck zero n )' !
‘ O
at the 6:00 o'clock position. •
The values for (a), (b), and (c) can be

positive or negative. Refer to the
accompanying figure to determine the
correct sign when recording these
values.
A CAUTION A
Do not force the crankshaft beyond
the point where the bearing
clearance has been removed. Do not
pry against the flywheel housing.
These actions can cause false
bearing clearance reading.
Rotate the crankshaft until the dial

indicator is at the 12-o'clock position
and zero the gauge.
Use a pry bar to raise the rear of the

crankshaft to its upper limit. Record the
value as (d) in the concentricity work
sheet. This is the vertical bearing
clearance adjustment and will always
be positive.
Use the concentricity work sheet (see

the accompanying illustration) to
determine the total vertical and
horizontal values.
The total horizontal is equal to the 9:00

o'clock reading (1) minus the 3 :00
o'clock reading (c). C c n c * ritr'd [y WQrfcltSMl

9 d 'c E o c * 1 a O .flfld
The total vertical is equal to the 12:00 3 o 'c lo c k e - -o o o e
o'clock reading (b) plus the bearing T o ll! H n u z m lil a - o ■ DM
clearance (d). 11 a c lo n i b r .003
9 « « i n g Cl ■ ■ ra ra « d « .frfjJ
Example: t o l s i V *J iL c n i b v d E ME
6:00 o'clock = reference = 0

9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Use the work sheet and the numbers

from the example. The total horizontal
value equals 0.006, and the total
vertical value equals 0.005.
Mark the total horizontal value on the

horizontal side of the chart and the total
vertical on the vertical side of the chart.
Use a straightedge to find the

intersection point of the total horizontal
and total vertical values. The
intersection point m ust fall within the ratJ.1 nowm mKuo
shaded area for the flywheel housing

concentricity to be within specification.
Using the total horizontal and total

vertical values from the previous
example, the intersection point falls
within the shaded area. Therefore, the
flywheel housing concentricity is within
specification.
Use the accompanying chart for SAE 1,

2, and 3 flywheel housings.

and % flywheel housings. ' 1
------ i f
—
OK) \
ns ■
—r
TOTAL frO A Q O N T A L ft LADINO

flywheel housings.
? KX ‘X
TOTAL M S n a O N T A L BEA DING
If the intersection point falls outside the

shaded area, the ring dowels m ust be
removed and the housing repositioned.
The ring dowels are not required to

maintain concentricity of the housing;
the clamping force of the capscrews
holds the housing in place.
After the ring dowels are discarded,

install the flywheel housing on the
engine.
To position the housing, tighten the

capscrews enough to hold the flywheel
housing in place, but loose enough to
enable small movement when struck
lightly with a mallet.
Recheck the concentricity. When

concentricity is within specification,
tighten the capscrews to the specified
value.
Face Alignm ent
C»
A CAUTION A
The dial indicator tip must not enter
the capscrew holes, or the gauge
will be damaged.
Install a dial indicator as illustrated.
The extension bar for the indicator

must be rigid for an accurate reading.
It m ust not sag. Position the indicator
at the 12:00 o'clock position. Adjust the
dial until the needle points to zero.
• \
Slowly rotate the crankshaft. Record 1 o
the readings at the 3:00 o'clock, 6:00
o'clock, and 9:00 o'clock positions.
c -Ä i
The crankshaft m ust be pushed toward I m
the front of the engine to remove the ß m ñ
crankshaft end clearance each time a : w
position is measured. 1
Continue to rotate the crankshaft until

the indicator is at the 12:00 o'clock
position. Check the indicator to make
sure that the needle points to zero. If it
does not, the readings will be incorrect.
Determine the total indicator runout.
Total Indicator Runout (Example)

Position Runout
0.00 mm [0.000
12:00 o'clock
in]
+0.08 mm
3:00 o'clock
[+0.003 in]
-0.05 mm [-0.002
6:00 o'clock
in]
+0.08 mm
9:00 o'clock
[+0.003 in]
Total Indicator 0.13 mm [0.005
Runout = in]
The maximum allowable total indicator

reading is determined by the diameter
of the housing bore. If out of
specifications, replace the housing.
Total ^
SAE Bore Indicator
Number Diameter Runout
Maximum
787.40 to
787.65 mm 0.30 mm
00
[30.88 to [0.012 in]
31.00 in]
647.70 to
647.95 mm 0.25 mm
0
[25.50 to [0.010 in]
25.51 in]
584.2 to
584.4 mm 0.25 mm
1/2
[23.000 to [0.010 in]
23.008 in]
511.18 to
511.30 mm 0.20 mm
1
[20.125 to [0.008 in]
20.130 in]
447.68 to
447.80 mm 0.20 mm
2
[17.652 to [0.008 in]
17.630 in]
409.58 to
409.70 mm 0.20 mm
3
[16.125 to [0.008 in]
16.130 in]
Install the remaining capscrews.

Tighten all capscrews in two steps
using the sequence shown.
Torque
Step 1 ,1b° 0 n m I7 4 « '
Value:
step 2 ;® 7 n m i i4 5 f t -
Last Modified: 01-0ct-2008
001-024 Crankshaft Seal, Rear
Install
A CAUTION A
Never use a hammer or mallet to
install the seal. Damage to the seal
can occur.
Do not use lubricants to install the seal.

Apply a 10-percent soap solution to the
outer-ribbed surface of the seal.
Guide the rear crankshaft seal (1),

spacer (2), and replacer plate (3) over
the crankshaft.
NOTE: Spacer, Part Number

4918688, is used to make sure o f the
correct installation depth o f the
crankshaft seal. The flat side o f the
spacer should contact the
crankshaft seal during installation.
NOTE: Three guide pins, Part

Number 3164765, are required on
REPTO applications to support the
REPTO crankshaft gear and the
replacer plate.
A CAUTION A
The rear crankshaft seal must be
pressed evenly into the bore.
Misalignment of the seal can cause
damage.
Install three flywheel mounting

capscrews or replacer screws and hex
nuts, through the replacer plate and
into the end of the crankshaft.
Finger-tighten the three installation

capscrews against the replacer plate.
Tighten the screws not more than % of

a turn at a time, in a clockw ise pattern,
until the installation tool seats against
the flywheel housing.
Tighten the screws.
Remove the replacer plate.
Measure
Measure the protrusion of the outer

rubber portion (A) of the seal relative to
the inner metal portion of the seal (B).
Set the dial indicator to zero on the

inner metal portion of the seal.
Measure and record the protrusion of

the outer rubber portion of the seal.
Repeat the measurement in four
locations equally spaced around the
crankshaft seal.
The protrusion measurement at each
location m ust be within +/-1 mm [+/-

0.04 in]. The difference between any of
the four protrusion measurements
m ust be within +/- 0.5 mm [0.02 in].
If either of these conditions are not

met, the rear crankshaft seal m ust be
removed and a new seal installed.
View Related Topic
016-005 Flywheel
Install
Install the pilot bearing spacer into the

rear of the crankshaft with the spacer
lip oriented outward.
NOTE: A small am ount of clean

Lubriplate™ 105 m ulti-purpose
lubricant, or its equivalent, can be
used to help keep the pilot bearing
spacer in position until the flywheel
is assembled.
A CAUTION A &
The flywheel mounting capscrews

must be a minimum of SAE Grade 8
with rolled threads. Use identical
replacements to avoid possible
flywheel failure resulting in personal
injury or property damage.
Lubricate the threads and underneath

the heads of the capscrews with clean
15W-40 oil. Allow the excess oil to drip
off the parts. Do not lubricate the
threads of the crankshaft.
A WARNING A
use a hoist or get assistance to lift
the component.
Use two M6 x 1.5 guide studs during

assembly.
Install the flywheel. The flywheel must

be firmly against the crankshaft.
Vf
Install the ten capscrews. \ T- ' \
f r- '
__ -—
Remove the t-handles and the guide ' ‘ \
studs.
Install the remaining two capscrews

into the holes from which the guide
studs were removed.
Tighten the capscrews in two steps,

use the sequence shown.
Torque Q. 1 125 n.m [92 ft-

Value: btep ' lb]
Step 2 25° nm I1 8 4 «-
Use a mandrel and hammer to install VÜ r i I f

the pilot bearing.
The pilot bearing must be installed

even with the pilot bore surface.
001-047 Piston Rings
Install_____
Articulated Piston
A CAUTION A
Use a copper or aluminum vise
protector when installing the
connecting rod in a vise to protect
the connecting rod from damage.
The ring gap of each ring m ust not be

aligned with the piston pin or with any
other ring. If the ring gaps are not
aligned correctly, the rings will not seal
properly.
Place the connecting rod in a vise to

hold the assembly in a horizontal
position while installing the rings.
A cross-sectioned view of an oil control

ring is shown.
The two-piece oil control ring m ust be

installed with the expander ring gap 180
degrees from the gap of the oil ring. Do
not overlap the ends of the expander
U J 0
ring.
Install the piston rings with TOP toward

the top of the piston.
The rings have the top marked for

correct installation.
The oil control ring is symmetrical and

can be installed in either orientation.
The piston m ust be held in a horizontal

position to install the rings in order to
keep the rings in the groove while
installing the ring compressor.
For articulated pistons, the top piston

ring (1) is a keystone ring with no twist
or cutback notch.
The intermediate ring (2) is a positive

twist design with a cutback notch (3) on
the topside and a two-degree taper
face.
The oil control ring (4) is the bottom

piston ring.
Rotate the rings to position the ring

gaps as shown.

aligned with the piston pin, or with any
other ring gap. If the ring gaps are not
properly.
Single-Piece Piston
protector when installing the

connecting rod in a vise to protect
the connecting rod from damage.

aligned with the piston pin or with any
other ring. If the ring gaps are not
properly.
Install the connecting rod in a vise to

hold the assembly in a horizontal
position while installing the rings.
A cross-sectioned view of an oil control

ring is shown.
The two-piece oil control ring m ust be

installed with the expander ring gap 180
degrees from the gap of the oil ring. Do
not overlap the ends of the expander
ring.
Install the piston rings with TOP toward

the top of the piston.
The rings have the top marked for

correct installation.
The oil control ring is symmetrical and

can be installed in either orientation.
For single-piece pistons, use a

universal piston ring expander to install
the second ring into the piston.
The single-piece ring set is similar to the

articulated ring set, with the exception of
the second ring. The second ring has a
rectangular cross-section (2) with an
angled cut (3) on the upper side of the
inner diameter to induce a positive twist.
This design improves the slobber-
resistance of the ring pack.
The oil control ring (4) is the bottom piston

ring.
Rotate the rings to position the ring

gaps as shown.

aligned with the piston pin, or with any
other ring gap. If the ring gaps are not
properly.
If failure resulted in coolant, oil, excessive

fuel or excessive black smoke entering the
exhaust system, the aftertreatment system
must be inspected. Refer to Procedure
014-013.
View Related Topic
001-005 Bearings, Connecting Rod
Install
A CAUTION A
Connecting rod bearings must match
the connecting rod design. Drilled
rods must use drilled rod bearings.
Non-drilled rods must use non-drilled
bearings. Mismatches will cause
engine damage.
Connecting rod design m ust be

matched with the proper connecting rod
bearing.
Drilled connecting rods m ust be fitted

with drilled connecting rod bearings.
Non-drilled connecting rods m ust be

fitted with non-drilled connecting rod
bearings.
Drilled and non-drilled connecting rods

can be mixed in the same engine as long
as the two piece piston is used.
Engines using single piece pistons can

not use non-drilled connecting rods.
A CAUTION A
The connecting rod and bearing
shell mating surfaces must be clean
and dry when the bearing shells are
installed. Used bearings must be
installed in their original location or

purpose lubricant, or its equivalent to
lubricate the crankshaft journal mating
surface of the upper bearing shell.
Install the upper bearing shell into the

connecting rod with the tang of the
bearing in the slot of the rod.
Install the bearing shell into the

connecting rod cap with the tang (2) of
the bearing in the slot (1) of the cap.

purpose lubricant, or its equivalent to
lubricate the bearing shell to crankshaft
journal mating surface and the
connecting rod capscrews.
A CAUTION A
The rod cap alpha characters must
match the alpha characters on the
connecting rod and must be installed
with the characters aligned to
prevent damage to the connecting
rods and crankshaft. The locking
tang of the connecting rod cap must
face toward the intake side of the
cylinder block. Rod and cap mating
surfaces must be clean or engine
damage can occur.
Install the cap onto the connecting rod.
Lubricate the threads of the capscrews i

_■ , jj i
with clean engine oil. ©
O t o 'C
Thread the capscrews into the
connecting rod and hand tighten.
© 0i f H J fM a i
The procedure for tightening used & •0
capscrews is different than the . — . "rfH“*-’
procedure for tightening new
capscrews.
For used connecting rod capscrews:
Tighten Capscrews in Numerical

Sequence
70 ±
Step 2 6 n.m [52
± 4 ft-lb]
Rotate
capscrews
in
Step 3 numerical
sequence
60 ± 5
degrees
For new connecting rod capscrews:
Tighten Capscrews in Numerical

Sequence
40 ±
Step 2 6 n.m [29
± 4 ft-lb]
Loosen
capscrews
Step 3 in
numerical
sequence
70 ±
Step 4 6 n.m [52
± 4 ft-lb]
Rotate
capscrews
in
Step 5 numerical
sequence
60 ± 5
degrees
Measure the connecting rod side

clearance. r
* &
áé ¡r-m
Connecting Rod Side Clearance
mm in
m
0.10
0.33
MIN
MAX
0.004
0.013
33»
NOTE: The connecting rod must
move freely from side to side on the
crankshaft journal. If the rod does
not move freely, remove the rod cap
and make sure the bearing shells are
the correct size. Check fo r d irt or
damage on the crankshaft and the
bearing shells.
Repeat the above steps to install the

remaining bearing shells and
connecting rod caps.
Piston Cooling Nozzle Page 1 of 1
001-046 Piston Cooling Nozzle
Install
A CAUTION A
Properly align the nozzles in the
locator notch before tightening the
capscrews. Damage to the engine
can occur.
The crankshaft m ust be rotated to

allow access to install all the nozzles.
Install the nozzle, washers, and

capscrews.
001-054 Piston and Connecting Rod Assembly
Install
Use piston ring compressor, Part

Number 3164846, to compress the
rings.
The cylinder block and all parts m ust

be clean before assembly.
Inspect the cylinder liners for reuse.

Refer to Procedure 001 -028.
Use a clean, lint-free cloth to clean the

connecting rods and bearing shells.
Do not lubricate the backside of the

bearing shells. The operating clearance
of the bearing will be reduced and the
bearing can be damaged during engine
operation.
If new bearings are not used, the used

bearings m ust be installed on the
same connecting rod from which they
were removed.
Install the upper bearing shell into the

connecting rod.
The tang of the bearing shell (2) m ust

be in the slot of the cap (1). The end of
the bearing shell m ust be even with the
cap mounting surface.
Use Lubriplate™ 105, Part Number

£X-
3163086, or equivalent, to coat the
entire inside circumference of the
bearing shell.
Apply a film of clean 15W-40 oil to the IÎW -I0
cylinder liner.
Use the compressor drive or barring

device to rotate the crankshaft so the
4 4
connecting rod journal of the connecting
rod being installed is at bottom dead
center.
A CAUTION A
Failure to align the deep valve
pocket and the piston skirt cooling
nozzle notch correctly will result in
extensive engine damage.
Align the piston crown deep valve

pocket on the exhaust side of the
engine, and the piston skirt cooling
nozzle notch to the intake side of the
engine.
If the deep valve pocket and the piston

skirt cooling nozzle notch are not on
opposite sides, the piston and
connecting rod assembly are not
assembled correctly. Disassemble the
piston and connecting rod and
assemble correctly.
Insert the connecting rod through the

cylinder liner until the ring compressor
contacts the top of the liner.
Both articulated pistons and single-piece

pistons have an arrow on the top of the
piston crown, which will point to the front
of the engine, when the piston is installed
properly.
A CAUTION A
Do not use a metal drift to push the
piston into the cylinder liner. The
piston rings or cylinder liner can be
damaged.
Hold the ring compressor against the

cylinder liner. Push the piston through
the ring compressor and into the
cylinder liner. Push the piston until the
top ring is completely in the cylinder
liner.
If the piston does not move freely,

remove the piston and inspect for
broken or damaged rings.
Use the nylon guide pins to align the

connecting rod with the crankshaft
while pushing the piston and t M l
connecting rod assembly into place.
' O S U k
Remove the nylon guide pins. L
----- ^ v
Block Stiffener Plate Page 1 of 1
001-089 Block Stiffener Plate
Install
Lubricating Oil Suction Tube (Block-Mounted) Page 1 of 1
007-035 Lubricating Oil Suction Tube (Block-

Mounted)
Install

Lubricating Oil Pan Page 1 of 1
View Related Topic
007-025 Lubricating Oil Pan
Install
Apply a 1.97 mm [1/8 in] bead of silicon

sealant, Part Number 3164067, to each of the
four T-joints where the front gear housing and
flywheel housing gaskets intersect the oil pan
gasket.
Install a new oil pan gasket.
Install the oil pan onto the cylinder block.

