Mechanical

CUMMINS - ISX - CM870/871 - MECHANICAL -2013 Volvo VNL - Series - VNL-64 Стр.
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ENGINE
Cummins ISX CM 870/871 - Engine Mechanical
IDENTIFICATION
ENGINE DATAPLATE
Fig. 1: Identifying Engine Dataplate
Engine model identification and other important data are printed on Engine dataplate. Dataplate can
be found on top of rocker lever cover.
Ensure you have acquired correct information on Engine model, Serial Number, Control Parts List,
and Advertised horsepower and RPM before consulting Authorized OEM Repair Location for a
problem. Information on dataplate is mandatory when sourcing service parts.
ECM DATAPLATE
These engines are equipped with Electronic Control Module (ECM) dataplate, which is found on
front of ECM. Abbreviations indicate:
l P/N = Part Number

l S/N = Serial Number
l D/C = Date Code.
Fig. 2: Locating ECM Dataplate (CM870 & CM871)
ENGINE DIAGRAMS
Location of major external engine components, filters, and other service and maintenance points can
be determined from below illustration. Some external components of different engine models can be
found at different locations.
CM870
Fig. 3: CM870 - Left Side View
Fig. 4: CM870 - Right Side View
Fig. 5: CM870 - Front View
CM871
Fig. 6: CM871 - Left Side View
Fig. 7: CM871 - Right Side View
SPECIAL TOOLS
SPECIAL TOOLS
Tool No. Tool Name
DBT2V700 Coolant Extractor
J-39500-A Refrigerant Recovery/Recycling/Recharging Unit
J-44773 Air Line Release Tool
ST 1111-3 Manometer
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CUMMINS - ISX - CM870/871 - MECHANICAL -2013 Volvo VNL - Series - VNL-64 Стр. 2 из 174
ST 1166-1 Magnetic Crack Detector

ST 1178 Main Bearing Cap Puller
ST 1257-1 Valve Vacuum Tester
ST 1276-1 Exhaust Seat Puller
ST 1279-1 Intake Seat Puller
ST 1325 Dial Gauge Attachment
3101789 Seal Carrier
3162461 Cylinder Liner Installation Kit
3162462 Cylinder Liner Puller Plate
3162464 Mounting Plate
3162813 Flywheel Socket - 21 mm (12 point)
3162871 Engine Lifting Fixture
3162892 Valve Guide Installer
3162986 Four-Valve Spring Compressor
3162992 Oil Seal Puller (Front Crankshaft Seal)
3162996 Cylinder Head Lifting Fixture
3163021 Timing Pin and Wedges Kit
3163059 Air Impact Wrench
3163069 Injector Cam and Valve Gear Puller
3163097 Connecting Rod Guide Pins
3163157 Guide Pin Kit
3163160 Barring Tool
3163162 Head Bolt Stretch Gauge
3163167 Overhead Setting Kit
3163171 Feeler Gauge (.014 inch)
3163172 Feeler Gauge (.027 inch)
3163293 Valve Seal Puller
3163294 Valve Seal Installation Tool
3163318 Intake Seat Installer
3163319 Exhaust Seat Installer
3163321 Valve Guide Removal Tool
3163483 Injector Installation and Removal Tool
3163484 24 mm Impact Socket
3163530 Brake Feeler Gauge (7 mm)
3163682 Datalink Adapter Kit - Inline II
3163745 Cylinder Liner Puller
Thick Wear Sleeve/Wet Flywheel Housing Oil Seal Installation
3163826 and Removal Tool
3163890 Engine Controller
3163895 Harness Extension
3164014 Mounting Plate
3164088 Valve Camshaft Bushing Installation and Removal Tool
3164089 Injector Camshaft Bushing Installation and Removal Tool
3164185 Benchtop Calibration Cable
3164242 ISX/ISM Engine Controller Harness
3164438 Depth Gauge Assembly
3164606 Cylinder Liner Installation Tool
3164764 Guide Pin
3164765 Guide Pin
3164780 Oil Seal Puller (Rear Crankshaft Seal)
3164846 Piston Ring Compressor

3165161 Marked Socket
3375432 Crack Detection Kit
3376015 Cylinder Liner Puller (Universal)
3376050 Dial Indicator and Sleeve Assembly
3376206 Spacer
3376375 Fuel Measuring Device
3376405 Valve Seat Grooving Tool
3376592 Inch Pound Torque Wrench
3376617 Slide Hammer Assembly
3377161 Digital Multimeter
3398105 Torque Wrench
3822567 Blowby Tool (0.354 orifice)
3822995 Pressure Gauge (0 to 60 psi)
3823258 ScotchBrite 7448
3823495 Depth Gauge
3823621 Hydraulic Camshaft Bushing Installation and Removal Tool
3823978 Dyno-room Charge Air Cooler
3824510 Safety Solvent
3824963 Thermocouple Module
3824965 Temperature Immersion Probe
3886388 EST Software Kit
4918276 Drill Guide Adaptor
4918319 Protective Plug Kit
4918530 Crankshaft Adapter and Gear Removal Kit
4918538 .25" (6.35mm) Bushing
4918541 Stop Collar
4918542 Stop Collar
4918546 Wedge
9996049 Coolant Drain Hose
20449325 Fuel Line Fitting Release Tool
DESCRIPTION & OPERATION

SAFETY
Important Safety Notice
WARNING: Use of proper practices, precaution, or aware of warnings is vital.

Ignorance will result in personal injuries or death.
For your personal safety, obtain proper knowledge on all safety precautions and warnings (included
in this section) prior to start any work. Special safety precautions are given where applicable.
Ensure your working area is dry, free from clutter, loose tools, components, flammable sources,
dangerous substances, and has regular flow of air with enough light. Be conscious of risky conditions
that may exist.
Wear protective glasses and protective shoes whenever working. Avoid wearing loose or torn
clothing and ensure all jewelry is removed before working.
Prior to start repairing, ensure battery is disconnected and capacitors are discharged. Disconnect
negative (-) cable first.
If air starting motor is equipped, disconnect it to prevent accidental start. Stick a "DO NOT
OPERATE" tag in operator's compartment or on controls.
To rotate engine by hand use proper engine barring techniques only. Pulling or prying on fan to turn
crankshaft is discouraged as this can result in personal injury, property damage, or damage to fan
blade(s).
Prior to loosening filler cap and relieve pressure from cooling system, engine must be cooled after
shut down.
Avoid working on any component that is supported ONLY by lifting jacks or a hoist. Using of blocks
or proper stands are always recommended.
Prior to disconnect or remove any lines, fittings, or any items associated with air, oil, fuel and cooling
systems, first relieve all pressure in system. Be aware of pressure that may exist while disconnecting
any device that utilizes pressure from a system. DO NOT inspect for pressure leaks using hands as
high pressurized oil or fuel may injure you.
Always wear protective clothing and work in properly ventilated area while disconnecting liquid
refrigerant lines to avoid risk of suffocation and frostbite. Removing and recharging of system liquid
refrigerant must be done using approved equipment that prevents release of refrigerant gas
(fluorocarbons) into atmosphere.
Use of a hoist or assistance from other personnel is suggested while lifting heavy components to
avoid personal injury. Ensure all lifting devices (e.g., chains, hooks, or slings) are okay and are of
correct capacity. Ensure hooks are in correct position and are not side loaded. If required, use a
spreader bar.
DO NOT let corrosion inhibitor (a constituent of SCA and engine oil) enter into your eyes or swallow
internally. It contains alkali. Prolonged contact with skin is also dangerous. If it gets into eyes,
immediately flush eyes with plenty of water for a minimum of 15 minutes. For contact with skin,