Install one of the 13 mm oil pan mounting
capscrews, hand tight, on each side of the oil
pan, halfway between the front and the rear of
the oil pan.
Finger-tighten all or the mounting capscrews.
Tighten the thirty-two 13 mm capscrews in the

sequence shown. QQQQQQ©©®®®©
At the end of the sequence, loosen and tighten
capscrew number 1again.
Install the oil drain plug.
Idler Gear, Lower Scissor Page 1 of 1
001-076 Idler Gear, Lower Scissor
General Information
Before installation or removal of any .'Ie (Its |Vh / A1

gears, read Engine Base Timing. Refer
if
I f

Engine Support Bracket, Front Page 1 of 1
View Related Topic
016-002 Engine Support Bracket, Front
Install
A WARNING A
This assembly weighs 23 kg [50 lb] or
more. To reduce the possibility of personal
injury, use a hoist or get assistance to lift
this assembly.
Lower the front of the engine to the rubber

engine mounts.
The capscrew holes in the support bracket

must be aligned with the capscrew holes in
the engine mounts.
Install the two capscrews in the support

bracket and engine mount. Tighten to the
manufacturer's specifications.
Remove the lifting fixture or the hoist from the

engine.
002-004 Cylinder Head
Install
Two different styles of head gaskets

are used on Signature™, ISX, and
QSX15 engines, based on the style of
liner used in the engine. Correctly
identify which style of liner is used
before installing the head gasket. Refer
Install the cylinder head gasket.
A WARNING A
Use engine lifting fixture, Part Number

4919360 or equivalent, to lift the
cylinder head.
Two long cylinder head capscrews

placed toward each end of the cylinder
head serve as convenient guides when
lowering the cylinder head into place.
Align the cylinder head over the dowel

pins and lower into position.

cylinder head capscrews. I
Allow the excess oil to drain from the

threads.
Install the 26 capscrews into the

cylinder head.
ç><2>ofî>0op9çoç>9^
A CAUTION A j
Make sure the four longer

capscrews placed in the correct
location. Engine damage can occur
if these capscrews are not placed in
the correct locations.
Tighten capscrews in sequence.
It is recommended to use an air impact

wrench and socket, Tool Number
3163059 and 3163484, to rotate the
capscrew 90 degrees.
Torque Value:
1. 203 n.m [150 ft-lb]

2. 407 n.m [300 ft-lb]
3. Rotate 90 degrees.
Install
A CAUTION A
Use caution when installing the camshaft to
avoid damaging the camshaft bushings.
Coat the inside of the injector camshaft

bearings with Lubriplate™ prior to installing
camshaft.
Install the injector camshaft.
Install new o-rings on the retainer plate.
Install the retainer plate and capscrews.
Install the injector camshaft cover plate with

new gasket.
Install the capscrews.
Install
A CAUTION A
Use caution when installing the
camshaft bushings.
Coat the inside of the valve camshaft

bushings with Lubriplate™ prior to
installing camshaft.
Install the valve camshaft.
Install
Timing Wedges:
The timing code is located on the engine 15L
dataplate.
• First number - injector wedge

• Second number - valve wedge.
Ò
Make sure the wedges with the proper

angles are used and that the wedges
are properly seated in their installed
position.
Insert the correct timing wedge to lock

the injector camshaft. Lightly tap the
top of the timing wedge with a mallet to
be sure it is properly seated.
Do not drive the wedges into place.

Engine damage can occur.

position.

the valve camshaft. Lightly tap the top
of the timing wedge with a mallet to be
sure it is properly seated.
The lower scissor idler gear m ust be

unloaded during installation. To unload
Apply Lubriplate™ to the thrust

bearing, shaft, and lower scissor idler
gear.
Install the thrust bearing, shaft, and

lower scissor idler gear. The shaft
must be installed with the word
rujJiL
“TOP” (stamped on the end of the
shaft) toward the top of the engine.
The lower idler scissor gear front

retainer plate is larger in diameter than
the adjustable idler retainer plate. The
slots in the plate go toward the scissor
gear
Install the retainer and capscrews.
Tighten all capscrews in a star pattern.
Torque Value:
1. 30 n.m [22 ft-lb]

2. Rotate each capscrew an
additional 60 degrees in the
same sequence as above.
A CAUTION A
Make sure all the scissor gear
screws are tightened to the proper
torque so that they do not back out
during engine operation. Severe
Load the lower idler scissor gear by

tightening all of the gear screws.

bearing, shaft, and lower non-scissor
idler gear.

lower non-scissor idler gear. The shaft
m ust be installed with the word
The lower idler non-scissor gear front

slots in the plate go toward the scissor / f 7
gear © *(*> m t
Torque Value:
1. 30 n.m [22 ft-lb]

Apply Lubriplate™ to the spacer, shaft,

and adjustable idler gear.
It is possible to install the shaft in an

incorrect orientation; however, it will
not be possible to set the gear
backlash correctly.
Install the spacer, shaft and adjustable

idler gear. The shaft m ust be installed
with the word “TOP” (stamped on the
front face of the shaft) oriented toward
the top of the engine.
The adjustable idler front retainer plate

is smaller in diameter than the lower
idler scissor gear retainer plate. The
slots on the retainer plate go toward the
gear.
The adjustable idler gear is installed

loosely, because it is moved into its
final position later in the timing process.

Finger-tighten the capscrews and then
loosen by one “flat,” which is 60
degrees.
The injector camshaft nose and

injector camshaft scissor gear must
be clean and dry prior to assembly.
Wipe off the taper surface with a
clean lint-free cloth and apply a thin
coat of Loctite™ 609, Part Number
3823718, to the inside diameter of
the camshaft gear. Use care not to
contaminate the joint with oil prior to
assembly or engine damage may
occur.

must be unloaded during installation.
To unload the gear, two of the gear
screws m ust be backed out far enough
to allow the teeth on the scissor gear to
be aligned.
The injector camshaft scissor gear needs

to be fully engaged on the camshaft nose
taper, yet loose enough so it can rotate on
the camshaft nose.
Install the injector camshaft scissor gear

loosely on the camshaft nose taper.

mounting washer is larger in diameter than
the valve camshaft mounting washer.
Install the mounting washer and capscrew.
Finger-tighten the capscrew and then
loosen by one “flat,” which is 60 degrees.
The injector camshaft scissor gear is still

loose at this point, to allow the adjustable
idler gear to be properly positioned.
Do not seat the gear.
Install the injector camshaft rear cover

plate
Torque Value: 40 n m [30 ft-lb]
A CAUTION A
injector camshaft non-scissor gear
must be clean and dry prior to
assembly. Wipe off the taper surface
with clean a lint-free cloth and apply
a thin coat of Loctite™ 609, Part
Number 3823718, to the inside
diameter of the camshaft gear. Use
care not to contaminate the joint with
oil prior to assembly or engine
damage may occur.
Apply a thin coat of Loctite™ 609, Part

diameter of the camshaft gear.
The injector camshaft non-scissor gear

needs to be fully engaged on the
camshaft nose taper, yet loose enough
so it can rotate on the camshaft nose.
Install the injector camshaft non-scissor

jy
gear loosely on camshaft nose taper.

mounting washer is larger in diameter
than the valve camshaft mounting
washer.
Install the mounting washer and

capscrew.

The injector camshaft non-scissor gear is

still loose at this point to allow the
adjustable idler gear to be properly
positioned.
Valve Camshaft Gear
A CAUTION ^
The valve camshaft nose and valve

camshaft gear must be clean and
dry prior to assembly. Wipe off the fix

taper surface with a clean lint-free
cloth and apply a thin coat of
Loctite™ 609, Part Number
occur.
The valve camshaft gear needs to be fully

engaged on the camshaft nose taper, yet
loose enough so it can rotate on the
camshaft nose.
Install the valve camshaft gear loosely on

the camshaft nose taper.
The valve camshaft mounting washer is

smaller in diameter than the injector
camshaft scissor gear mounting washer.

The valve camshaft gear is still loose at

this point to allow the adjustable idler gear
to be properly positioned.
Adjust_________________
Backlash (Scissor Gear Com binations)
A CAUTION A
Do not set backlash between the
adjustable idler gear and the lower
scissor idler gear. Severe engine
damage can occur.
This backlash step works with the

scissor type injector camshaft gear and
lower idler gear, and the non-scissor
injector camshaft gear with a scissor
type lower idler gear.

m ust still be unloaded during this step.
be aligned.
Insert, as shown, a narrow shim (0.25

mm [0.010 in]) into the gear teeth mesh
between the adjustable idler gear and
the w ide (rear side) gear of the injector
camshaft scissor gear.
Shim Tolerance
mm in
0.225 MIN 0.009
0.275 MAX 0.011
NOTE: The qear backlash set

procedure fo r engines that have a
non-scissor injector camshaft gear
and a scissor type lower idler gear is
the same as that o f engines that
utilize two scissor type gears.
Use hand pressure, only, to move the

adjustable idler gear toward the center
of the engine (into mesh), so there is
no gap on either side of the shim.
* -
Both of the camshaft gears will rotate
slightly on the camshafts during this
step.
Slight drag will be felt on the shim while

pulling the shim in and out.
Backlash (Non-Scissor Gear Com binations)
Removal of the lower front cover is not

required when setting the gear backlash
on engines that utilize all non-scissor
gears. An access hole is provided to insert
a shim between the lower non-scissor idler
gear and the adjustable idler gear. The
access hole is sealed with a plug. The
plug can be pushed out from the rear side
without removing the gear cover.
The following procedure will be shown

with the lower gear cover removed.
Insert, as shown, a shim (0.25 mm

[0.010 in]) into the gear teeth mesh
the injector camshaft gear. The shim is
inserted on the load side of the gear
teeth.

between the adjustable idler and the
lower non-scissor idler gear. The shim
is inserted on the load side of the gear
teeth.

adjustable idler gear so there is no gap
between the teeth and either side of the
shims.

step.

While holding the adjustable idler gear

in position, tighten the adjustable idler
gear mounting capscrews.
Torque Value:
1. 30 n.m [22 ft-lb]

Remove the feeler gauge.
A CAUTION A
Load the injector camshaft scissor gear

by tightening all of the gear screws.
The valve camshaft gear will rotate

slightly on the valve camshaft during
this step.
Tighten the injector camshaft scissor

gear retaining capscrew.
Torque Value:
1. 136 n.m [100 ft-lb]

2. Rotate an additional 90
degrees
Loosen the capscrew 360 degrees and

tighten again using the toruqe-plus-
angle method.
Torque Value:
1. 136 n.m [100 ft-lb]

degrees
Use hand pressure only to rotate the

injector camshaft gear clockw ise until the
gear train backlash is taken up. Obtain
tooth-to-tooth contact between the
crankshaft gear and the injector camshaft
gear.
Tighten the injector camshaft non-

scissor gear retaining capscrew. ©
Torque Value:
1. 136 n.m [100 ft-lb]


angle method.
Torque Value:
1. 136 n.m [100 ft-lb]

Valve Camshaft Scissor Gear
Tighten the valve camshaft scissor

Valve Camshaft Non-Scissor Gear
Use hand pressure, only, to rotate the

valve camshaft gear counterclockwise
until the backlash between the injector
camshaft gear is taken up. Obtain tooth-
to-tooth contact between the injector
camshaft gear and the valve camshaft
gear.
Tighten the valve camshaft non-scissor

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Install
Pin the engine crankshaft. Refer to

Rotate the gear on the air compressor

until the mark on the gear is in line with
the V-notch on the air compressor
housing, located at the three o'clock
position as viewed from the front.
Loctite™, Part Number 3824040 or

equivalent, m ust be used on the
capscrews that mount the air
compressor to the gear housing. This
seals the threads in the housing.
To evenly distribute the sealant as the

capscrew is torqued, a line of sealant
should be placed along the length of
the capscrew.
Install the air compressor and the four

capscrews onto the front gear housing.
Install the air compressor mounting

brace and four capscrews on the block
beneath the air compressor. Start
threading all four capscrews.
Tighten the capscrews on the cylinder

block and air compressor.
Install the air discharge line.
Install the air inlet line.
Tighten the hose clamp.
Install the air governor (if removed).

Connect the air governor pressure
signal line. Refer to the OEM service
manual.
Install
Use two elbows and run the locking

nuts all the way up prior to installation.
Start threading the elbows into the

cylinder head.
Use a 24 mm open-end wrench to

position the elbows.
Push the tube nut away from the bell flare

on the U-shaped coolant supply line.
Position the sealing grommet behind the

bell flare.
Install the U-shaped coolant supply line

into the coolant supply elbow.
Verify the bell flare and grommet seat

correctly in the elbow.
Start threading the compression nut

onto the elbow.
@ _
Install the other end of the coolant

supply line into the grommet in the
cylinder block.

on the coolant return line. h

bell flare. M i.
Install the coolant return line into the —
coolant return elbow.

A— W
correctly in the elbow. jw u

onto the elbow. v a iM
Install the capscrews in the two

locations designated by the arrows.
Tighten the capscrews
Tighten the compression nuts and

elbow locking nuts.
Finishing Steps
View Related Topic
Install
Install a new strip seal.
Orient the overlap joint to the upper left

of the gear housing as shown.
Use a small amount of RTV at the

overlap joint of strip seal.
NOTE: Do not tighten the capscrews

until the new crankshaft seal is
installed. The crankshaft seal must
be installed firs t to locate the gear
cover properly.
Position the lower gear cover with the

15 capscrews. Hand-tighten the
capscrews.
Install a new crankshaft seal. Refer to

Front) in Section 1.
im
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View Related Topic
Install
The position of the front crankshaft seal on

the crankshaft is determined by the
position of the lower gear cover.
The lower gear cover is mounted to the

gear cover housing using clearance holes.
This allows for slight movement of the
cover when the mounting capscrews are
loose.
The unitized crankshaft seal m ust be

centered on the crankshaft for correct
operation.
The seal attaches to the lower gear cover,

and m ust be installed with the lower gear
cover capscrews loose and the cover free
to move.
In order for the seal to be properly

centered on the crankshaft during
assembly and maintain its location during
operation, the following installation
instructions m ust be followed.
The crankshaft seal removal and

installation tool correctly centers the seal
and correctly positions the dust seal
portion of the seal on the crankshaft.
cover can cause the front crankshaft

seal to be misaligned and cause
premature seal wear.
The front gear cover m ust be aligned

as follows:
Removing the gear cover mounting

capscrews around the crankshaft seal
allows the replacer plate to set against
the gear cover during seal installation.
Remove the gear cover mounting

capscrews around the crankshaft seal.
Loosen the remaining mounting

capscrews on the gear cover so the
cover can move freely.
A CAUTION A
Failure to follow the installation and
tightening sequence can lead to the
crankshaft seal being off center and
installed at the wrong depth causing
A CAUTION A
install the seal. Use of a hammer can
damage the crankshaft seal and/or
crankshaft.
The seal removal and installation tool

has provisions for any seal nut
orientation, although one seal nut must
always be located at the 11 o'clock
position.
Do not use lubricants on the crankshaft

seal.
Position the crankshaft seal (1) onto the

crankshaft until the gear cover studs
are protruding through the seal carrier

mounting holes.
Place the replacer plate (1) against the M)

crankshaft seal.
2n*
Make sure the welded nuts on the front
,
fi
1 :lip
crankshaft seal are seated in their (
-—
respective slots on the replacer plate i\\
0
(1).
\
—
11 wmm<m
■
The large notch between the teeth
m ust bridge the raised gear cover
surface.
Install three washers (4) and

capscrews (5) through the three slots in 4V/
the replacer plate (1) and into the
crankshaft end. r /1
The capscrews in the replacer plate
m ust be equally spaced. This allows
the crankshaft seal to be installed a
correctly.
Tighten the capscrews hand-tight.
A CAUTION A
The crankshaft seal must be
pressed evenly. If the crankshaft
seal is not pressed in evenly the seal
can be damaged.
Inspect the crankshaft seal during

installation to make certain it is being
pressed evenly.
Tighten the capscrew(s) no more than

% of a revolution at a time, alternating
in a clockwise pattern until the
replacer plate (1) bottoms out against
the face of the lower gear cover.
To maintain the cover position while the

replacer plate is removed, tighten the
two gear cover mounting capscrews, as
indicated by the arrows in the graphic.
Install the crankshaft seal mounting

nuts (1) through the holes provided in
©
the replacer plate. •r- J d N f c r - i ' —-
Tighten the mounting nuts in the

sequence shown.
Install all the gear cover mounting

capscrews.
The torque sequence m ust be followed

to prevent the gear cover strip seal
from squeezing out of the groove.

shown.
Install_________
Install a new strip seal. Orient the

overlap at the top and center of the
gear housing.

overlap joint of the strip seal.
A WARNING A
Install the cover with 16 capscrews.

gear housing.

A WARNING A

stamped steel cover with a clamping
plate.
Install two guide pins in the gear

housing.
Install the front gear cover over the

guide pins.
Install the clamping plate, if used.
Last M odified: 29-Mar-2005

View Related Topic
Install
Make sure the mounting surfaces of the

crankshaft nose, vibration damper, and
the pulley are clean, dry, and free from
burrs.
Install two guide studs into the

crankshaft nose.
Align the dowel pin in the crankshaft wit

the dowel hole in the vibration damper.
Install the vibration damper, pulley, and

clamping plate onto the guide plate.