immediately clean with soap and water. Seek prompt medical attention. Keep this substance AWAY
from children and pet.
Be cautious while using Naptha and Methyl Ethyl Ketone (MEK) and obey manufacturer's
instructions only. They are inflammable. Keep this substance AWAY from children and pet. Be
careful for hot components on products (just turned OFF), and hot fluids in lines, tubes, and
compartments.
Ensure service tools that are in good condition and familiarize yourself with using procedures. ONLY
NEW or reconditioned replacement components are recommended.
While replacing fasteners ensure same fastener (Part No.) is used. DO NOT replace fasteners with
lesser quality products.
DO NOT let anybody who is fatigued or drunk or using drugs to perform any kind of work.
Used engine oil is determined as carcinogenic and as reason for reproductive toxicity by some state
and federal agencies. Inhalation of vapors, ingestion, and prolonged contact with used engine oil is
dangerous.
Since natural gas is lighter than air, they can accumulate under hood and awnings whereas liquefied
petroleum gas can accumulate near floor, in sumps, and low-lying areas and they are heavier than
water.
Always wear protective clothing to reduce risk of suffocation and frostbite. Ensure natural gas and
liquefied petroleum gas lines are disconnected in a well ventilated area.
Dispose of coolant that should not be reused per local environmental regulations. Coolant is toxic.
DO NOT let catalyst reagent to contact eyes; they contain urea. Prolonged contact with skin is
dangerous. For contact with eyes, immediately wash eyes with plenty water for at least 15 minutes.
For skin contact, use soap and immediately wash with water. NEVER swallow. In case of ingestion,
SEEK PROMPT MEDICAL ATTENTION.
Vanadium Pentoxide, which has been classified as carcinogenic by State of California is contained in
catalyst substrate. Be extremely cautious while handling catalyst assembly. Wear proper protection
wears to avoid any kind of contact. For accidental contact with eyes and skin, provide same first aid
as mentioned above. While replacing catalyst, dispose of per local regulations
California Proposition 65 Warning - State of California determines diesel engine exhaust and some of
its constituents as a cause for cancer, birth defects, and other reproductive harm.
GENERAL REPAIR INSTRUCTIONS
General Information
These engines incorporate latest technology of time. However any repair work to them can be carried
out at quality standard using normal repair practices.
Safety-related components are given:
l Air Compressor
l Air Controls
l Air Shutoff Assemblies
l Balance Weights
l Cooling Fan
l Fan Hub Assembly
l Fan Mounting Brackets)
l Fan Mounting Bolts
l Fan Hub Spindle
l Flywheel
l Flywheel Crankshaft Adapter
l Flywheel Mounting Bolts
l Fuel Shutoff Assemblies
l Fuel Supply Tubes
l Lifting Brackets
l Throttle Controls
l Turbocharger Compressor Casing
l Turbocharger Oil Drain Line(s)
l Turbocharger Oil Supply Line(s)
l Turbocharger Turbine Casing
l Vibration Damper Mounting Bolts
For cleaning, follow recommended instructions in procedures and ensure environment is clean.
Ensure engine and components are clean during any repair since contamination of engine or
components result in rapid wear.
Use of manufacturer's instruction is recommended while using solvents and other substances for
cleaning. Some solvents and used engine oil are determined as toxic or carcinogenic by government
agencies. Excessive breathing, ingestion and contact with such substance are dangerous. Aware of
safety practices for using tools and equipment.
For inspections, follow recommended procedure. Damaged or excessively worn components or