1 * «
capscrew threads. 1 ft -— vC1 ÿ'
n »* 4 ^ ^ < 1 /
Install 10 capscrews. - v V flfv fV iv
Remove the two guide studs and install

the remaining capscrews.
MM
Tighten the capscrews in a star pattern.

crankshaft nose, vibration dampers,
mounting spacer, and pulley are clean,
dry, and free from burrs.
Install one of the vibration dampers (1), -U-

mounting spacer (2), second vibration I - 'Q P G y-v
damper (3), and the pulley (4) onto the ' ; F 9
guide studs.
;flT
QUI UU
Lubricate the capscrew threads with

clean 15W-40 oil.
Install four capscrews.

the remaining two capscrews.
Tighten the six capscrews in a star

pattern.
rf\
Install the crankshaft adapter (1).
Make sure the crank shaft adapter sets

flush against the pulley (2).

clean 15W-40 oil.
Install the six capscrews and tighten in

a star pattern.
Industrial and Power Generation w ithout Crank-Driven Fan or PTO


crankshaft nose.

clean 15W-40 oil.
Install 10 capscrews.

the two remaining capscrews.
Tighten the 12 capscrews in a star

pattern.
Eccentricity Check
All Applications
Clean the outside surface of the

vibration damper. a
To measure the vibration damper
eccentricity (out of round), install a dial
indicator onto the gear cover as
©
indicated.
- À il C ^ l MM
Rotate the crankshaft with the
accessory driveshaft one complete
revolution (360 degrees), and record
the total indicator movement.
Vibration Damper Eccentricity

mm in
0.28 MAX 0.011
If the vibration damper is not within

specifications, it m ust be replaced.
Wobble Check
All A pplications
To measure wobble (face alignment),

install a dial indicator as shown.
Push the crankshaft to the front or rear

of the engine and set the indicator to
“0” (zero).
Rotate the crankshaft one complete

revolution (360 degrees) while
maintaining the position of the
crankshaft, either toward the front or
rear of the engine.
006-026 Injector
Install
A CAUTION A
Make sure the injector hold down ff\
clamp is properly aligned before
tightening the capscrew. It is
possible for the clamp to contact a
nearby ledge, and result in low
clamp load.
Install the injector into the cylinder

head.
Install the injector clamp and the

capscrew with washer.
Tighten the capscrew.
Install the crossheads.
Overhead Set Page 1 of 13
View Related Topic
003-004 Overhead Set
Measure
General Information
All overhead lash measurements must be made when - // y "“

the engine is cold. Stabilized coolant temperature must
be at 60DC [H O T ] or below. '
~ —
n (a
ILXA
*0'C ’
1 r*S
V
1 1 v- / mL-jL "1 I I ïI
M ir ili Lm J
Remove the rocker lever cover. Refer to Procedure

003-011 (Rocker Lever Cover) in Section 3.
Make sure the engine base timing is properly set before

attempting to measure, adjust, or set the overhead.
Refer to Procedure 001-088 (Engine Base Timing) in
Section 1.
\ r * Pi
Early engine vibration dampers are marked with

BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4.
The engine brakes must be set at the appropriate mark
on these engines. Newer engine vibration dampers are
marked with only A, B, or C, and are adjusted with the
valves and injector on the same cylinder.
Locate the valve set marks on the outside of the

vibration damper.
The set marks are A, B, and C:
Set to mark A to adjust cylinder 1 or 6.

Set to mark B to adjust cylinder 2 or 5.
Set to mark C to adjust cylinder 3 or 4.
Two complete revolutions are required to set all valves,

engine brakes, and injectors.
If the engine is equipped with an air compressor:
Remove the oil fill connector from the lower gear case
cover.
*
Insert a 3/4-inch drive ratchet and extension into the
air compressor drive.
Rotate the air compressor drive clockwise, as viewed

from the front of the engine.
A WARNING A
Do not pull or pry on the fan to manually rotate the
engine. To do so can damage the fan blades.
Damaged fan blades can cause premature fan
failures which can result in serious personal injury or
property damage.
The crankshaft rotation is clockwise, as viewed from

the front of the engine.
The cylinders are numbered from the front of the

engine (1-2-3-4-5-6).
The engine firing order is 1-5-3-6-2-4.
Use a 1% inch socket to push the barring gear into the

gear mesh and rotate the barring adapter
counterclockwise to bar the engine.
Rock the barring device back and forth until it

disengages.
Each cylinder has four rocker levers:
• The exhaust valve rocker lever (1)

• The injector rocker lever (2)
• The intake valve rocker lever (3)
• The engine brake rocker lever (4).
The intake valve rocker lever is always the long lever

on the valve rocker lever shaft.

BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 3
4. The engine brakes must be set at the appropriate
mark on these engines. Newer engine vibration
dampers are marked with only A, B, or C, and are
adjusted with the valves and injector on the same
cylinder.
The valves, brakes, and the injectors on the same

cylinder are adjusted at the same index mark on the
vibration damper.
Injector
and Valve
Adjustment
Sequence
Bar Engine Set Set Set
Pulley
in Direction Cylinder Cylinder Cylinder
Position
of Rotation Injector Valve Brake
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing
Order: 1-5
3-6-2-4
NOTE: For illustrative purposes, position A is

shown as the first step. It is not necessary to start
with position A, as long as the proper sequence is
followed.
Use the compressor drive or barring device to bar the

engine over in the direction of engine rotation,
clockwise as viewed from the front of the engine.
Align the A mark on the vibration damper with the
pointer on the gear cover.
Check the valve rocker levers on the given cylinder to

see if both intake and exhaust valves are closed.
Both sets of valves are closed when the rocker levers

and the brake lever are loose. If both sets of valves are
not closed, rotate the compressor drive gear one
complete revolution, and align the A mark on the front
damper with the pointer again.
Valve Lash
Use feeler gauges to measure the amount of

clearance (lash) between the crosshead and the
rocker lever nose. Measure and record the intake,
exhaust, and brake valve lash. If the valve lash is not
within the specifications listed below, the valve must
be adjusted. See the adjust step in this procedure.
Press the brake lever down to verify the camshaft

follower is in contact with the camshaft prior to
measurement of the brake lash.
ISX, QSX Series Valve Lash Recheck Limits

Intake 0.23 mm minimum 0.006 in
Intake 0.48 mm maximum 0.019 in
Exhaust 0.56 mm minimum 0.022 in
Exhaust 0.81 mm maximum 0.032 in
Brake 6.87 mm minimum 0.271 in
Brake 7.13 mm maximum 0.281 in
Brake Running Clearance
Rotate the brake lever to the detent (neutral) position.

Check the clearance between the engine brake
actuator piston and the cross head guide pin (1). If the
brake running clearance is not within the specifications
listed below, the running clearance must be adjusted.
See the Adjust step in this procedure.

mm________________________ in _
0.635 MIN 0.025
2.79 MAX 0.110
Injector Lash
There is no service procedure to check the injector free

load.
Install the rocker lever cover. Refer to Procedure 003-
011 (Rocker Lever Cover) in Section 3.
Adjust
Read the entire procedure for overhead adjustment

before attempting to perform this operation.
Valves, injectors, and engine brakes (if equipped)

must be correctly adjusted for the engine to operate
efficiently. Valve, injector, and engine brake
adjustment must be performed using the values listed
in this section.
After an engine rebuild or any major repair where the

injector and valve setting must be disturbed, set all of
the valves, injectors, and brakes.
Valve, Brake, and Injector Adjustment Values

Injector Adjustment is 8 N*m [70 in-lb]
Intake Valve 0.35 mm [0.014 in]
Exhaust Valve 0.68 mm [0.027 in]
Engine Brake 7.00 mm [0.276 in]

cylinder.

vibration damper.

Two complete revolutions are required to set all

valves, engine brakes, and injectors.
cover.

*

A WARNING A
failures which can result in serious personal injury or VPi J
property damage.
The crankshaft rotation is clockwise as viewed from


engine (1-2-3-4-5-6).


disengages.
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cylinder.
The valves, brakes, and injectors on the same cylinder

are adjusted at the same index mark on the vibration
damper.
Injector
and Valve
Adjustment
Sequence
Pulley
Position
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing
Order: 1-5
3-6-2-4

followed.



Loosen the injector adjusting screw locknut on the

cylinder.
Do not use a click-type torque wrench.
Use a dial-type torque wrench with a range of 0 to 150

in-lb to tighten the injector rocker lever adjusting screw.
If the screw chatters during setting, repair the screw
and lever as required.
Back out the adjusting screw one or two turns.
Hold the torque wrench in a position that allows you to

look in a direct line at the dial. This is to make sure the
dial will be read accurately.
Make sure the parts are aligned, and squeeze the oil
out of the valve and injector train by tightening the
adjusting screw.
Use this initial adjustment to preload the valve train and

injector.
Tighten the injector lever adjusting
Back the adjusting lever screw out 1 or 2 turns,
Tighten the injector lever adjusting screw.
After setting the injector on a cylinder, set the valves

and engine brakes on the same cylinder.

valve and injector on the same cylinder.
With the set mark aligned with the pointer on the gear
cover and both sets of valves closed on the cylinder,
loosen the locknuts on the intake and exhaust valve
adjusting screws.
Back out the adjusting screws one or two turns.
IÉf§t
Select a feeler gauge for the correct valve lash
specification.
Valve Lash Specification

mm in
Intake 0.36 NOM 0.014
Exhaust 0.69 NOM 0.027
Insert the feeler gauge between the top of the

crosshead and the rocker lever nose pad.
Make sure the feeler gauge is completely under the

pivoting rocker lever nose pad.
Tighten the adjusting screw.
Torque Value: 0.6 n.m [5 in-lb]
Use a torque wrench and crows foot adapter to

tighten the locknut. 0
Hold the adjusting screw in this position. The
adjusting screw must not turn when the locknut is
tightened.
After tightening the locknut to the correct torque value,

remove the feeler gauge.
¡ Ë Ü Ü
A C A U TIO N ^
To get maximum brake operating efficiency and to

prevent engine damage, the brake adjustment
instructions must be followed.
For older engines, locate the engine brake set marks

on the outside of the vibration damper.
The set marks are BRAKE SET 1-6, and BRAKE SET
2-5, and BRAKE SET 3-4.
BRAKE SET 1-6: Cylinder 1 or 6 adjust

engine over in the direction of rotation, clockwise as
viewed from the front of the engine. Align the A mark
on the vibration damper with the pointer on the gear
cover.
For illustrative purposes, position A is shown as the

first step. It is not necessary to start with position A, as
long as the proper sequence is followed.

see if both intake and exhaust valves are closed. (£ )
© - -
Press the engine brake lever down to verify the

camshaft follower is in contact with the camshaft.
Loosen the locknut on the brake lever adjusting

screw, and back out the adjusting screw one turn.
Insert the feeler gauge, Part Number 3163530,

between the bottom of the engine brake piston and
the top of the exhaust valve pin on the exhaust valve
crosshead.
Brake Lever Lash Specification

mm in
7.00 NOM 0.276
Tighten the adjusting screw until drag on the feeler

gauge is felt. Proper drag means that there is no
motion of the brake lever camshaft follower against
the cam lobe.
10
A C A U T IO N ^
Engine damage can occur if the running clearance

is not within specifications.
Check the running clearance:
1. Rotate the engine brake rocker lever to the

detente (neutral) position.
2. Check the clearance (1) between the engine
brake lever actuator piston and the crosshead
guide pin.
Engine Brake Rocker Lever Running Clearance

mm___________________________in_______
0.635 MIN 0.025
2.790 MAX 0.110
If the running clearance does not meet specification,

loosen, but do not remove the rocker shaft capscrews,
and rotate the shaft in the direction required to bring
the running clearance within the listed specification. It
is critical that this clearance be set and verified on all
six brake levers. Engine damage can result if this task
is not completed.
Check the brake running clearance.
The rocker lever shafts must be adjusted so that all

three engine brake levers fall within the given running
clearance specification.
Repeat the process to adjust all injectors, engine

brakes, and valves according to the chart shown
below.
Injector
and Valve
Adjustment
Sequence
Pulley
Position
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing
Order: 1-5
3-6-2-4
C o p y rig h t © 2 0 0 0 -2 0 1 0 C u m m in s Inc. A ll rig h ts re s e rv e d .
Install
Install the injector rocker levers on the

shaft.
Install the exhaust (1), intake (2), and

engine brake (3) rocker levers onto the
shaft.
A WARNING A
Clear the rocker lever assembly
mounting capscrew holes of oil and
debris. Extensive engine damage
can result if this warning instruction
is not followed.
Install the valve crossheads.
Position the valve/brake rocker lever

assemblies onto the cylinder head.
A CAUTION A
To reduce the possibility of valve rocker
shaft damage due to inadequate brake
rocker lever running clearance, follow
the specified procedure to seat the
valve rocker shafts on the cylinder head
pedestals (1).
Each valve rocker shaft m ust be seated in

the cylinder head pedestals prior to
tightening the rocker shaft capscrews.
The front and rear rocker lever shaft

assemblies will seat separately as the
engine is rotated in the clockwise
direction.

device to bar the engine over in the
direction of rotation, clockw ise as
viewed from the front of the engine.
Align the A mark on the vibration

damper with the timing mark on the
gear cover.
Either the front or the rear rocker shaft

assembly will be fully seated on the
cylinder head pedestals at this point.
Check the position of the front and rear O-

valve rocker shaft assemblies to
determine which one is fully seated.
Lubricate the capscrews of the fully

seated rocker shaft with clean 15W-40
oil.
A CAUTION A
To reduce the possibility of valve

rocker shaft damage because of
inadequate brake rocker lever
running clearance, follow the
specified capscrew torque
procedure. The valve rocker lever
shaft has a machined flat on the
front of the shaft to provide proper
brake rocker lever position.
Therefore, the front rocker shaft
capscrew (1) must be tightened first
to control brake rocker lever
position. Brake lever running
clearance must always be checked
after valve rocker lever shaft
installation.

Tighten the front mounting capscrew

for the fully seated valve rocker lever
shaft to the initial torque value to locate
the shaft.
Tighten all the capscrews to the final

torque value using the torque plus
angle method. Tighten the capscrews
from the center out.
Torque - 30 n.m [22 ft-

Value: btep 1 lb]
Rotate
Step 2 60
degrees

I
Align the B mark on the vibration
gear cover.
The remaining rocker shaft will be fully

seated at this point.

oil.
XX
A CAUTION A
capscrew must be tightened first to
control brake rocker lever position.
Brake lever running clearance must
always be checked after valve
rocker lever shaft installation.


for the remaining valve rocker lever
the shaft.

Torque 30 n.m [22 ft-

Step 1
Value: lb]
Rotate
Step 2 60
degrees
I I I I
Position the injector rocker lever

Lubricate the injector rocker lever shaft

capscrews with clean 15W-40 oil. Install
the capscrews and washers.
Tighten all the mounting capscrews.
Loosen capscrews one at a time 360°

and tighten again, using the torque-
plus-angle method. Tighten capscrews
from center out.
Torque Q. . 30 n.m [22 ft-

Value: btep 1 lb]
Rotate
Step 2 60
degrees
Adjust the valve, injectors, and brake.
Refer to Procedure .
008-062 Water Pump
Install_________
A CAUTION A
Do not use petroleum based
lubricants. Petroleum based
lubricants cause the o-ring seals to
crack, leading to a coolant leak.
Lubricate and install the new o-ring

seal.
Install the two guide studs.
Install the water pump and three

capscrews.

the remaining mounting capscrews.
A CAUTION A
Install a new o-ring seal in the water

pump outlet groove.
Apply a thin layer of non-petroleum-

based lubricant, such as vegetable oil,
to both o-ring seals.
Use clean engine oil to lubricate the

threads and bottom of the capscrew
heads of all the water pump capscrews.
Install the water pump and two lower

capscrews.
Tighten the capscrews to hold the

pump in place.
NOTE: Some configurations do not

use the middle alum inum belt
tensioner bracket shown. Refer to
Procedure fo r the appropriate
tensioner bracket installation.
Install the belt tensioner bracket, if

equipped, and capscrews in the
location shown.
Finger tighten all capscrews.
Tighten the water pump mounting

(K
capscrews in the sequence and values
shown.
Capscrews 1,2,
58 n.m [43 ft-lb]
and 3
Capscrews 4 and -,0 rco ,. ., ,

5 K 72 n.m [53 ft-lb]
All Capscrews,
Engines Without r(-0 ,. ...
D r.-r . 72 n.m [53 ft- b]
Belt Tensioner L J
Bracket
A CAUTION A
Do not use petroleum based 0-

pump outlet groove.

http://127.0.0.1:5000/https@quickserve. cummins.com/qs2/pubsys2/xml/en/procedure 2014/12/08


Position the water pump on the engine.
Install the bottom two capscrews finger

tight.

tensioner bracket. Refer to
Procedure 008-088 fo r the
appropriate tensioner bracket
installation.
NOTE: Early engines that did not

have a slotted hole on the middle
alum inum belt tensioner idler
bracket required the vibration
dampers to be removed to remove
and install the water pump.

equipped, and the capscrews in the
locations shown.

capscrews in the sequence and values ©
shown.
andP3°reWS1' 2' 58 n m I4 3 “ '
Capscrews 4 and J2n m [5 3 ft_|b] mmm
All Capscrews,
Engines Without
Belt Tensioner -,0 rco ,

Bracket 72 n m [53fW bl
Align the idler pulley (1) and the shaft

of the pilot adapter (2) with the belt ^ ' *■ J
tensioner bracket (3) using the guide
pin on the pilot adapter (4), if equipped.
Install the belt idler pulley and shaft on

©
the belt idler bracket using one washer
and capscrew. W iS % _
Install the dust seal.
A CAUTION A
lubricants, petroleum based
lubricants cause the o-ring to crack
or swell, leading to a coolant leak.
Install a new water pump inlet o-ring

seal and a new EGR tube outlet o-ring
seal.
Install the five water pump housing

capscrews.
Install the two bracket capscrews.
Install the EGR tube outlet capscrew.
Install
Replace the o-ring and gasket.
Install the gasket, water inlet

connection, and the four capscrews.
(K
Install the coolant hoses.

Bracket
Install
Sanden
Install the two mounting capscrews and

the refrigerant compressor mounting
bracket.

r m
ST: 3k
)
‘T —
Install the refrigerant compressor

mounting bracket to the refrigerant
compressor. The refrigerant
compressor is positioned on top of the
bracket ledge.
Install the four mounting capscrews

and the refrigerant compressor bracket.
Before installation, inspect the

refrigerant compressor bracket to make w 1
sure the mounting spacers are installed
properly.
Position both links in the assembly with

the part number facing outward.
Insert one capscrew through the

elongated hole in the long link and
attach the long link to the left side of
the refrigerant compressor bracket.
Insert one capscrew through the small

hole in the short link and attach the
short link to the right side of the
refrigerant compressor bracket.
Assemble

w ith CM570 and Power Generation with
CM570
• To install the turbine housing,

position the V-band clamp over the
bearing housing and align the ink /» Ml
marks applied during the
disassembly process.
• Apply anti-seize compound to the
bearing housing locating bore of the
turbine housing.
• Carefully slide the bearing and
compressor housing assembly into
the turbine housing. Use the ink
alignment mark to locate the turbine
housing assembly in the correct
orientation with the turbine housing.
Place the new V-band clamp in the correct

orientation and torque the locknut.
Torque value for Cummins®-branded

turbochargers.
Torque value for Holset®-branded

turbochargers.
Loosen the locknut 180 degrees, and

torque the locknut.

turbochargers.
turbochargers.
Make certain the rotor assembly rotates

freely and neither compressor wheel or
turbine wheel is rubbing against the
housing.
Install

w ith CM570, and Power Generation
w ith CM570
• Apply a film of high-temperature anti

seize compound, Part Number
3823097, or equivalent, to the
turbocharger mounting studs.
A WARNING A
NOTE: If the exhaust m anifold and

turbocharger were removed together
in order fo r the turbocharger to clear
the lubricating oil cooler assembly,
see the follow ing procedure fo r
Section 11.
Install a new mounting gasket, the

turbocharger, and the four mounting
nuts.
Tighten the mounting nuts.
Torque value for the standard nut:
Torque value for the Spiralock™ nut

(identified by "SPL" on the nut flange):
/ /vd
If a new turbocharger is being installed,
the variable geometry turbocharger V / v
actuator from the original turbocharger
must be reused.
Refer to Procedure 010-134 in Section © Y$JJp

10.
Install a new o-ring, the clamp, and the

w7
discharge elbow to the turbocharger.
Tighten the clamp.

Install the turbocharger anti-rotation

brace (if equipped). The end rests on
the oil cooler housing. L '
f i L
This brace requires longer, 1.25 mm
[0.049 in], capscrews. \ x \ \
Tighten the capscrews. __s\ \ __
Pour approximately 50 to 60 cc [1.7 to 2

oz] of clean engine oil into the
turbocharger oil supply opening. J
A CAUTION A
Proper routing of the turbocharger oil
supply tube is critical to prevent
failure. Avoid any tube-to-metal
contact. (The inlet supply fitting must
be oriented slightly off vertical to
allow proper alignment.)
If installing a new turbocharger, make

sure the turbocharger is aligned, loosen
the compressor and turbine v-bands,
and adjust as needed. Tighten the v-
bands.

If installing a new turbocharger, install
the male union elbow.
Install the turbocharger oil supply tube

on the elbow.
Install the intake and exhaust pipes to

the turbocharger. Tighten the clamp.
A WARNING A
A CAUTION A
When installing lifting eye, be sure

the shoulder of the lifting eye is
bottomed against bearing housing.
Failure to do so can result in failure
of lifting eye and personal injury.
A CAUTION A
If a lifting eye is installed in
turbocharger bearing housing, it is to
be used exclusively for turbocharger
removal and installation. It is not to
be used in removal of the exhaust
manifold, or engine. Doing so will
cause damage to the turbocharger.
A CAUTION A
Do not rotate the turbocharger
turbine housing. Loosening turbine
v-band and rotating the turbine
housing can cause damage to
internal variable geometry
mechanism.
The capscrew in the top of the

turbocharger bearing housing can be
removed and replaced with a lifting eye
to aid in the installation of the
turbocharger.
Install a new gasket, the turbocharger,

and the four mounting nuts. Tighten the
mounting nuts.
Install the discharge elbow and clamp

onto the charge-air cooler pipe
connection. (ft A
/ )])t '*■ j L ——
)
Do n o t tighten the clamp until the
m
elbow is installed on the turbocharger.
Apply a film of high-temperature anti

turbocharger mounting studs and to the
flange area on the retaining nuts.
Properly applying anti-seize compound
will reduce the possibility of the nuts
loosening over time.

the coolant and oil fittings into the •
bearing housing. ' „ •
1 v .v >
NOTE: Use a ratchet and deepwell

socket to install these fittings.
c à
Torque Value: 30 n.m [22 ft-lb] aaossq
A C A U T IO N A

contact.
Install the turbocharger oil supply hose

onto the oil supply fitting. The oil supply
hose m ust point directly downward in
order for it to properly connect to the oil
supply fitting on the lubricating oil filter
head.
Install the turbocharger actuator

coolant supply and return fittings into
the electronic actuator. Refer to
A W A R N IN G A

this component.
À CAUTION ^

mechanism.
NOTE: Thread a lifting strap around

the turbocharger bearing housing.
Take care not to bend the coolant
lines when liftin g the turbocharger.
Care m ust be taken not to damage the

turbocharger compressor inlet air
temperature sensor, the turbocharger
speed sensor, and the turbocharger
actuator coolant lines when installing
the turbocharger.

mounting nuts.
Install a new o-ring seal, the clamp,

and the discharge elbow to the /N i
turbocharger.
Tighten the clamps. rf
Install a new gasket, oil drain tube, and

capscrews.
Connect the oil supply hose to the oil

supply fitting located on the lubricating
oil filter head.
Tighten the oil supply hose.

Mounting Bracket
Install_________
Install the wire harness jumper to the

alternator/refrigerant compressor
mounting bracket.
Tap the split washers out slightly. This

will ease the installation.
Install the alternator/refrigerant

compressor mounting bracket to the
gear housing.
Install the five mounting capscrews.

shown.
( 1, 2 3 and 4) 36 n.m [27 ft-lb]
(5) 56 n.m [41 ft-lb]
The alternator/refrigerant compressor * .
mounting bracket mounts to the gear

housing at the top and the water pump
at the bottom.
Install the bracket and six mounting

capscrews.
©
Tighten the capscrew that threads into
the gear housing.
013-001 Alternator
Install
Install the alternator, capscrew,

<v> 0
washer, and nut to the alternator
mounting bracket. Tighten the nut.
•
r * ¿ :.
( > V
Install the adjusting link and mounting

capscrews. Tighten the capscrews. - ,±tmm
Install
Install the thermostat housing cover,

gasket, and four capscrews on the
cylinder head.
Tighten the capscrews to the values

shown.
Short Capscrews 34 n.m [25 ft-lb]
Long Capscrews 56 n.m [41 ft-lb]
Connect the vent line Refer to the

OEM instructions
Connect the coolant sensor connector
Industrial engines use a thermostat

housing cover with either a cover plate
or a water connection.
If removed, tighten the capscrews to

the following specification.
Install the upper radiator hose. Tighten

the hose clamp.

ifv
. ..
Install
Single Thermostat
To reduce the possibility of a coolant

leak, the 90-degree elbow on the
thermostat housing m ust be positioned
appropriately and tightened before the
thermostat housing is installed on the
cylinder head.
Use two thermostat housing capscrews

to align the thermostat housing.
Install the thermostat housing, gasket,

and three capscrews to the cylinder
block.
Tighten the three thermostat housing

mounting capscrews.
Dual Thermostat
Use two thermostat housing cover

capscrews to align the thermostat
housing.

and two capscrews on the cylinder
head.
Tighten the two thermostat housing

capscrews.
Remove the two thermostat housing

cover capscrews used as guides.
Install the two thermostats into the

thermostat housing cover by pushing
on the outer rims.
m §

cylinder head.
Tighten the capscrews. ©
Connect the vent line. Refer to the

OEM instructions.
Connect the coolant sensor connector K M /'

Install the thermostat cover if removed.

<S>
Automotive has a similar design with

connector for transmission cooler.
Install
A CAUTION A
Use caution when installing the camshaft to
avoid damaging the camshaft bushings.
Coat the inside of the injector camshaft

bearings with Lubriplate™ prior to installing
camshaft.
Install the injector camshaft.
Install new o-rings on the retainer plate.
Install the retainer plate and capscrews.
Install the injector camshaft cover plate with

new gasket.
Install the capscrews.
Install
A CAUTION A
Use caution when installing the
camshaft bushings.
Coat the inside of the valve camshaft

bushings with Lubriplate™ prior to
installing camshaft.
Install the valve camshaft.
Install
Timing Wedges:
The timing code is located on the engine 15L
dataplate.
• First number - injector wedge

• Second number - valve wedge.
Ò

position.

the injector camshaft. Lightly tap the
top of the timing wedge with a mallet to
be sure it is properly seated.
Do not drive the wedges into place.

Engine damage can occur.

position.

the valve camshaft. Lightly tap the top
of the timing wedge with a mallet to be
sure it is properly seated.
The lower scissor idler gear m ust be

unloaded during installation. To unload

bearing, shaft, and lower scissor idler
gear.

lower scissor idler gear. The shaft
must be installed with the word
rujJiL
The lower idler scissor gear front

slots in the plate go toward the scissor
gear
Torque Value:
1. 30 n.m [22 ft-lb]

A CAUTION A
Load the lower idler scissor gear by

tightening all of the gear screws.

bearing, shaft, and lower non-scissor
idler gear.

lower non-scissor idler gear. The shaft
m ust be installed with the word
The lower idler non-scissor gear front

slots in the plate go toward the scissor / f 7
gear © * (* > m t
Torque Value:
1. 30 n.m [22 ft-lb]

Apply Lubriplate™ to the spacer, shaft,

and adjustable idler gear.
It is possible to install the shaft in an

incorrect orientation; however, it will
not be possible to set the gear
backlash correctly.
Install the spacer, shaft and adjustable

idler gear. The shaft m ust be installed
with the word “TOP” (stamped on the
front face of the shaft) oriented toward
the top of the engine.
The adjustable idler front retainer plate

is smaller in diameter than the lower
idler scissor gear retainer plate. The
slots on the retainer plate go toward the
gear.
The adjustable idler gear is installed

loosely, because it is moved into its
final position later in the timing process.

Finger-tighten the capscrews and then
loosen by one “flat,” which is 60
degrees.

injector camshaft scissor gear must
be clean and dry prior to assembly.
Wipe off the taper surface with a
clean lint-free cloth and apply a thin
coat of Loctite™ 609, Part Number
occur.

m ust be unloaded during installation.
screws m u st be backed out far enough
be aligned.
The injector camshaft scissor gear needs

to be fully engaged on the camshaft nose
taper, yet loose enough so it can rotate on
the camshaft nose.
Install the injector camshaft scissor gear

loosely on the camshaft nose taper.

mounting washer is larger in diameter than
the valve camshaft mounting washer.
The injector camshaft scissor gear is still

loose at this point, to allow the adjustable
idler gear to be properly positioned.
Install the injector camshaft rear cover

plate
Torque Value: 40 n m [30 ft-lb]
A CAUTION A
injector camshaft non-scissor gear
must be clean and dry prior to
assembly. Wipe off the taper surface
with clean a lint-free cloth and apply
a thin coat of Loctite™ 609, Part
diameter of the camshaft gear. Use
care not to contaminate the joint with
oil prior to assembly or engine
damage may occur.
Apply a thin coat of Loctite™ 609, Part

diameter of the camshaft gear.

needs to be fully engaged on the
camshaft nose taper, yet loose enough
so it can rotate on the camshaft nose.
Install the injector camshaft non-scissor

jy
gear loosely on camshaft nose taper.

mounting washer is larger in diameter
than the valve camshaft mounting
washer.
Install the mounting washer and

capscrew.

The injector camshaft non-scissor gear is

still loose at this point to allow the
adjustable idler gear to be properly
positioned.
Valve Camshaft Gear
A CAUTION ^
The valve camshaft nose and valve

camshaft gear must be clean and
dry prior to assembly. Wipe off the f ix

taper surface with a clean lint-free
cloth and apply a thin coat of
Loctite™ 609, Part Number
occur.
The valve camshaft gear needs to be fully

engaged on the camshaft nose taper, yet
loose enough so it can rotate on the
camshaft nose.
Install the valve camshaft gear loosely on

the camshaft nose taper.
The valve camshaft mounting washer is

smaller in diameter than the injector
camshaft scissor gear mounting washer.

The valve camshaft gear is still loose at

this point to allow the adjustable idler gear
to be properly positioned.
Adjust_________________
Backlash (Scissor Gear Com binations)
A CAUTION A
Do not set backlash between the
adjustable idler gear and the lower
scissor idler gear. Severe engine
damage can occur.
This backlash step works with the

scissor type injector camshaft gear and
lower idler gear, and the non-scissor
injector camshaft gear with a scissor
type lower idler gear.

m ust still be unloaded during this step.
be aligned.
Insert, as shown, a narrow shim (0.25

mm [0.010 in]) into the gear teeth mesh
the w ide (rear side) gear of the injector
camshaft scissor gear.
Shim Tolerance
mm in
0.225 MIN 0.009
0.275 MAX 0.011
NOTE: The qear backlash set

procedure fo r engines that have a
non-scissor injector camshaft gear
and a scissor type lower idler gear is
the same as that o f engines that
utilize two scissor type gears.

adjustable idler gear toward the center
of the engine (into mesh), so there is
no gap on either side of the shim.
* -
step.

Backlash (Non-Scissor Gear Com binations)
Removal of the lower front cover is not

required when setting the gear backlash
on engines that utilize all non-scissor
gears. An access hole is provided to insert
a shim between the lower non-scissor idler
gear and the adjustable idler gear. The
access hole is sealed with a plug. The
plug can be pushed out from the rear side
without removing the gear cover.
The following procedure will be shown

with the lower gear cover removed.

the injector camshaft gear. The shim is
inserted on the load side of the gear
teeth.

between the adjustable idler and the
lower non-scissor idler gear. The shim
is inserted on the load side of the gear
teeth.

adjustable idler gear so there is no gap
between the teeth and either side of the
shims.

step.

While holding the adjustable idler gear

in position, tighten the adjustable idler
gear mounting capscrews.
Torque Value:
1. 30 n.m [22 ft-lb]

Remove the feeler gauge.
A CAUTION A
Load the injector camshaft scissor gear

by tightening all of the gear screws.
The valve camshaft gear will rotate

slightly on the valve camshaft during
this step.
Tighten the injector camshaft scissor

Torque Value:
1. 136 n.m [100 ft-lb]

degrees

angle method.
Torque Value:
1. 136 n.m [100 ft-lb]

degrees
Use hand pressure only to rotate the

injector camshaft gear clockw ise until the
gear train backlash is taken up. Obtain
tooth-to-tooth contact between the
crankshaft gear and the injector camshaft
gear.
Tighten the injector camshaft non-

scissor gear retaining capscrew. ©
Torque Value:
1. 136 n.m [100 ft-lb]


angle method.
Torque Value:
1. 136 n.m [100 ft-lb]

Valve Camshaft Scissor Gear
Tighten the valve camshaft scissor

Valve Camshaft Non-Scissor Gear
Use hand pressure, only, to rotate the

valve camshaft gear counterclockwise
until the backlash between the injector
camshaft gear is taken up. Obtain tooth-
to-tooth contact between the injector
camshaft gear and the valve camshaft
gear.
Tighten the valve camshaft non-scissor

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Install
Pin the engine crankshaft. Refer to

Rotate the gear on the air compressor

until the mark on the gear is in line with
the V-notch on the air compressor
housing, located at the three o'clock
position as viewed from the front.
Loctite™, Part Number 3824040 or

equivalent, m u st be used on the
capscrews that mount the air
compressor to the gear housing. This
seals the threads in the housing.
To evenly distribute the sealant as the

capscrew is torqued, a line of sealant
should be placed along the length of
the capscrew.
Install the air compressor and the four

capscrews onto the front gear housing.
Install the air compressor mounting

brace and four capscrews on the block
beneath the air compressor. Start
threading all four capscrews.
Tighten the capscrews on the cylinder

block and air compressor.
Install the air discharge line.
Install the air inlet line.
Install the air governor (if removed).

Connect the air governor pressure
signal line. Refer to the OEM service
manual.
Install
Use two elbows and run the locking

nuts all the way up prior to installation.
Start threading the elbows into the

cylinder head.
Use a 24 mm open-end wrench to

position the elbows.

on the U-shaped coolant supply line.

bell flare.
Install the U-shaped coolant supply line

into the coolant supply elbow.

correctly in the elbow.

onto the elbow.
@ _
Install the other end of the coolant

supply line into the grommet in the
cylinder block.

on the coolant return line. h

bell flare. M i.
Install the coolant return line into the —
coolant return elbow.