assemblies should be replaced.
ONLY NEW or reconditioned service parts and assemblies are recommended for replacement.
Use of specified disassembly/assembly procedures is recommended for long service life of

components.
Guidelines on assembly are provided to use again as many components and assemblies as possible.
Procedure for replacement of a component or assembly is based on use of NEW or reconditioned
components.
Welding on a Vehicle with an Electronic Controlled Fuel System
It is important to disconnect both battery positive and negative cable prior to welding on vehicle.
Connect welder ground cable not exceeding 2 feet (0.61 meters) from welded component.
CAUTION: Avoid connecting welder ground cable to ECM cooling plate or

ECM. DO NOT weld on engine or engine mounted components.
This may damage engine or components.
GENERAL CLEANING INSTRUCTIONS
It is important for all components to be debris free regardless of their appearance. This is required to
prevent system contamination.
Polishing gasket surfaces unless factory machining marks are disturbed is discouraged as it may
prevent seal forming. In order to form a good sealing surface, maintain surface finish and flatness
tolerances. Gaskets are designed to fill small voids in specified surface finish.
It is unnecessary to polish gasket surfaces where edge-molded gaskets are used. Edge-molded gaskets
are metal carriers with sealing material bonded to edges of gasket to seal while metal portion forms a
metal to metal joint for stability. To remove small sealing material, use blunt-edged scraper on spot.
Avoid polishing whole surface with an air sander or disc.
Almost all gaskets with no edge molding have a material that contains release agents for sticking
protection. This does not mean that removal of some gaskets is not a problem because gasket (in
place for a long time), has been overheated or application of some sealant has beaten action of release
agent.
Removal of gasket should be done ensuring neither mating parts surfaces are damaged nor engine
contamination has occurred. Ensure little bits are not fall where removal will be difficult.
Bead blasting piston crowns before removing dark stain is useless. Removing carbon buildup above
top ring and in ring grooves is suggested. No more information on bead blasting and piston cleaning
is available in this literature.
DO NOT sand or grind carbon ring at top of cylinder liners until clean metal is visible to avoid
damaging of liner and destroying of any signs of a problem at top ring reversal point (like a dust-out).
Carbon ring must be removed to facilitate piston assembly removal. Use of a medium bristle, high
quality, steel wire wheel that is rated above RPM of power tool is suggested for quick removal with
less damage. Inspect for broken wires after piston removal. Wires are more visible and can be
attracted by a magnet.
Dirt may get adhered to oil on components that have been removed. Let old oil remain on component
while doing repair process. Thoroughly remove all dirt when it is time to install.
Always clean components and apply clean oil before installation despite it was cleaned earlier.
Ensure area between moving parts are lubricated properly. Or conduct a good lube system priming
process prior to cranking engine.
DO NOT bead blasting parts to remove exterior paint. Part will most likely be painted again so all
that needs happen is remove any loose paint.
Abrasive Pads & Abrasive Paper
No part of an engine is designed to resist abrasion. They are all supposed to lock together or slide
across each other. Abrasives and dirt particles will degrade both functions.
WARNING: Remove abrasive material from oil passages and worn areas of
components to prevent bearing and bushing failures that may
bring excessive component damage. This problem is inherent to
main and rod bearings.
It is discouraged to use emery cloth or sand paper on any part of an assembled engine or component.
Use of emery cloth or sand paper is also avoidable while removing carbon ridge from cylinder liners
or cleaning block decks or counterbores.
Be careful while cleaning engine components with abrasive products, specifically on partially
assembled engines. Abrasive cleaning products are available in many forms and sizes and they
contain following materials which are harder than most of engine components: aluminum oxide
particles, silicon carbide, or sand or some other similar hard material.
Pressing these material against softer material will either damage soft material or become embedded
in it. These materials fall off holding media as product is used. If products are used with power
equipment particles are thrown about engine. If particles fall between two moving parts, moving
parts may get damaged.
If particles smaller than clearance (between components) with engine stopped, but larger than
clearance while operating, then damage will occur when components move relative to each other
with engine started.
In presence of oil pressure (engine running), particles smaller than bearing clearance are likely to
pass between components and trap in oil filter. However, particles larger than bearing clearance will
remove material from one component and can become embedded in one of components.
If particle is embedded in one component, then it starts abrading other component until contact is lost
between two components. When damage is excessive and degrades oil film, two components will
come into contact. This shortage of lubrication consequently brings early wear-out or failure.
Be sure to block and protect engine from abrasive particles to prevent flying out during cleaning. Use
this caution particularly for engine oil ports and oil drilling holes, especially those located
downstream of engine oil filters. Then plug holes to remove debris.
NOTE: Blowing debris out of oil drilling using compressed air on an

assembled engine is discouraged since debris will blown further into
oil drilling.
Ensure old gasket material are removed from components gasket surfaces. Cleaning and polishing
gasket surface is useless until machining marks are erased. DO NOT sand or buff gasket surface
excessively.
Edge molded type gaskets that is a steel carrier with a sealing member bonded to steel, are commonly
used. Using abrasive pads or paper to clean gasket surfaces of this type is useless. Use a blunt-edged
scraper or putty knife to remove sticky sealing material.
WARNING: DO NOT sand or grind carbon ring from top of cylinder liners.
Failure to do so will result in several undesired outcomes;
damage to surface finish, forcing of abrasive particles into liner
material causing early cylinder wear or piston ring failures, and
excessive damage to liner.
Prior to using abrasive pads or wire brushes, tape off or plug all openings to any component interior.
If use of power tool with abrasive pads is required, tape oil passages closed or use plug. Use tool and
clean surfaces,
NOTE: Use hand to clean around oil hole/opening to prevent contamination of

drilling.
Now remove tape or plug and clean remaining area carefully and without tool.
NOTE: Blowing debris out of oil drilling using compressed air on an

assembled engine is discouraged since debris will blown further into
oil drilling.
If both ends of drilling are open, you can use compressed air to blow debris out.
Gasket Surfaces
Cleaning of gasket surfaces is necessary for removal any gasket material. This practice does not mean
to refinish component gasket surface.
Use of any specific brand of liquid gasket remover is discouraged. If used, it is important to inspect
directions for protection of material being cleaned.
Using air powered gasket scrapers requires less time, however proper care of surface from damage is
necessary. Ensure angled part of scraper is against gasket surface so as to prevent blade from digging
into surface.
CAUTION: If these scrapers are used on soft materials based components,

use care and proper skills to prevent damage.
DO NOT scrape or brush across gasket surface if possible.
Solvent & Acid Cleaning
Various solvent and acid-type cleaners are available to clean disassembled engine components except
pistons. To obtain best results use a cleaner that can be heated to 180-200°F (90-95°C).
Specification is different for kerosene emulsion based cleaners specifications. Use of a cleaning tank
that provides a constant mixing and filtering of cleaning solution is suggested.
NOTE: Obey manufacturer's instructions ONLY while cleaning.
Prior to placing components in a cleaning tank, use a wire brush or scraper and remove these
materials with care: all gasket material, "O" rings, and deposits of sludge, carbon, etc. Steam clean
parts, if possible.
WARNING: Obey manufacturers instructions to use solvents, acids, or

alkaline materials for cleaning purpose. For your personal safety,
use protective eye wear and protective clothing.
It has been proved that kerosene emulsion based cleaners are best to clean pistons. DO NOT apply
more than 170° F (77° C) temperature to them. At temperatures more than 180°F (82°C) solution
begins to break down that renders process inefficient.
NOTE: pH value 7.0 is considered as normal, above 7.0 is alkaline and below
7.0 is acidic.
NOTE: As much as pH value of a chemical, increases from neutral 7.0,

chemicals become highly alkaline. Use of high alkaline solutions is
discouraged since solution with a pH above 9.5 will turn aluminum
BLACK
Use of solutions based on chlorinated hydrocarbons with cresols, phenols and/or cresylic components
is discouraged since they often fails to remove deposits from ring groove. Proper disposal of these
products also needs high attention.
Prior to placing components in a cleaning tank, use a wire brush or scraper and remove these
materials with care: all gasket material, "O" rings, and deposits of sludge, carbon, etc. Steam clean
parts, if possible. It is suggested to remove heaviest dirt before placing in tank for effective operation
of cleaner and long life of cleaning agent.
Use hot water and clean all components after cleaning. Use compressed air and blow dry. Blow rinse
water from all bolt holes and oil passages.
For parts not going to use immediately after cleaning, let them dip in a suitable rust proofing
compound. Remove rust proofing compound from components before assembly or installation.
Steam Cleaning
Steam cleaning is a good practice to remove all types of dirt that can contaminate cleaning tank. Use
this method to clean oil passages and coolant passages.
WARNING: Hot steams are dangerous. Wear goggles, a face shield, and
protective clothing while using steam cleaner.
A listing of components that should be avoided from steam cleaning are:
l Bearings (ball or taper roller)