A— W
correctly in the elbow. jw u

onto the elbow. v a iM
Install the capscrews in the two

locations designated by the arrows.
Tighten the capscrews
Tighten the compression nuts and

elbow locking nuts.
Finishing Steps
View Related Topic
Install
Install a new strip seal.
Orient the overlap joint to the upper left

of the gear housing as shown.

overlap joint of strip seal.
NOTE: Do not tighten the capscrews

until the new crankshaft seal is
installed. The crankshaft seal must
be installed firs t to locate the gear
cover properly.
Position the lower gear cover with the

15 capscrews. Hand-tighten the
capscrews.
Install a new crankshaft seal. Refer to

Front) in Section 1.
i m
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View Related Topic
Install
The position of the front crankshaft seal on

the crankshaft is determined by the
position of the lower gear cover.
The lower gear cover is mounted to the

gear cover housing using clearance holes.
This allows for slight movement of the
cover when the mounting capscrews are
loose.
The unitized crankshaft seal m ust be

centered on the crankshaft for correct
operation.
The seal attaches to the lower gear cover,

and m ust be installed with the lower gear
cover capscrews loose and the cover free
to move.
In order for the seal to be properly

centered on the crankshaft during
assembly and maintain its location during
operation, the following installation
instructions m ust be followed.
The crankshaft seal removal and

installation tool correctly centers the seal
and correctly positions the dust seal
portion of the seal on the crankshaft.
cover can cause the front crankshaft

seal to be misaligned and cause
The front gear cover m u st be aligned

as follows:
Removing the gear cover mounting

capscrews around the crankshaft seal
allows the replacer plate to set against
the gear cover during seal installation.
Remove the gear cover mounting

capscrews around the crankshaft seal.
Loosen the remaining mounting

capscrews on the gear cover so the
cover can move freely.
A CAUTION A
Failure to follow the installation and
tightening sequence can lead to the
crankshaft seal being off center and
installed at the wrong depth causing
A CAUTION A
install the seal. Use of a hammer can
damage the crankshaft seal and/or
crankshaft.
The seal removal and installation tool

has provisions for any seal nut
orientation, although one seal nut m ust
always be located at the 11 o'clock
position.
Do n o t use lubricants on the crankshaft

seal.
Position the crankshaft seal (1) onto the

crankshaft until the gear cover studs
are protruding through the seal carrier

mounting holes.
Place the replacer plate (1) against the M)

crankshaft seal.
2n*
Make sure the welded nuts on the front
,
fi
1 :lip
crankshaft seal are seated in their (
-—
respective slots on the replacer plate i\\
0
(1).
\
—
11 wmm<m
■
The large notch between the teeth
m ust bridge the raised gear cover
surface.
Install three washers (4) and

capscrews (5) through the three slots in 4V/
the replacer plate (1) and into the
crankshaft end. r /1
The capscrews in the replacer plate
m ust be equally spaced. This allows
the crankshaft seal to be installed a
correctly.
Tighten the capscrews hand-tight.
A CAUTION A
The crankshaft seal must be
pressed evenly. If the crankshaft
seal is not pressed in evenly the seal
can be damaged.
Inspect the crankshaft seal during

installation to make certain it is being
pressed evenly.
Tighten the capscrew(s) no more than

% of a revolution at a time, alternating
in a clockwise pattern until the
replacer plate (1) bottoms out against
the face of the lower gear cover.
To maintain the cover position while the

replacer plate is removed, tighten the
two gear cover mounting capscrews, as
indicated by the arrows in the graphic.
Install the crankshaft seal mounting

nuts (1) through the holes provided in
©
the replacer plate. •r- J d N f c r - i ' —-
Tighten the mounting nuts in the

sequence shown.
Install all the gear cover mounting

capscrews.
The torque sequence m ust be followed

to prevent the gear cover strip seal
from squeezing out of the groove.

shown.
Install_________

gear housing.

A WARNING A
Install the cover with 16 capscrews.

gear housing.

A WARNING A

stamped steel cover with a clamping
plate.
Install two guide pins in the gear

housing.
Install the front gear cover over the

guide pins.
Install the clamping plate, if used.
Last M odified: 29-Mar-2005

View Related Topic
Install

crankshaft nose, vibration damper, and
the pulley are clean, dry, and free from
burrs.

crankshaft nose.
Align the dowel pin in the crankshaft wit

the dowel hole in the vibration damper.
Install the vibration damper, pulley, and

clamping plate onto the guide plate.

1 * «
capscrew threads. 1 ft -— vC1 ÿ'
n »* 4^ ^ < 1 /
Install 10 capscrews. - v V flfv fV iv

the remaining capscrews.
MM
Tighten the capscrews in a star pattern.

Install one of the vibration dampers (1), -U-

mounting spacer (2), second vibration I - 'Q P G y-v
damper (3), and the pulley (4) onto the ' ; F 9
guide studs.
;flT
QUI UU

clean 15W-40 oil.
Install four capscrews.

Tighten the six capscrews in a star

pattern.
rf\
Install the crankshaft adapter (1).
Make sure the crank shaft adapter sets

flush against the pulley (2).

clean 15W-40 oil.
Install the six capscrews and tighten in

a star pattern.
Industrial and Power Generation w ithout Crank-Driven Fan or PTO


crankshaft nose.

clean 15W-40 oil.
Install 10 capscrews.

Tighten the 12 capscrews in a star

pattern.
Eccentricity Check
All Applications
Clean the outside surface of the

vibration damper. a
To measure the vibration damper
eccentricity (out of round), install a dial
indicator onto the gear cover as
©
indicated.
- À il C ^ l MM
Rotate the crankshaft with the
accessory driveshaft one complete
revolution (360 degrees), and record
the total indicator movement.
Vibration Damper Eccentricity

mm in
0.28 MAX 0.011
If the vibration damper is not within

specifications, it m ust be replaced.
Wobble Check
All A pplications
To measure wobble (face alignment),

install a dial indicator as shown.
Push the crankshaft to the front or rear

of the engine and set the indicator to
“0” (zero).
Rotate the crankshaft one complete

revolution (360 degrees) while
maintaining the position of the
crankshaft, either toward the front or
rear of the engine.
006-026 Injector
Install
A CAUTION A
Make sure the injector hold down ff\
clamp is properly aligned before
tightening the capscrew. It is
possible for the clamp to contact a
nearby ledge, and result in low
clamp load.
Install the injector into the cylinder

head.
Install the injector clamp and the

capscrew with washer.
Install the crossheads.
View Related Topic
003-004 Overhead Set
Measure
General Information
All overhead lash measurements must be made when - // y "“

the engine is cold. Stabilized coolant temperature must
be at 60DC [H O T ] or below. '
~ —
n (a
ILXA
*0'C ’
1 r*S
V
1 1 v- / mL-jL "1 I I ïI
M ir ili Lm J
Remove the rocker lever cover. Refer to Procedure

003-011 (Rocker Lever Cover) in Section 3.
Make sure the engine base timing is properly set before

attempting to measure, adjust, or set the overhead.
Refer to Procedure 001-088 (Engine Base Timing) in
Section 1.
\ r * Pi

valves and injector on the same cylinder.

vibration damper.

Two complete revolutions are required to set all valves,

engine brakes, and injectors.
cover.
*

A W A R N IN G A

failures which can result in serious personal injury or
property damage.
The crankshaft rotation is clockwise, as viewed from


engine (1-2-3-4-5-6).


disengages.



cylinder.
The valves, brakes, and the injectors on the same

cylinder are adjusted at the same index mark on the
vibration damper.
Injector
and Valve
Adjustment
Sequence
Pulley
Position
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing
Order: 1-5
3-6-2-4

followed.



Valve Lash
Use feeler gauges to measure the amount of

clearance (lash) between the crosshead and the
rocker lever nose. Measure and record the intake,
exhaust, and brake valve lash. If the valve lash is not
within the specifications listed below, the valve must
be adjusted. See the adjust step in this procedure.
Press the brake lever down to verify the camshaft

follower is in contact with the camshaft prior to
measurement of the brake lash.
ISX, QSX Series Valve Lash Recheck Limits

Intake 0.23 mm minimum 0.006 in
Intake 0.48 mm maximum 0.019 in
Exhaust 0.56 mm minimum 0.022 in
Exhaust 0.81 mm maximum 0.032 in
Brake 6.87 mm minimum 0.271 in
Brake 7.13 mm maximum 0.281 in
Rotate the brake lever to the detent (neutral) position.

Check the clearance between the engine brake
actuator piston and the cross head guide pin (1). If the
brake running clearance is not within the specifications
listed below, the running clearance must be adjusted.
See the Adjust step in this procedure.

mm________________________ in _
0.635 MIN 0.025
2.79 MAX 0.110
Injector Lash
There is no service procedure to check the injector free

load.
Install the rocker lever cover. Refer to Procedure 003-
011 (Rocker Lever Cover) in Section 3.
Adjust
Read the entire procedure for overhead adjustment

before attempting to perform this operation.
Valves, injectors, and engine brakes (if equipped)

must be correctly adjusted for the engine to operate
efficiently. Valve, injector, and engine brake
adjustment must be performed using the values listed
in this section.
After an engine rebuild or any major repair where the

injector and valve setting must be disturbed, set all of
the valves, injectors, and brakes.
Valve, Brake, and Injector Adjustment Values

Injector Adjustment is 8 N*m [70 in-lb]
Intake Valve 0.35 mm [0.014 in]
Exhaust Valve 0.68 mm [0.027 in]
Engine Brake 7.00 mm [0.276 in]

cylinder.

vibration damper.

Two complete revolutions are required to set all

valves, engine brakes, and injectors.
cover.

*

A W A R N IN G A

failures which can result in serious personal injury or VPi J
property damage.
The crankshaft rotation is clockwise as viewed from


engine (1-2-3-4-5-6).


disengages.
http://127.0_0. l:5000/https@quickserve.cummins.com/qs2/pubsys2/xml/en/procedure. . 2014/12/08




cylinder.
The valves, brakes, and injectors on the same cylinder

are adjusted at the same index mark on the vibration
damper.
Injector
and Valve
Adjustment
Sequence
Pulley
Position
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing
Order: 1-5
3-6-2-4

followed.



Loosen the injector adjusting screw locknut on the

cylinder.
Do not use a click-type torque wrench.
Use a dial-type torque wrench with a range of 0 to 150

in-lb to tighten the injector rocker lever adjusting screw.
If the screw chatters during setting, repair the screw
and lever as required.
Back out the adjusting screw one or two turns.
Hold the torque wrench in a position that allows you to

look in a direct line at the dial. This is to make sure the
dial will be read accurately.
Make sure the parts are aligned, and squeeze the oil
out of the valve and injector train by tightening the
adjusting screw.
Use this initial adjustment to preload the valve train and

injector.
Tighten the injector lever adjusting
Back the adjusting lever screw out 1 or 2 turns,
Tighten the injector lever adjusting screw.
After setting the injector on a cylinder, set the valves

and engine brakes on the same cylinder.

valve and injector on the same cylinder.
With the set mark aligned with the pointer on the gear
cover and both sets of valves closed on the cylinder,
loosen the locknuts on the intake and exhaust valve
IÉf§t
adjusting screws.
Back out the adjusting screws one or two turns.
Select a feeler gauge for the correct valve lash

specification.
Valve Lash Specification

mm in
Intake 0.36 NOM 0.014
Exhaust 0.69 NOM 0.027
Insert the feeler gauge between the top of the

crosshead and the rocker lever nose pad.
Make sure the feeler gauge is completely under the

pivoting rocker lever nose pad.
Tighten the adjusting screw.
Use a torque wrench and crows foot adapter to

tighten the locknut. 0
Hold the adjusting screw in this position. The
adjusting screw must not turn when the locknut is
tightened.
After tightening the locknut to the correct torque value,

remove the feeler gauge.
¡ Ë Ü Ü
A C A U TIO N ^
To get maximum brake operating efficiency and to

prevent engine damage, the brake adjustment
instructions must be followed.
For older engines, locate the engine brake set marks

on the outside of the vibration damper.
The set marks are BRAKE SET 1-6, and BRAKE SET
2-5, and BRAKE SET 3-4.

engine over in the direction of rotation, clockwise as
viewed from the front of the engine. Align the A mark
on the vibration damper with the pointer on the gear
cover.
For illustrative purposes, position A is shown as the

first step. It is not necessary to start with position A, as
long as the proper sequence is followed.

see if both intake and exhaust valves are closed. (£ )
© - -
Press the engine brake lever down to verify the

camshaft follower is in contact with the camshaft.
Loosen the locknut on the brake lever adjusting

screw, and back out the adjusting screw one turn.
Insert the feeler gauge, Part Number 3163530,

between the bottom of the engine brake piston and
the top of the exhaust valve pin on the exhaust valve
crosshead.
Brake Lever Lash Specification

mm in
7.00 NOM 0.276
Tighten the adjusting screw until drag on the feeler

gauge is felt. Proper drag means that there is no
motion of the brake lever camshaft follower against
the cam lobe.
10
A C A U T IO N ^
Engine damage can occur if the running clearance

is not within specifications.
Check the running clearance:
1. Rotate the engine brake rocker lever to the

detente (neutral) position.
2. Check the clearance (1) between the engine
brake lever actuator piston and the crosshead
guide pin.
Engine Brake Rocker Lever Running Clearance

mm___________________________in_______
0.635 MIN 0.025
2.790 MAX 0.110
If the running clearance does not meet specification,

loosen, but do not remove the rocker shaft capscrews,
and rotate the shaft in the direction required to bring
the running clearance within the listed specification. It
is critical that this clearance be set and verified on all
six brake levers. Engine damage can result if this task
is not completed.
The rocker lever shafts must be adjusted so that all

three engine brake levers fall within the given running
clearance specification.
Repeat the process to adjust all injectors, engine

brakes, and valves according to the chart shown
below.
Injector
and Valve
Adjustment
Sequence
Pulley
Position
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing
Order: 1-5
3-6-2-4
C o p y rig h t © 2 0 0 0 -2 0 1 0 C u m m in s Inc. A ll rig h ts re s e rv e d .
Install
Install the injector rocker levers on the

shaft.
Install the exhaust (1), intake (2), and

engine brake (3) rocker levers onto the
shaft.
A WARNING A
Clear the rocker lever assembly
mounting capscrew holes of oil and
debris. Extensive engine damage
can result if this warning instruction
is not followed.
Install the valve crossheads.
Position the valve/brake rocker lever

A CAUTION A
To reduce the possibility of valve rocker
shaft damage due to inadequate brake
rocker lever running clearance, follow
the specified procedure to seat the
valve rocker shafts on the cylinder head
pedestals (1).
Each valve rocker shaft m ust be seated in

the cylinder head pedestals prior to
tightening the rocker shaft capscrews.
The front and rear rocker lever shaft

assemblies will seat separately as the
engine is rotated in the clockwise
direction.

Align the A mark on the vibration

gear cover.
Either the front or the rear rocker shaft

assembly will be fully seated on the
cylinder head pedestals at this point.
Check the position of the front and rear O-

valve rocker shaft assemblies to
determine which one is fully seated.

oil.
A CAUTION A

capscrew (1) must be tightened first
to control brake rocker lever
position. Brake lever running
clearance must always be checked
after valve rocker lever shaft
installation.


for the fully seated valve rocker lever
the shaft.

Torque - 30 n.m [22 ft-

Value: btep 1 lb]
Rotate
Step 2 60
degrees

I
Align the B mark on the vibration
gear cover.
The remaining rocker shaft will be fully

seated at this point.

oil.
XX
A CAUTION A
capscrew must be tightened first to
control brake rocker lever position.
Brake lever running clearance must
always be checked after valve
rocker lever shaft installation.


for the remaining valve rocker lever
the shaft.

Torque 30 n.m [22 ft-

Step 1
Value: lb]
Rotate
Step 2 60
degrees
I I I I
Position the injector rocker lever

Lubricate the injector rocker lever shaft

capscrews with clean 15W-40 oil. Install
the capscrews and washers.
Tighten all the mounting capscrews.
Loosen capscrews one at a time 360°

and tighten again, using the torque-
plus-angle method. Tighten capscrews
from center out.
Torque Q. . 30 n.m [22 ft-

Value: btep 1 lb]
Rotate
Step 2 60
degrees
Adjust the valve, injectors, and brake.
Refer to Procedure .
008-062 Water Pump
Install_________
A CAUTION A
Lubricate and install the new o-ring

seal.
Install the two guide studs.
Install the water pump and three

capscrews.

the remaining mounting capscrews.
A CAUTION A

pump outlet groove.


Install the water pump and two lower

capscrews.
Tighten the capscrews to hold the

pump in place.

tensioner bracket shown. Refer to
Procedure fo r the appropriate
tensioner bracket installation.

equipped, and capscrews in the
location shown.

(K
capscrews in the sequence and values
shown.
Capscrews 1,2,
58 n.m [43 ft-lb]
and 3
Capscrews 4 and -,0 rco ,. ., ,

5 K 72 n.m [53 ft-lb]
All Capscrews,
Engines Without r(-0 ,. ...
D r.-r . 72 n.m [53 ft- b]
Belt Tensioner L J
Bracket
A CAUTION A
Do not use petroleum based 0-

pump outlet groove.

http://127.0.0.1:5000/https@quickserve. cummins.com/qs2/pubsys2/xml/en/procedure 2014/12/08


Position the water pump on the engine.
Install the bottom two capscrews finger

tight.

tensioner bracket. Refer to
Procedure 008-088 fo r the
appropriate tensioner bracket
installation.
NOTE: Early engines that did not

have a slotted hole on the middle
alum inum belt tensioner idler
bracket required the vibration
dampers to be removed to remove
and install the water pump.

equipped, and the capscrews in the
locations shown.

capscrews in the sequence and values ©
shown.
andP3°reWS1' 2' 58 n m I4 3 “ '
Capscrews 4 and J2n m [5 3 ft_|b] mmm
All Capscrews,
Engines Without
Belt Tensioner -,0 rco ,

Bracket 72 n m [53fW bl
Align the idler pulley (1) and the shaft

of the pilot adapter (2) with the belt ^ ' *■ J
tensioner bracket (3) using the guide
pin on the pilot adapter (4), if equipped.
Install the belt idler pulley and shaft on

©
the belt idler bracket using one washer
and capscrew. W iS % _
Install the dust seal.
A CAUTION A
lubricants, petroleum based
lubricants cause the o-ring to crack
or swell, leading to a coolant leak.
Install a new water pump inlet o-ring

seal and a new EGR tube outlet o-ring
seal.
Install the five water pump housing

capscrews.
Install the two bracket capscrews.
Install the EGR tube outlet capscrew.
Install
Replace the o-ring and gasket.
Install the gasket, water inlet

connection, and the four capscrews.
(K
Install the coolant hoses.

Bracket
Install
Sanden
Install the two mounting capscrews and

the refrigerant compressor mounting
bracket.

r m
ST: 3k
)
‘T —
Install the refrigerant compressor

mounting bracket to the refrigerant
compressor. The refrigerant
compressor is positioned on top of the
bracket ledge.

and the refrigerant compressor bracket.
Before installation, inspect the

refrigerant compressor bracket to make w 1
sure the mounting spacers are installed
properly.
Position both links in the assembly with

the part number facing outward.
Insert one capscrew through the

elongated hole in the long link and
attach the long link to the left side of
the refrigerant compressor bracket.
Insert one capscrew through the small

hole in the short link and attach the
short link to the right side of the
Assemble

CM570

turbine housing.


turbochargers.

turbochargers.

torque the locknut.

turbochargers.
turbochargers.

housing.
Install

w ith CM570

A WARNING A

Section 11.

nuts.


the variable geometry turbocharger
/vd v
/ V /
must be reused.

10.

w7
Tighten the clamp.


f i L

A CAUTION A

bands.


on the elbow.

A WARNING A
A CAUTION A

A CAUTION A
A CAUTION A
mechanism.

turbocharger.

mounting nuts.

connection. (ft A
/ )])t '*■ j L ——
)
m


1 v .v >

c à
A C A U T IO N A

contact.

head.

A W A R N IN G A

this component.
À CAUTION ^

mechanism.


the turbocharger.

mounting nuts.

turbocharger.

capscrews.

oil filter head.

Mounting Bracket
Install_________
Install the wire harness jumper to the

alternator/refrigerant compressor
mounting bracket.
Tap the split washers out slightly. This

will ease the installation.
Install the alternator/refrigerant

compressor mounting bracket to the
gear housing.
Install the five mounting capscrews.

shown.
( 1, 2 3 and 4) 36 n.m [27 ft-lb]
(5) 56 n.m [41 ft-lb]
The alternator/refrigerant compressor * .
mounting bracket mounts to the gear
©
housing at the top and the water pump
at the bottom.
Install the bracket and six mounting

capscrews.
Tighten the capscrew that threads into
the gear housing.
013-001 Alternator
Install
Install the alternator, capscrew,

washer, and nut to the alternator <v> 0
•
mounting bracket. Tighten the nut.
( > V
r * ¿ :.
Install the adjusting link and mounting

capscrews. Tighten the capscrews. - ,±tmm
Install

cylinder head.
Tighten the capscrews to the values

shown.
Short Capscrews 34 n.m [25 ft-lb]
Long Capscrews 56 n.m [41 ft-lb]
Connect the vent line Refer to the

OEM instructions
Connect the coolant sensor connector

If removed, tighten the capscrews to

the following specification.
Install the upper radiator hose. Tighten

the hose clamp.

ifv
. ..
Install
Single Thermostat
To reduce the possibility of a coolant

leak, the 90-degree elbow on the
thermostat housing m ust be positioned
appropriately and tightened before the
thermostat housing is installed on the
cylinder head.
Use two thermostat housing capscrews

to align the thermostat housing.

and three capscrews to the cylinder
block.
Tighten the three thermostat housing

mounting capscrews.
Dual Thermostat
Use two thermostat housing cover

capscrews to align the thermostat
housing.

and two capscrews on the cylinder
head.
Tighten the two thermostat housing

capscrews.
Remove the two thermostat housing

cover capscrews used as guides.
Install the two thermostats into the

thermostat housing cover by pushing
on the outer rims.
m §

cylinder head.
Tighten the capscrews. ©
Connect the vent line. Refer to the

OEM instructions.
Connect the coolant sensor connector K M /'

Install the thermostat cover if removed.

<S>
Automotive has a similar design with

connector for transmission cooler.
Last M odified: 10-Jul-2006
Engine Lifting Brackets Page 1 of 1
016-001 Engine Lifting Brackets
Install_______________
Install the front bracket and four

capscrews.
Install the rear bracket and four

capscrews.
View Related Topic
007-003 Lubricating Oil Cooler
Install
All A pplications
A WARNING A
When installing a new two-element oil

cooler on an older engine, be sure the
cooler element mounting capscrews do
not interfere with the cylinder block.
Install the guide pins.
Remove the protective plugs from the

oil passages. Make sure no debris
enters the lubrication system. Using a
clean shop towel, carefully wipe out the
oil passages and inspect to make sure
no debris is left in these passages.
Install a new mounting gasket and the

oil cooler housing assembly.
Install the 18 capscrews.
Remove the guide pins and install the

two capscrews.
&h
Tighten the capscrews in a circular
motion from the center out.
w

011-019 EGR Cooler
Install_________
Install new o-rings on the coolant

supply and vent tubes on the EGR
cooler and the jumper tubes.
Use clean engine coolant, soapy water, De

or vegetable oil to lubricate the o-rings
for easier installation.
Install the coolant supply and the vent

jumper tubes onto the EGR cooler.
Align the coolant supply and vent tubes

to the corresponding openings on the
block.
Install the EGR cooler on the studs in

the lubricating oil cooler assembly.
install a new gasket on the pilot end of

the EGR cooler where it connects to
the EGR cooler connection.

seize compound to the inside of the v-
band clamp, to make sure of proper
loading on the clamp.
Install a v-band clamp.
Install and hand tighten the four

mounting nuts and capscrews. Tighten
the capscrews and nuts in the
sequence shown.
Torque Value:
Capscrews 47 n.m [35 ft-lb]
Torque Value:
Nuts 23 n.m [204 in-lb]
Tighten the hose clamps.
Torque Value:
Breeze Clamp (1) 7 n.m [62 in-lb]
Torque Value:
Normal Clamp (2) 5 n.m [44 in-lb]
Tighten the v-band clamp between the

EGR cooler connection and the EGR
cooler.
©
A CAUTION A
Keep all protective caps on the EGR
cooler in place while grinding
clearance in the upper mounting
bracket. Failure to do so could cause
progressive damage to the engine
once the EGR cooler is installed. It's
important to prevent any debris from
entering the cooler.
Inspect for an interference fit between

the upper EGR cooler mounting bracket
and the lower portion of the exhaust
manifold flange. If this interference is
present, grind a clearance on the upper
EGR cooler mounting bracket in the
area shown in the illustration.

seize compound to the inside of the v-
band clamp, to make sure of proper
loading on the clamp.
a.
Install a v-band clamp onto the exhaust
manifold front section.
Install a new gasket on the pilot end of

the EGR cooler where it connects to
the exhaust manifold front section.
Install the EGR cooler on the studs in

the lubricating oil cooler assembly.
Install the four EGR cooler mounting

capscrews at the top of the EGR cooler
mounting bracket. I
Install and hand tighten the four

mounting nuts. Tighten the capscrews
and nuts in the sequence shown.
Torque Value:
Capscrews 47 n.m [35 ft-lb]
Torque Value:
Nuts 23 n.m [204 in-lb]
A CAUTION A
Do not use air tools to remove or
install the nut on the v-band clamp.
Use of these tools can seriously
damage the threads or the bolt and
cause the clamp to not be able to be
reused.
Position the v-band clamp onto the

EGR cooler inlet connection.
Tighten the two retaining capscrews on

the rear EGR connection tube.

©

011-025 EGR Connection Tubes
Install

Handling Clean Care Kit, Part Number
4919403 and Part Number 4919425, at
the end of the rear EGR connection
tube that interfaces with the EGR
cooler before working the tube into
©
position, to reduce the possibility of
introducing dirt or debris.
© i
f / /^r
L / -vU.
Install the p-clips onto the rear EGR

connection tube.
Make sure the tube insulation is

properly and fully located under the p-
clips and that the p-clip rubber sleeve
does not block the mounting hole.
Install the rear EGR connection tube

and the p-clip mounting capscrew and
nuts.
Hand-tighten the capscrew and nuts.
Remove the protective caps from the p

component.
Install a new hose with the hose

clamps loosely attached between the r \ \ \ vv \ \
rear EGR connection tube and the ©
\ \V r
EGR cooler.
Tighten the p-clip mounting capscrews,

nuts, and hose clamps.
Torque Value:
M10 P-clip nut 46 n.m [34 ft-lb]
Torque Value:
M8 P-clip nut 23 n.m [204 in-lb]
Torque Value:
P-clip capscrew and
nut 45 n.m [33 ft-lb]
Torque Value:
Breeze Clamp (1) 7 n.m [62 in-lb]
Torque Value:
m
Norma Clamp (2) 5 n.m [44 in-lb]

clamps loosely attached on the rear
EGR connection tube where it
interfaces with the front EGR
connection tube.
Install the p-clips onto the front EGR

connection tube.
Install the front EGR connection tube

and the p-clip mounting capscrews or
nuts. Finger tighten the capscrews or
nuts.
Tighten the p-clip mounting capscrews

or nuts and the hose clamps.
Torque Value:
M10 p-clip nut 46 n.m [34 ft-lb]
Torque Value:
Hose clamps 5 n.m [44 in-lb]
Torque Value:
P-clip capscrew and

clamps loosely attached between the
front EGR connection tube and the
EGR mixer.
Tighten the p-clip mounting capscrews,

nuts, and clamps.
Torque Value:
P-clip capscrews and
Torque Value:
Hose clamps 5 n.m [44 in-lb]
Remove the protective caps from the

component. <2">% A
' h
V M .ia
Apply lubricant to the hose end of the
rear EGR connection tube.
k Q
Loosely install the hose clamp and
install the rear EGR connection tube
and gasket onto the EGR cooler and
EGR valve mounting bracket.
Tighten the two capscrews.
Make sure the indentation near the end of

the hose slides past the hose bead on the
EGR valve mounting bracket. Position the
hose clamp on this indentation groove.
NOTE: Install the protective sleeve onto

the exposed threads o f a T-bolt style
clamp.
NOTE: Two different types of hose

clamps can be used in this location.
The torque value fo r each clamp is the
same, regardless of w hich clamp is
used.
Loosen the two rear tail support

mounting capscrews.
Install a new press-in place seal on the

EGR venturi.
Install the EGR venturi on the air intake

connection by loosely installing all three
capscrews. Hand-tighten all five
capscrews.
In order to reduce assembly stress,

tighten the capscrews in the following
sequence:
Tighten the two front EGR venturi

mounting capscrews.
Tighten the rear EGR venturi mounting

capscrews.
Tighten the two rear tail support

mounting capscrews.
Apply lubricant to the hose end of the

front EGR connection tube and the
EGR venturi inlet. , ;
rn r • . r y 'Z '
Slide the new EGR connection hose on / I "
the EGR venturi inlet and loosely install
both retaining clamps. ° ^ H '
Attach a new EGR gasket to the front

EGR connection tube flange, holding it
in place with the two retaining
capscrews.
Insert the hose end of the EGR

connection tube into the EGR
connection hose, and align the
mounting flange with the EGR valve
outlet.
Install the two retaining capscrews into

the EGR valve.
Tighten the capscrews in the following

sequence: Capscrew 1, Capscrew2,
Capscrew 1.
Make sure to tighten Capscrew 1 twice.
Center the EGR connection hose

evenly between the tube and the EGR
venturi and tighten both retaining
clamps.
NOTE: Two different types of hose

clamps can be used in this location.
The torque value fo r each clamp is
the same, regardless of w hich clamp
is used.
Last Modified: 11-Oct-2010

View Related Topic
011-007 Exhaust Manifold, Dry
Install_______________
Autom otive w ith CM870 and CM871
Remove the tape from the open

exhaust ports and cylinder head.
Install two guide studs into the center

section mounting location.
Do not use adhesive, grease, or heavy

grease to hold the gaskets in place on
the cylinder head.
Install a new center section gasket.
Special capscrews with spacers are

required for this particular manifold.
C @
Do not use short capscrews.
V
A WARNING A
Install the exhaust manifold over the

guide studs.

seize compound to the capscrew
threads to make sure of proper loading
on capscrews.
Slide each manifold gasket between

the exhaust manifold and the cylinder
head.
Install the capscrews and spacers

through the exhaust manifold and
gasket into the cylinder head.

A WARNING A
Install the exhaust manifold assembly

on the guide pins.
Special capscrews with spacers are

required for this particular manifold.
< x ©
Do not use short capscrews.
Slide each exhaust manifold gasket

between the manifold and cylinder
head.
Insert the exhaust manifold mounting

capscrews and spacer through the
manifold and gasket and start
capscrews into the cylinder head.
I I 1----------------------------------------------- 1
To aid in future capscrew removal,

apply a film of high-temperature anti
seize compound to the capscrew
threads.
Remove the guide studs and install the

remaining two capscrews.

shown.
Torque values given have been

established using anti-seize compound
as a lubricant.
Torque
Value:
Step 1 fb° nm >22ft'
Step 2 S® n m I41 ft-
Exhaust Gas Pressure Sensor Adapter Page 1 of 1
011 -033 Exhaust Gas Pressure Sensor Adapter
Install
All Applications
EGR Valve Mounting Bracket Page 1 of 1
View Related Topic
011-044 EGR Valve Mounting Bracket
Install
Install the EGR valve mounting bracket

onto the engine block and the EGR
valve mounting bracket rear support.
Install three capscrews into the engine

block and the rear support.
Tighten the two EGR valve mounting

bracket capscrews first (1).
Tighten the rear support bracket

capscrew into the back of the engine
block (2).
Exhaust Gas Pressure Sensor Tube Page 1 of 1
011-027 Exhaust Gas Pressure Sensor Tube
Install
011-022 EGR Valve
Install
Install the smaller v-band clamp on the

EGR cooler connection. Do not tighten.
°
Install the larger v-band clamp on the
end of the EGR valve that connects
with the exhaust manifold. Do not
tighten. ^¡sr
Install a new gasket on the piloted end
of the EGR cooler connection.
Install a new gasket on the piloted end

of the EGR valve where it connects to
the exhaust manifold.
Install the EGR valve. Position the EGR

connection v-band clamp, as shown,
and tighten.
Lubricate the EGR valve seal with

clean engine oil.
Install the EGR valve onto the EGR

valve mounting bracket.
Install the four mounting capscrews into

the EGR valve mounting bracket.
NOTE: The longest capscrew passes

through the EGR valve and EGR
valve m ounting bracket and threads
into the engine block.
EGR Valve Coolant Lines Page 1 of 1
011-030 EGR Valve Coolant Lines
Install
Connect the EGR valve coolant lines ft® * '

making sure the sealing washers are in
place on the banjo connector. A .
Tighten the EGR valve coolant line nut - « V j /t

and capscrew.
Torque Value: 10 n.m [88 in-lb] ■ X " .
011 -031 EGR Cooler Coolant Lines
Install_________
A CAUTION A
Do not use petroleum products on 0-
the EGR cooler coolant line o-rings.
The o-rings will swell and cause the
connection to leak.
Install new the o-rings on the EGR

cooler coolant return line.
Lubricate the o-rings with clean engine

coolant, soapy water, or vegetable oil
for easier installation.
Install the EGR cooler coolant return

line from the EGR cooler to the
thermostat housing.
Tighten the mounting capscrews.
Install the EGR cooler coolant vent line. ^ i /

Attach the rigid section of the vent line /
to the EGR cooler and the flexible r? ^ < V
section to the EGR cooler coolant £
return line.
A CAUTION A
Do not use petroleum products on I
the EGR cooler coolant line o-rings.
connection to leak.
Install the new o-rings on the EGR

cooler coolant supply tubes and jumper
connection.

coolant, soapy water, or vegetable oil
to aid in installation.
Insert the EGR cooler coolant supply

jumper tube into the EGR cooler
coolant supply tube.

jumper tube into the EGR cooler inlet.
Install the retaining clamp and

capscrew to the EGR cooler.
NOTE: Do not tighten at this time.
Insert the EGR cooler coolant supply

tube into the water pump outlet.
Install the EGR cooler coolant supply

tube retaining clamp and capscrew.
NOTE: Do not tighten at this time.
Tighten in the following sequence.

Y / -
Install the EGR cooler coolant supply
tube mounting capscrew and tighten.
Tighten the EGR cooler coolant supply j^ |
jumper tube retaining clamp capscrew.
Tighten the EGR cooler coolant supply

tube retaining clamp capscrew.
Install the EGR cooler coolant vent line

to the thermostat housing and the EGR
cooler. •y
(
Install the o-rings on the coolant return

tube jumper tube.

coolant, soapy water, or vegetable oil,
for easier installation. ®
Install the jumper tube into the EGR

cooler.
Install the press in place seal and the

coolant return tube.
Install and tighten the capscrews.
Heat Shield Page 1 of 1
011-032 Heat Shield
Install_________
Apply high temperature anti-seize

compound onto the mounting
capscrews.
Install the three mounting capscrews

and the heat shield.
Apply high temperature anti-seize

compound onto the mounting
capscrews.
Install the four capscrews and the heat

shield.

SH7?
Assemble

CM570

turbine housing.


turbochargers.

turbochargers.

torque the locknut.

turbochargers.
turbochargers.

housing.
Install

w ith CM570

A WARNING A

Section 11.

nuts.

/ /vd
the variable geometry turbocharger
V / v
must be reused.

10.
w 7
Tighten the clamp.


f i L

A CAUTION A

bands.


on the elbow.

A WARNING A
A CAUTION A

A CAUTION A
A CAUTION A
mechanism.

turbocharger.

mounting nuts.

connection. (ft A
/ )])t '*■ j L ——
)
m


1 v .v >

c à
A C A U T IO N A

contact.

head.

A W A R N IN G A

this component.
À CAUTION ^

mechanism.


the turbocharger.

mounting nuts.

turbocharger.

capscrews.

oil filter head.
View Related Topic
010-041 Turbocharger Coolant Hoses
Install
A CAUTION A
Do not bend or kink hoses while
tightening. Doing so can damage the
hoses.
Install the turbocharger coolant supply

hose to the bottom of the turbocharger
and the lubricating oil filter head.
Tighten the fittings.

coolant hose coupling while tightening
the line.
A CAUTION A
lines.
Check the face of the coolant fittings on

the engine and on the turbocharger to
be sure the o-ring is in place and is not
damaged.
A damaged or missing o-ring will result

in a coolant leak.
Install the turbocharger coolant return

hose to the top of the turbocharger and
the thermostat housing. Tighten the
fittings.

coolant hose coupling while tightening
the line.
Install the tube brace onto the

turbocharger coolant return hose and
the air tube.
A CAUTION ^ •• tr » k. % Wr-. a •% >

w
{ ■
Do not bend or kink hoses while ©
hoses.
A CAUTION A
Do not use petroleum products on
the turbocharger coolant hose o-
rings. The o-rings will swell and
cause the connection to leak.
Install the four new banjo sealing

washers on the turbocharger coolant
supply hose.
Lubricate the sealing washers with

clean engine coolant, soapy water, or
vegetable oil.

hose to the turbocharger bearing
housing (3).

hose to the turbocharger actuator (2).

hose to the lubricating oil filter head (1).
NOTE: Use a second wrench to hold

the coolant hose coupling while
tightening the hose.
Tighten the fittings.
A CAUTION A *
if?
V
lines.
A CAUTION A
Do not use petroleum products on
the turbocharger coolant line o-rings.
connection to leak.
Install four new banjo sealing washers

on the turbocharger bearing housing
coolant return hose and turbocharger
actuator coolant return tube.

hose to the turbocharger. Tighten the
fitting.

hose in the thermostat housing. Tighten
the banjo fitting.

coolant hose to the thermostat housing.
Tighten the fitting.
It is possible for the turbocharger

actuator coolant return hose to contact
the turbocharger coolant return hose
when the fittings are torqued. Be sure
to space the hoses apart while the
fittings are torqued. If the hoses are not
spaced apart, hose failure can result.
NOTE: Use a second wrench to hold

the coolant line coupling while
tightening the line.

coolant hose to the turbocharger
actuator. Tighten the banjo fitting.