l Belts and Hoses
l Dosing Control Unit
l ECM
l ECM Connectors
l Electrical Components
l Fuel Pump
l Injectors
l Wiring Harnesses
Plastic Bead Cleaning
Read and digest following information regarding cleaning:
1. DO NOT use glass bead blast or walnut shell media on any engine component. Use of Plastic
Bead Media (3822735) or equivalent is always recommended.
2. Sanding (as a blast media) to clean engine component is a bad practice. Failure to use
manufacturer's guidelines in case of glass and walnut shell media may result in excess dust and
can embed in engine component. This in turn, causes early components failure due to abrasive
wear.
3. Use of plastic bead cleaning for removing carbon deposits is okay for several components.
Cleaning process is controlled by use of plastic beads, operating pressure and cleaning time.
4. It is unnecessary to use bead blasting cleaning methods on aluminum pistons skirts or pin bores
in any piston, piston skirt or piston crown. Early wear of cylinder liner, piston rings, pins and
pin bores will result since small particles of media will embed in aluminum or other soft metal.
This method may also damage valves, turbocharger shafts, etc. Use guidelines given in
procedures.
5. Ensure wash tanks and tank type solvent cleaners are not contaminated with unknown objects
and plastic beads. Use compressed air, hot high pressure water or steam clean these undesired
materials prior to putting them in tanks or cleaners.
6. If unknown object and plastic beads contaminate tank and any other engine components
(cleaned in tank) component failures will result in through abrasive wear.
7. Using of Plastic Bead Blasting Media (3822735) for cleaning all piston ring grooves is okay.
DO NOT sure any bead blasting media on piston pin bores or aluminum skirts.
8. Always obey manufacturer's cleaning guidelines. Adjust air pressure in blasting machine to
bead manufacturer's recommendations. If pressure is turned up, material can move on
component causing rapid wear of plastic bead media. Following guidelines may help you to
familiarize manufacturer's instructions:
A. BEAD SIZE - U.S. size Number 16 - 20 for piston cleaning with Plastic Bead Media
(3822735)
B. OPERATING PRESSURE - 40 Psi (270 kPa) for piston cleaning. Pressure should excess
enough to break beads.
C. Use solvent and steam clean or wash components to remove unknown matters and
plastic beads after cleaning. Clean with ample hot water. Use compressed air and blow
dry.
CAUTION: Ensure bead blasting operation does not disturb metal

surface otherwise damage to engine will result as
clearance of parts increases or surface finish on
component becomes insufficient when moving against
another component.
D. DO NOT remove all dark stain from piston while cleaning instead remove carbon on rim
and in ring grooves by directing blast across component as opposed to straight at part.
Ensure blast operation do not disturb metal surface.
NOTE: Disturbance of machining marks by blasting process

indicates pressure is too high or blast is being held on one
spot for long time.
E. Sometimes, walnut shell bead blast material are used to clean ferrous metals (iron and
steel). With this method there is threat of media embedment and subsequent engine
contamination, since high amount of dust may be produced particularly if air pressure on
blasting machine exceeds above media manufacturer's recommendation. Use of walnut
shell media for cleaning is not recommended.
F. Glass bead media can be embedded easily into material particularly in soft materials and
when air pressures exceeds media manufacturer's recommendation. Use of glass bead
media is discouraged to clean engine components. Due to its abrasive characteristic,
glass will abrade all parts it comes to contact with.
G. At higher pressures, glass bead media will break down forming tiny size dust that can
float easily in air. It is not easy to control this dust in shop, particularly if using
compressed air only (NOT hot water) to blow media after its removal from blasting
cabinet. Note blowing part off inside cabinet may remove large accumulations but fails
to remove all media).
H. If steam/higher pressure washing then even washing in a heated wash tank has failed to
remove dirt/carbon buildup, bead blasting method is recommended. This is specially
applicable for pistons.
I. For using plastic bead method to remove carbon remaining in grooves safely, it is
important to steam and soak pistons first. Avoid using a wire wheel or end of a broken
piston ring. To prevent blockage of return on blasting machine, parts should be dry and
oil prior to bead blasting.
J. Ensure bead blaster nozzle is directed "across" rather than directly at part to allow bead
to get under stubborn material. DO NOT hold nozzle at one place, keep it moving. If
nozzle is kept directed at one-place for long, metal will heat up and move around.
NOTE: Spray does not just hit dirt or carbon. Disturbance of

machining marks on piston groove or rim indicates not
enough movement of nozzle and/or very high air pressure.
K. DO NOT bead blast valve stems. It is suggested to tape or use a sleeve for stem
protection during bead blasting. Nozzle should be directed across seat surface and radius
instead of straight direction. This will remove any carbon build up. Continuing to blast to
remove stain is useless.
ENGINE BASE TIMING
General Information
Front Gear Assembly Configuration
Currently Signature and ISX engines uses 2 front gear train combinations. Signature, ISX3, and ISX2
use a scissor gear for lower idler gear and injector cam gear. Scissor gear at idler location is not used
by ISX1.
ISX2 engine manufactures between January 1999 to January 2000 used a scissor gear for lower idler
gear only. Injector cam gear was a straight cut spur gear like ISX1. After January 2000, ISX2
contains scissor gears for both cam and lower idler.
Fig. 8: Front Gear Assembly (Non-Scissor Gears)
This procedure describes removal, inspection, and installation of all different gear combinations.
Scissor Gears
WARNING: Read scissor gear definitions before removing gears. Adhere to

instructions to prevent engine damage.
1. Unloaded: When removing, installing, and setting gear backlash.