Install
A CAUTION A
valve.
A CAUTION A
Do not use thread sealant. The use
of thread sealant will cause damage
to the turbocharger control valve.
Mask both ends of the turbocharger

actuator supply line before installing.
Install the turbocharger actuator air

supply line.
Connect the air supply line to the

turbocharger air control valve.
Connect the p-clip to the thermostat

housings.

turbocharger actuator.

Start and run the engine.
Verify proper operation.
Check for air leaks.
011 -042 Aftertreatment Fuel Injector
Inspect for Reuse
Attach the heat shield to the injector.
Install a new high temperature EZ tie to

hold the injector harness to the heat
shield.
©
Install a new fibrous insulator.
Install a new metal gasket.
NOTE: The fibrous insulator w ill be

against the injector.
Install the aftertreatment injector onto

the adapter pipe.
Apply a coat of high temperature anti

seize compound to the capscrews.
Install the capscrews and spacers.
Install
Attach the heat shield to the injector.

1
Install a new high temperature EZ tie to
hold the injector harness to the heat
shield. © y
Install a new fibrous insulator.
Install a new metal gasket.
NOTE: The fibrous insulator w ill be

against the injector.
Install the aftertreatment injector onto

the adapter pipe.
Apply a coat of high temperature anti

seize compound to the capscrews.
Install the capscrews and spacers.
Aftertreatment Adapter Pipe Page 1 of 1
011-043 Aftertreatment Adapter Pipe
Install
Install the aftertreatment injector

assembly onto the adapter pipe. Refer
to Procedure 011 -042 in Section 11.
Install new gaskets on each end of the

adapter pipe.
Place the exhaust adapter pipe in

position with the pin in the correct
location in the turbocharger.
Tighten the v-band clamps on each

end.

Install
A CAUTION A
valve.
A CAUTION A

actuator supply line before installing.
Install the turbocharger actuator air

supply line.

turbocharger air control valve.
Connect the p-clip to the thermostat

housings.

turbocharger actuator.

Turbocharger Control Shutoff Valve Filter Head Page 1 of 1
010-115 Turbocharger Control Shutoff Valve

Filter Head
Install
Variable Geometry

Control Valve Air Supply Line
Install
A CAUTION A
valve.
A CAUTION A

control valve air supply line before
installing.
Install the turbocharger control valve air

supply line.

Connect the p-clips holding air line to

engine.

turbocharger control shutoff valve.
View Related Topic
010-113 Turbocharger, Variable Geometry Actuator
Install_____________________
Variable Geometry
A WARNING A
Keep fingers and hands away from the
actuator link to reduce the possibility of
personal injury as a result of sudden
movement when air is supplied.
Use coupling, Part Number 3824843, to apply

414 kPa [60 psi] regulated air pressure to the
actuator.
Install the actuator on the turbocharger

bearing housing.
Install and tighten the two capscrews.
Install the actuator rod to the turbocharger

cross-shaft.
Install the snap ring.
Install and tighten the capscrew.
Turbocharger Air Shutoff Valve Filter Page 1 of 1
010-114 Turbocharger Air Shutoff Valve Filter
Install_____
Variable Geometry
Apply a thin coat of lubricant on the

filter gasket.
Install and hand tighten a new

turbocharger control shutoff valve filter
on the turbocharger control shutoff
valve body.
Use a filter wrench to tighten the filter

full turn after gasket contact.
Integrateci Fuel System Module (IFSM) Page 1 of 2
005-073 Integrated Fuel System Module (IFSM)
Install
Install two guide pins into the mounting

holes on the cylinder head.
A WARNING A
Install the IFSM on the guide pins.
Install and tighten the capscrews.
Remove the guide pins.
Integrated Fuel System Module (IFSM) Page 2 of 2
Install and tighten the remaining

capscrews.
011-052 Aftertreatment Fuel Shutoff Manifold
Install
NOTE: The pressure sensor and

s h u to ff valve are located on the
same side o f the sh u to ff manifold.
? I i f
NOTE: The pressure sensor is ®
mounted above the sh u to ff valve.
Install the pressure sensor, the fuel i 'i< A M 4
shutoff valve, and the fuel drain valve.
Torque Value:
Pressure Sensor 14 n.m [124 in-lb]
Torque Value:
Fuel Shutoff Valve 14 n.m [124 in-lb]
Torque Value:
Fuel Drain Valve 14 n.m [124 in-lb]
Install the two capscrews to attach the i - ilT y ,

ScV v1
aftertreatment fuel shutoff manifold to
the bracket on the engine.

® A . 1
' W
NOTE: The pressure sensor and

s h u to ff valve are located on the ^|iT«7
same side o f the sh u to ff manifold.
NOTE: The pressure sensor is

mounted above the sh u to ff valve.
0
\ /
Install the pressure sensor, the fuel

shutoff valve, and the fuel drain valve.
Torque Value:
Pressure Sensor 14 n.m [124 in-lb]
Torque Value:
Fuel Shutoff Valve 14 n.m [124 in-lb]
Torque Value:
Fuel Drain Valve 14 n.m [124 in-lb]
Install the two capscrews to attach the

4 k
aftertreatment fuel shutoff manifold to .¿Ofc

f .
011 -051 Aftertreatment Injector Lines
Install
Connect the aftertreatment injector fuel

supply line to the aftertreatment
injector. !& i
’
Connect the aftertreatment injector fuel \ ^ ;

supply line to the outlet of the union
valve.
Install the P-clips.

supply line to the inlet of the union
valve.
v

supply line to the outlet of the fuel
shutoff manifold.
Connect the fuel return line to the fuel

shutoff valve manifold and the fuel
control module.
Torque Value:
O-ring joint 24 n.m [212 in-lb]
Torque Value:
Banjo joint 15 n.m [133 in-lb]
Install the two capscrews to attach the

aftertreatment fuel shutoff manifold to
Connect the aftertreatment injector fuel « J

supply line to the inlet of the shutoff
manifold.
Torque Value: -
• i
Banjo joint 34 n.m [25 ft-lb]
Connect the aftertreatment injector fuel t
supply line to the fuel rifle.
Torque Value:
O-ring joint 24 n.m [212 in-lb]
Connect the aftertreatment injector

coolant return line to the coolant return
line to the coolant return manifold.
•
Connect the aftertreatment injector
coolant return line to the aftertreatment ^ \
injector.

supply line to the aftertreatment *
injector. - V V ' J

©
&
supply line to the outlet of the fuel i t
shutoff manifold
Connect the fuel return line to the fuel

shutoff valve manifold and the fuel return
tee fitting, located in front of the engine
control module.
Install the P-clips
Torque Value: r>

O-ring fitting 24 n.m [212 in-lb]
Torque Value:
Banjofitting 15 n.m [133 in-lb]

supply line to the inlet of the shutoff
valve manifold. ' ÎS
T V

supply line to the fuel rifle.
006-006 ECM Cooling Plate, Fuel Cooled
Install
Install five insulating washers. The one

ground washer m ust be installed in the
upper left cooling plate mounting
capscrew hole.
A CAUTION A
Make sure that the insulating
washers and the ground washer are
installed properly on the cooling
plate or malfunction of the ECM can
occur.
Install the cooling plate gasket.
Install the six cooling plate mounting

capscrews and washers.
Install the ECM.
Install and tighten the five ECM

mounting capscrews.
Install the ECM cooling plate fuel

4 k
supply line (bottom) to the integrated
fuel system module and the ECM
View Related Topic
010-080 Air Intake Connection
Install a new gasket between the

cylinder head and the air intake
connection.
Install and tighten the four capscrews. ©

Install a new gasket between the

cylinder head and the air intake
connection.
: %
* % $ •.../, i
Install and tighten the four capscrews. © i .

ê W /$ '
EGR Mixer Page 1 of 1
011-021 EGR Mixer
Install
Install a new hose at the EGR mixer

inlet.
Install a new o-ring between the EGR

mixer and the air intake connection.
Install and tighten capscrews.
Lubricating Oil Dipstick Tube Page 1 of 1
007-011 Lubricating Oil Dipstick Tube
Install
Install the dipstick tube and tighten the
0
nut finger-tight.
Install the dipstick tube clamp,

capscrew, and nut.
Tighten the dipstick tube nut.
Tighten the clamp.
Install the dipstick tube and tighten the

-O h " 7 A - Í' ,
nut finger-tight. r*, >
< V . % '
# fJ ■
Install the dipstick tube clamp, -

capscrew, and nut. ©
Tighten the dipstick tube nut. X \ ”

:"X te ts n
Tighten the clamp.

View Related Topic
003-001 Crankcase Breather (External)
Install
Two p-clips attach the vent hose to the v • -i • ’

*1. r jr -
gear housing and two p-clips attach the r** |
vent hose to the side of the block. With v/ I IQkJ ■• ‘ P
the breather hose installed on the new
cover, the hose (3) m ust extend lower i ') i L A j l
than the flywheel housing. k A \
/» —
Install the crankcase vent hose (1). Use . .i-
the four p-clips (2), to secure the
crankcase vent hose to the engine.
Connect the inlet and outlet rubber

hoses, oil drain line, and install the
three hose clamps to the housing. Be
sure to push the hose on until it stops wZiir / /
on the housing connector. Verify that
© * C jf'* J i/
the hose clears the fan blade. ■i 1 ,
Connect the breather sensor wiring ’ -T« I v,
connector to the breather sensor.
Install and tighten the four mounting

capscrews.
M10 47 n.m [35 ft-lb]
M8 20 n.m [15 ft-lb]
Remove and install the crankcase

pressure sensor. Refer to Procedure
019-445 in the Troubleshooting and
Repair CM871 and CM876 Electronic
Control System, ISX and ISM Engines,
Bulletin 4021560.
007-065 Lubricating Oil Fill Tube
Install_________
Install a new oil fill connection ring seal.
Use clean engine oil to lubricate the oil

fill connection ring seal.
Install the oil fill tube cap and the oil fill


Install the new o-rings on the bottom of

the oil fill tube and a new ring seal on
the oil fill tube cap.
9MW

Refrigerant Compressor Page 1 of 1
009-051 Refrigerant Compressor
Install
Sanden

through the refrigerant compressor and

through the refrigerant compressor to
the alternator/refrigerant compressor
mounting bracket. Make sure the roll
pins align properly.
Install
Drives A lternator
Install the belt tensioner and mounting

capscrew.

©

#
Install the belt tensioner bracket to the
water pump.
Tighten capscrew.
©
Install the belt tensioner and capscrew.
Install the belt tensioner mounting

capscrew and the belt tensioner from fm
the bracket. fq Ml * '^

7
Ml
due to common capscrew usage. Refer
to Procedure 008-062.
For the low-mount (small tensioner):

front engine support with three
mounting capscrews. ©
m ©
Install the belt tensioner.
© m i
For the low-mount (large tensioner): r MU


" , ,w »
©
* ' ««ir
Idler Pulley, Refrigerant Compressor Page 1 of 1
009-054 Idler Pulley, Refrigerant Compressor
Install______________________________
Install the refrigerant compressor idler

pulley and the mounting capscrew.
NOTE: A special alignm ent

procedure is not required fo r the
refrigerant com pressor idler pulley
to the alternator/refrigerant
com pressor m ounting bracket.
Drive Belt, Refrigerant Compressor Page 1of 1
009-052 Drive Belt, Refrigerant Compressor
Install______________________________
A CAUTION A
injury.
Pivot counterclockw ise and hold the

belt tensioner. Install the drive belt and
relieve the tensioner.
008-088 Fan Support
Install______________
Use clean 15W40 oil to lubricate the

capscrew threads.
Install six capscrews.

Tighten the eight capscrews in the

sequence shown.
Tighten capscrew numbers 1 and 2 finger

tight to mate the surfaces of the belt
tensioner support bracket to the fan
support.
Tighten capscrew numbers 1, 2, 7, and

8.
008-036 Fan Hub, Belt Driven
Install________________
A WARNING A
Install the fan hub assembly and the

capscrews.
A WARNING A
this assembly.
Install the fan hub and the capscrews.
Install the belt tensioner bracket.

The fan hub m ust be installed in the

correct location on the fan support to
allow proper clearance between the fan
and fan shroud. Refer to the OEM
service manual.
Make certain the correct fan center is

used for the application. nri
Install the fan hub on the fan support
using four capscrews and washers.
© »
û
3 »
»
;
Install
Drives A lternator
Install the belt tensioner and mounting

capscrew.

©

#
water pump.
Tighten capscrew.
©
Install the belt tensioner and capscrew.
Install the belt tensioner mounting

capscrew and the belt tensioner from fm
the bracket. fq Ml * '^

7
Ml
due to common capscrew usage. Refer
to Procedure 008-062.
For the low-mount (small tensioner):

m ©
© m i
For the low-mount (large tensioner): r MU


" , ,w »
©
* ' ««ir
Drive Belt, Cooling Fan Page 1 of 1
008-002 Drive Belt, Cooling Fan
Install_____
Drives A lternator
A CAUTION A !♦'

injury.
Pivot and hold the belt tensioner.
Install the drive belt and release the

tensioner.
013-020 Starting Motor
Install
All Except 50MT With Alum inum Flywheel Housing
Make sure to use the same

thickness of starting motor spacer (if
used) as the one removed to install
the starting motor to reduce the
possibility of engine or starting motor
damage.
Install the starting motor, spacer (if

applicable), and the three mounting
capscrews.
Tighten the mounting capscrews.
5/8-11 x 1.75 in [103 ft-

140 n.m
capscrew Ib]
5/8-11 x 2.00 in [148 ft-

201 n.m
capscrew Ib]
^«,iW ujh % V lX \
Assemble the upper bracket (1) to the
block mounting stud and to the starter
motor end bracket. Tighten capscrews
and nuts finger tight.
Assemble the lower bracket (2) to the ©

oil pan rail mounting stud and to the
starter motor end bracket.
Tighten the capscrews and nuts finger

tight.
Tighten all capscrews and nuts.
Tighten all capscrews and nuts in the

following sequence:
(1) 45 n.m [33 ft-lb]
(2) and (3) 23 n.m [17 ft-lb]
(4) and (5) 41 n.m [30 ft-lb]
View Related Topic
003-011 Rocker Lever Cover
Install
NOTE: Engines built after September

7, 2006, or engines that have the
cover gasket embedded in the
rocker lever cover.
• If the cover gasket was removed,

install the cover gasket as soon
as possible to avoid swelling of
the cover gasket as the cover
gasket swells due to its prior
exposure to lubricating oil.
• If a new cover gasket is required,
use P80 lubriplate™, Part
Number 3163086, or soapy water
to lubricate the cover gasket.
If the cover gasket was removed or

requires replacement, start the
installation of the cover gasket at each
bolt hole and press the cover gasket
into the groove in the rocker level cover
around each bolt hole.
After the cover gasket is in place

around all bolt holes, press the cover
gasket into the grove of the rocker level
cover starting from the bolt holes
moving to the center of each span.
Inspect and make certain that there are

no kinks, twists or other damage.
Align the capscrew holes in the cylinder

head to the cover gasket, and rocker
lever cover prior to installing the
capscrews and isolator assemblies.
Install the eight capscrews and isolator
assemblies.
NOTE: Engines built before

September 7, 2006, have the
separate cover and a separate
gasket, install the eight capscrews
and isolator assemblies.
Tighten capscrews in sequence shown
Last Modified: 31-0ct-2006
006-015 Fuel Filter (Spin-On Type)
Install_____________
With Pressurized Fuel Filtering
A
Use the correct filter(s) for your engine.
It m ust remove a minimum of 95
percent of free and emulsified water. It
m ust also have a minimum of 98.7
,W
percent 15-micron particle-removal 1
efficiency. < > /

V.
Apply a thin coating of clean engine oil

to the filter gasket surface.
A CAUTION A
Mechanical overtightening of the
filter can distort the threads or
damage the filter element seal.
NOTE: Do not prefill the fuel filter.

Damage to the fuel system may
result.
Install the filter onto the filter head.

Turn the filter until the gasket contacts
the filter head surface.
Tighten the filter an additional % of a

turn after the gasket contacts the filter
head surface, or as specified by the
filter manufacturer.
To perform the priming procedure, use the

following items to fabricate a fuel bypass
hose:
• 2- Quick-disconnect fittings, Part

Number 3376859
• Clear tubing (capable of 2758 kPa
[400 psi])
Install the fuel bypass hose fabricated

above between the suction-side
Compuchek™ fitting at the top of the IFSM
and the fuel pump Compuchek™ fitting
located on the head of the fuel pump.
Connect the clear hose and the shutoff

valve normally used to check for air-in-fuel
to the rail Compuchek™ fitting. Refer to
Procedure 006-003 in Section 6. Place the
open end of the tube in a suitable
container and fully open the shutoff valve
in the hose.
Fill the fuel filter by turning the ignition

switch to the ON position, but do not
start the engine. The fuel lift pump
should begin to operate. Monitor the
open end of the bleed line from the rail
Compuchek™. When fuel is seen
coming out of this line, turn the ignition
OFF. Remove the bleed line and the
air-in-fuel test line.
With Vacuum Fuel Filtering and Priming Pump

m ust also have a minimum of 98.7
percent at 25-micron particle-removal
efficiency.

V.
© * > ■
Apply a thin coating of clean engine oil

to the filter gasket surface and the
center seal.
I I
A CAUTION A
Mechanical overtightening of the filter
can distort the threads or damage the
filter element seal.
NOTE: Do not prefill the fuel filter.

Damage to the fuel system may result.
Install the filter onto the filter head. Turn

the filter until the gasket contacts the filter
head surface.
Tighten the filter an additional 3/4 of a turn

after the gasket contacts the filter head
surface, or as specified by the filter
manufacturer.
If the filter is equipped with a water-in-fuel

sensor, rotate the sensor to the desired
location and connect the wiring harness.
NOTE: The engine w ill, perhaps, run

rough fo r several minutes until the air
is out o f the system.
Fill the fuel filter by turning the ignition

keyswitch to the ON position. The priming
pump will operate for 2 minutes, which will
adequately fill the fuel filter. The engine
can then be started.
Some engines utilize a manual, remote

mount priming pump. Flip the priming
pump mounted toggle switch to the ON
position. Operate the pump for 2 minutes
and shut it off. The engine can then be
started.
With Vacuum Fuel Filtering and W ithout Priming Pump

must also have a minimum of 98.7
percent at 25-micron particle-removal
A CAUTION A
Mechanical overtightening of the filter
PI
can distort the threads or damage the
NOTE: If the filte r is equipped with a

water-in-fuel sensor, rotate the sensor
on the filte r to the desired location and
connect the w iring harness. Fill the
filte r w ith clean fuel prior to
installation.
Install the filter onto the filter head. Turn

the filter until the gasket contacts the filter
head surface.
Tighten the filter an additional 3/4 of a turn

after the gasket contacts the filter head
surface, or as specified by the filter
manufacturer.
NOTE: The engine w ill, perhaps, run

rough fo r several minutes until the air
is out o f the system.
Remove the external hex plug on the top

ofthe integrated fuel system module.
Crank the engine until a solid stream of
fuel comes out of the port.
Install the hex plug.
Crank the engine for 20 seconds. If the
engine does not start within 20 seconds,

wait two minutes. It will probably be
necessary to remove the filter, fill the filter
with clean fuel, and install the filter.
Repeat these steps until the engine starts.
008-006 Coolant Filter
Install
A CAUTION A A
Mechanical overtightening can

distort the threads or damage the
filter head.
Apply a thin film of clean engine oil, or

its equivalent, to the coolant filter
gasket sealing surface before installing
the coolant filter.
Tighten the coolant filter % to % of a

turn after initial gasket contact, or as
specified by the manufacturer.
Turn the coolant on/off valve to the ON

position.
A WARNING A

Operate the engine until the coolant

temperature is above 82°C [180°F], and
check for coolant leaks.
After the air has been purged from the

system, check the coolant level again.
007-013 Lubricating Oil Filter (Spin-On)
Install
NOTE: The o-ring can stick onto the

filte r head. Make sure it is removed
before installing a new filter.
Clean the oil filter head surface.

gasket surface of the filter.
A CAUTION A
Mechanical overtightening can
distort the threads or damage the
Fill the oil filter with clean 15W-40 oil.
Install the oil filter onto the oil filter

head. Tighten the filter until the gasket
contacts the filter head surface.
Use oil filter wrench, Part Number

3375049, 3397929, or 3400157 to
tighten the filter an additional 3/4 to 1
turn, or follow the instructions supplied
with the filter.
Confirm that the oil level in the pan is to

the full mark.

temperature reaches 82°C [180°F],
Check the oil pressure and for leaks.

Engine Installation Page 1 of 4
000-002 Engine Installation
Install__________
Autom otive and Industrial
If the rear engine mounts are attached to

the transmission, it will possibly be
necessary to install the engine and the
transmission as an assembly.
A WARNING A
A WARNING A


engine lifting fixture, Part Number
brackets to install the engine.
*7 I rn r
A CAUTION A
Make sure all lines, hoses, and
tubes are correctly routed and
fastened to prevent damage.
Align the engine in the chassis, and

tighten the engine mounting
capscrews. Refer to the equipment
manufacturer's torque specifications.
Connect all engine and chassis-

mounted accessories that were
removed.
Connect the OEM wiring harness to the

ECM. R eferto Procedure 019-071 in
CM870 Electronic Control Systems
Signature and ISX Engines, Bulletin
4021334.
Power Generation
If the rear engine mounts are attached to

the transmission, it will possibly be
necessary to install the engine and the
transmission as an assembly.
A WARNING A
A WARNING A

engine lifting fixture, Part Number
brackets to install the engine.
A CAUTION A
Make sure all lines, hoses, and
tubes are correctly routed and
fastened to prevent damage.
Align the engine in the chassis, and

tighten the engine mounting
capscrews. Refer to the equipment

manufacturer's torque specifications.
Connect all engine and chassis-

mounted accessories that were
removed.
Connect the OEM wiring harness to the

ECM. Refer Procedure 019-071 in the
Troubleshooting and Repair Manual
Electronic Control System Signature,
ISX and QSX15 Engines, Bulletin
3666259. n u .
007-037 Lubricating Oil System
Prime
A CAUTION A
The lubricating oil system must be
primed before operating the engine
after any internal engine repairs or
extended engine storage (beyond 6
months) to avoid internal component
damage.
Bar the engine during oil priming.
Remove the oil plug from the

lubricating oil cooler housing and install
fitting and hose.
Use the coupler, Part Number

3376859, to connect the priming pump
to the coupling.
Connect the priming pump oil supply

hose to the lubricating oil pump
coupling. Use clean 15W-40 lubricating
oil from a drum or a container to supply
oil to the lubricating oil pump and
engine.
Turn the priming pump on.
Allow the oil to flow until the oil

pressure gauge indicates a maximum
pressure of 69 to 138 kPa [10 to 20 psi]
at the main oil rifle.
Turn the priming pump off.
Remove the priming pump oil supply

hose and fitting. Install the oil cooler
housing plug.
Check the oil level on the dipstick

before adding additional oil.
If necessary, fill the engine with t

lubricating oil.
it
Fill
Fill and install the lubricating oil filter

before putting oil into the engine. Refer «
to Procedure 007-013. rw U
*§)
Add the specified amount of clean
15W-40 oil to fill the oil pan. m i
Oil Pan Capacity

A utom otive and Power
Industrial Generation
83.3 liters [22
41.6 liters [11 gal]
gai]
Check the oil level on the dipstick. It

m ust be filled to the H (high) mark.
Refer to Procedure 007-009 for dipstick

calibration.

temperature reaches 82°C [180°F], and
check for leaks.
Shut off the engine. Wait 15 minutes for .j

the oil to drain back to the oil pan.
®7 ® ¡®
Check the oil level. Add oil as
RPtri
S 10 1 If 'if 'fi
necessary to bring the level up to the H W ->y\
(high) mark on the dipstick. * 7„ ño
: •_ /
008-018 Cooling System
Fill
CM570
The cooling system must be filled

properly to prevent air locks, or
serious engine damage can result.
Close the radiator drain valve(s).
Install the lower radiator hose(s).
Tighten the hose clamps. Refer to the

OEM service manual.
Cummins Inc. recommends the use of

either a 50/50 mixture of good-quality
water and fully-formulated antifreeze, or
fully-formulated coolant when filling the
41
cooling system. The fully-formulated
antifreeze or coolant must meet TMC
RP329 or TMC RP330 specifications.
Good-quality water is important for

cooling system performance. Excessive
levels of calcium and magnesium
contribute to scaling problems, and
excessive levels of chlorides and sulfates
cause cooling system corrosion.
Water Quality
Calcium Maximum 170 ppm

Magnesium as (CaC03 +
(Hardness) M gC03)
Chloride 40 ppm as (Cl)

Sulfate 100 ppm as (S 0 4)

Fleetguard® ES COMPLEAT™. It is
available in glycol forms (ethylene and
propylene) and complies with TMC RP329
and RP330 standards.
Referto Cummins® Coolant Requirement

1
and Maintenance, Bulletin 3666132 for more
engine coolant specifications.
A CAUTION A
Opening the manual bleed valve or
removing the pipe plug on applicable
installations is critical. Failure to do so
can result in engine damage.
NOTE: Some applications can have a

manual bleed valve or pipe plug that is
required to be opened to properly fill the
system. The upper radiator pipe is a
common location.

pipe plug installed in place o f the manual
bleed valve.
If applicable, open the manual bleed valve

or remove the pipe plug before filling the
cooling system.

manual fo r special coolant fill
system access point or fill door on the
vehicle.
NOTE: The system has a designed fill

rate of 19 liters [5 gal] per minute.
Fill the cooling system with heavy-duty

coolant and install the correct service
filter.
Identify the correct filter. For automotive

applications, use the Signature™ and
ISX Operation and Maintenance Manual,
Bulletin 3666251. Refer to Procedure
018-004 in Section V.

Industrial and Power Generation QSX15
Engines Operation and Maintenance
Manual, Bulletin 3666423. Refer to
Procedure 018-004 in Section V.
1 V
NOTE: Some radiators have two fill \ I ^
locations, both o f which must be filled ;f\>
when the cooling system has been
drained.
Fill the cooling system with coolant to the
(D
bottom of the fill neck in the radiator fill (or
expansion) tank. ® 1
A CAUTION A
If applicable, install the manual bleed valve

or the pipe plug after filling the cooling
system. Refer to the OEM service manual.
NOTE: All coolant shutoff valves

should be returned to their open
positions once the system has been
refilled and the deaeration process is
ready to begin. Refer to the OEM
service manual fo r specific
• '
instructions. ^ /
^ n r T /ir iiiiiii!
Install the radiator cap or expansion tank
fill cap.
Turn the cab heater temperature switch
to high to allow maximum coolant flow

through the heater core. The blower does
not have to be on.
Operate the engine at HIGH IDLE until

the thermostat opens, at least 93°C [200°
F].
Operate the engine at LOW IDLE for 2

minutes before shutting it down. This
allows adequate cool down of pistons,
cylinders, bearings, and turbocharger
components.
(D
Shut the engine off and allow it to cool.
. B0W£'
® (:
V
_ f i —HI
A WARNING A
Do not remove the pressure cap from
a hot engine. Wait until the coolant
temperature is below 50°C [120°F]
before removing the pressure cap.
Heated coolant spray or steam can
cause personal injury.
A CAUTION A
Do not add cold coolant to a hot
engine. This can cause engine casting
damage. Allow the engine to cool to
below 50°C [120°F] before adding
coolant.
NOTE: If all coolant drained from the

system was collected, the same
volume or more must go back into the
system. If any drained coolant

remains after filling, this is an
indication o f an air pocket which must
be purged before returning the vehicle
to service.
Remove the radiator or expansion tank

fill cap and check the coolant level
according to the OEM service manual.
Add coolant if necessary. Do not overfill.
Autom otive with CM870 and CM871
. k«i

properly to prevent air locks, or
serious engine damage can result. h
Close the radiator drain valve(s).
Install the lower radiator hose(s).
Tighten the hose clamps. Refer to the

OEM service manual.

either a 50/50 mixture of good-quality
water and fully-formulated antifreeze, or
fully-formulated coolant when filling the
49
cooling system. The fully-formulated
antifreeze or coolant must meet TMC
RP329 or TMC RP330 specifications.
1» T . *, "V
Good-quality water is important for

cooling system performance. Excessive
levels of calcium and magnesium
contribute to scaling problems, and
excessive levels of chlorides and sulfates
cause cooling system corrosion.
Water Quality
Calcium Maximum 170 ppm

Magnesium as (CaC03 +
(Hardness) M gC03)
Chloride 40 ppm as (Cl)

Sulfate 100 ppm as (S 0 4)

Fleetguard® ES COMPLEAT™. It is
available in glycol forms (ethylene and I/ v‘ ^ j i \ \
propylene) and complies with TMC RP329 tàfeBh I I
and RP330 standards.
M B
Referto Cummins® Coolant Requirement
and Maintenance, Bulletin 3666132 for more •M .
engine coolant specifications.
A CAUTION A

manual bleed valve or pipe plug that is
required to be opened to properly fill the
system. The upper radiator pipe is a
common location.

pipe plug installed in place o f the manual
bleed valve.
If applicable, open the manual bleed valve

or remove the pipe plug before filling the
cooling system.

manual fo r special coolant fill
system access point or fill door on the
vehicle.
NOTE: The system has a designed fill
rate of 19 liters [5 gal] per minute.
Fill the cooling system with heavy-duty

coolant and install the correct service
filter.
Identify the correct filter. For automotive

applications, use the Signature™ and
ISX Operation and Maintenance Manual,
Bulletin 3666251. Refer to Procedure
018-004 in Section V.

Industrial and Power Generation QSX15
Engines Operation and Maintenance
Manual, Bulletin 3666423. Refer to
Procedure 018-004 in Section V.
NOTE: Some radiators have two fill

locations, both o f which must be filled
when the cooling system has been
drained.
Fill the cooling system with coolant to the

bottom of the fill neck in the radiator fill (or
expansion) tank.
A CAUTION A
properly to prevent air locks or serious
engine damage can result.
NOTE: Do not install the radiator cap or

expansion tank fill cap. The engine is
operated w ithout the cap in this step.
Turn the cab heater temperature switch to

high to allow maximum coolant flow through
the heater core. The blower does not have
to be on.
Wait 2 to 3 minutes without starting engine

to allow the system to deaerate and the fluid
level to stabilize.
Add coolant to bring the level back to FULL

COLD.
A CAUTION A
If applicable, install the manual bleed valve

or the pipe plug after filling the cooling
system. Refer to the OEM service manual.
A CAUTION A
properly to prevent air locks or serious
engine damage can result.
NOTE: Do not install the radiator cap or

expansion tank fill cap. The engine is
operated w ithout the cap in this step.
With the radiator cap or expansion tank fill

cap off:
• Operate the engine at LOW IDLE for 2

minutes.
• Turn the engine off and add clean
water to bring the level back to FULL
COLD.
A WARNING A
Do not remove the pressure cap from a
hot engine. Wait until the coolant
temperature is below 50°C [120°F] before
removing the pressure cap. Heated
coolant spray or steam can cause
personal injury.
A WARNING A
Coolant is toxic. Keep away from children
and pets. If not reused, dispose of in
regulations.
NOTE: All coolant shutoff valves should

be returned to their open positions once
the system has been refilled and the
deaeration process is ready to begin.
Refer to the OEM service manual fo r
specific instructions.
Operate the engine at HIGH IDLE until the

thermostat opens, at least 93°C [200°F],
Operate the engine at LOW IDLE for 2

minutes before shutting it down. This allows
adequate cool down of pistons, cylinders,
bearings, and turbocharger components.
Shut the engine off and allow to cool.
A WARNING A
Do not remove the pressure cap from
a hot engine. Wait until the coolant
temperature is below 50°C [120°F]
before removing the pressure cap.
Heated coolant spray or steam can
cause personal injury.
A CAUTION A
Do not add cold coolant to a hot
engine. This can cause engine casting
damage. Allow the engine to cool to
below 50°C [120°F] before adding
coolant.
NOTE: If all coolant drained from the

system was collected, the same
volume or more must go back into the
system. If any drained coolant
remains after filling, this is an

indication o f an air pocket which must
be purged before returning the vehicle
to service.
Remove the radiator cap or expansion

tank fill cap and check the coolant level
according to the OEM service manual.
Add coolant if necessary. Do not overfill.
See Figure 1, illustrating the steps of the

coolant fill and deaeration process.
Sequence of Events for Coolant Fill and Deaeration

Volume
after 2 Volume
Figure 1: Coolant Fill and Deaeration Process
Copyright © 2000-2010 Cum m ins Inc. All rights reserved.

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ßDC

Cummins ISX QSX Service Manual

From the Library o f Barrington Diesel Club

(1Q-008-Q18-shQDdsi Cooling System

È flP rih g to n D iesel C lub

008-018 Cooling System

Position the equipment on level ground

NOTE: If the coolant is being

NOTE: Refer to the OEM service

Isolate the engine from the vehicle

will prevent the heater circuit from

This air can be very difficult to purge in

Remove the radiator cap or expansion

Do not allow the cooling system to dry

If the coolant is to be reused, the

A drain pan with a capacity of 57 liters

Before adding coolant back into the

For automotive applications, use the

For industrial applications, use the

Open the radiator drain valve(s).

Remove the lower radiator hose(s).

Do not remove the coolant filter.

Check for damaged hoses and loose or

Close the drain valve(s).

Install the lower radiator hose(s). Refer

Last Modified: 09-Jun-2010

C opyright © 2000-2010 C um m ins Inc. All rights reserved.

007-037 Lubricating Oil System

Operate the engine until the water

Shut off the engine.

Remove the oil drain plug.

Drain the oil immediately to make sure

If lubricating oil element failure occurs

• Inspect the lubricating oil filter by

• If debris is not found, drain the

Last Modified: 12-Apr-2005

C opyright © 2000-2010 C um m ins Inc. All rights reserved.

http://127.0.0.1:5000/https@quickserve. cummins.com/qs2/pubsys2/xml/en/procedure. 2014/12/10

000-001 Engine Removal

Disconnect the intake and the exhaust

Disconnect all chassis-mounted,

Disconnect the OEM wiring harness

NOTE: If the rear engine m ounts are

attached to the transm ission, it will

Remove all chassis components

Use a correctly rated hoist, and attach

If the transmission is not removed,

Remove the engine.

Cover all engine openings to prevent dirt

Place the engine on suitable engine

Remove and use all remaining

Disconnect the intake and the exhaust

Disconnect all chassis-mounted,

Disconnect the OEM wiring harness

Remove all chassis components