2. To unload gear, back out 2 gear adjusting screws until gear teeth align.
3. Idler scissor gear is loaded if gear backlash is set.
4. Loaded: Gear teeth are loaded (functional) and are spread between mating gear teeth.
5. To load gear, tighten all of adjusting screws. Gear teeth will be spread and movement will not
felt against valve cam gear. Gear will be in loaded condition for engine operation.
ADJUSTABLE IDLER GEAR
General Information
NOTE: Before installation or removal of any gears, inspect engine base

timing.
LOWER IDLER GEAR
General Information
Before installation or removal of any gears, inspect engine base timing.
ENGINE
General Information
Engine Nomenclature
Engine's ECM model number has been used in title of each procedure in order to simplify
identification of correct engine family. Engine(s) for corresponding ECM model number
nomenclature are:
CM870
This includes ISX automotive EGR engines manufactured with CM870 model ECM, which were
introduced in 2002.
CM570
This category includes ISX automotive and Signature engines manufactured with CM570 model
ECM, built 1998 through 2002.
Repair
Many cases of engine failures after a short time of engine in-frame repair has been reported. Most of
failures are determined to be a result of dirt entered into engine during repair work.
After analysis, it has been confirmed that 30% of failures of ISX engine connecting rod and main
bearings shortly after field repairs of oil cooler, front cover, or cylinder head are due to contamination
of some main oil passages. Investigation into type and source of contamination indicates it is
appropriate to restate, review and revise parts cleaning instructions for all engines.
It is not irrelevant to mention here that field technician are often put on high pressure in terms of time
required to perform a quality repair. Since customer expectations and regulatory requirements are
increasing along with increasing of complexity of diesel engine product, very often technician
attempt to reduce customer down time. In this effort, technician may employ many different labor
saving devices, techniques, and shortcuts that render contamination to internal engine components
accidentally. Consequently this result in additional failures in short time.
Magnetism
If engine has determined to be magnetized, and engine will need to be disassembled, investigate for
following conditions: electrical pass-through damage, magnetism of ferrous components, debris in
lubrication system, component or wear damage. Also, investigate for damage to bearings and
bushings that includes crankshaft thrust bearings, main bearings, connecting rod bearings, and
camshaft bushings.
PERMISSIBLE MAGNETISM LEVELS

Injectors and Ferrous Injector Components All other Ferrous Components
5 or less gauss units 15 or less gauss units
Use a gaussmeter and measure each ferrous component and note results. If magnetism fails to meet
specification, engine must be treated as if debris (fine particles) is circulating in lubrication system
causing component wear and damage.
If gauss units are greater than specification, replace or demagnetize component. To demagnetize
(degauss), use a facility capable of magnetic testing (Magnaflux) of engine components.
Carefully inspect lubrication system component closely. After cleaning oil galleries, replace these
items: all main bearings, thrust bearings, connecting rod bearings, and camshaft bushings.
NOTE: NEVER demagnetize sensors, engine control modules, or actuators.
Two methods for demagnetization are available. One is by passing part through an alternating current
coil (50 or 60 cycles per second) and other is passing a reversing, 30 point step-down current through
part.
Use "reversing 30 point step-down" method for larger mass parts. Use Alternating current coil
method for smaller parts.
Clean parts with permissible levels of magnetization and inspect for reuse.
Ensure alternating current coil are large enough for parts to pass through. Either allowing small part
through a large coil or passing through a smaller coil will prevent demagnetization.
Locate coil so that longest part axis of part falls perpendicular to coil while passing. To obtain
effective demagnetization parts must pass through at least 18-24 in. (457.2-609.6 mm) beyond coil.
It is avoidable to demagnetize small parts by loading them into a basket and passing basket through a
coil.
DO NOT attempt to demagnetize a whole engine assembly.
To achieve direct current demagnetization, use magnetizing unit. Clamp part between head and tail
stock. Activate demagnetization controls, and reversing, step-down current passes through part. Use
gaussmeter and inspect all parts.
A problem in electric current can be suspected if tiny pits occurred in clearly defined patterns, or
surfaces are fluted. Patterns may vary with metals, sources, and movement.
Pitting is a main indication for insert bearings. For anti-friction bearings, such as ball bearings, fluted
surfaces, or wavy lines of pitting in patterns differing with rotation, vibration, and current are main
indications.
Following are sources of electrical damage:
l Electrically actuated components e.g., clutch.

l Grounding of electrical system through crankshaft when some component such as generator or
engine block has not been grounded properly.
l Incorrectly grounded 6-Volt system.
l Static current from belts or other moving parts.
Contaminated Intake Air
Contamination of engine oil system with debris can be assumed if dust outs due to an intake air
system component failure is causing cylinder liner and piston ring wear. Disassemble engine and
clean thoroughly to remove debris from these parts: oil galleries, block cavities, cylinder head, and
air intake system. Clean and investigate camshafts and rocker lever pins and rollers for wear.
According to engine models, procedures for replacing an engine vary according to:
l Type of equipment
l Optional equipment
l Facilities provided by shop
Whenever making any replacement, remember:
l Not all replacement procedures are applied to all types of equipment.

l Procedures that apply to equipment involved MUST only be completed.
l Obey equipment manufacturer's recommendations and precautions for removal of chassis parts
to gain access to engine.
Fig. 9: Engine Lifting Brackets
CYLINDER BLOCK
General Information
Articulated pistons, a 2-piece piston that contains a forged steel crown and an aluminum skirt, are
used in some Signature and ISX engines. Underside crown of piston houses an open chamber oil
gallery. This gallery assures more oil contact with piston and better piston cooling.
Oil is captured in shaker trays, hence it is not easy to target piston cooling nozzle.
Single-piece pistons, a 1-piece piston with no bushing, is used in several engines. This piston is
forged from a high-strength, alloy steel. Underside of piston houses a cover plate to capture oil and
provide cooling to piston.
NOTE: This cover plate cannot be removed. DO NOT remove this cover plate
under any circumstances.
Pistons of same engine MUST have same design; either articulated or single piece design. DO NOT
intermix piston designs in same engine.
Articulated pistons may have either drilled or non-drilled connecting rods and connecting rod
bearings while single piece uses drilled connecting rods and connecting rod bearings.
Connecting Rod
Connecting rod big bore of ISX engine is straight-cut and has a 4- bolt design. If single-piece piston
is used, connecting rod I-beam is drilled to lubricate piston pin. Drilled connecting rods should be
used by these pistons.
Cylinder Liner
Cylinder liners has a mid-stop cylinder liner design. Cylinder liners of EGR engines are induction
hardened. Signature and ISX engines employ two different designs of cylinder liners. Design for a
particular engine is engine's production vintage dependent.
Groove-top cylinder liners are used on those engines assembled prior to engine serial number
14022615. These liners have a groove machined into cylinder liner flange top surface.
Flat-top cylinder liners are used on those engines assembled with engine serial number 14022615 and
after. These liners have a cylinder liner flange that is flat, except for fire dam.
CYLINDER HEAD
General Information
Cylinder head has one slab head and two overhead camshafts. Cylinder head group is comprised of:
l Cylinder head
l Valves and Valve guides
l Valve springs
l Valve seat inserts
l Crossheads, and injector sleeves
Intake and exhaust valves are of different sizes. Exhaust valves can be operated at higher temperature
than intake valves since material from which exhaust valves are made is more heat resistant than
from which intake is made.
Mark for identification on cylinder head parts such as crossheads, valves, and valve springs with
cylinder number and location. To simplify future installation, use a paint pen and mark intake and
exhaust valve positions on cylinder head combustion face.
Signature and ISX engines employ two different designs of cylinder liners. Liner design of an engine
depends on series of production:
l Groove-top cylinder liners: This liner type is used on engines prior to engine serial number
14022615. This includes a groove machined into cylinder liner flange top surface.
l Flat-top cylinder liners: This liner type is used on those engines assembled with engine serial
number 14022615 and after. This includes a cylinder liner flange that is flat, except for fire
dam.
Fig. 10: Identifying Groove-Top Liners & Flat-Top Liners
A cylinder head gasket and fire rings must be used on groove-top cylinder liners based engines. A
one-piece cylinder head gasket without fire rings should be used on flat-top liners based engines.
CAUTION: Cylinder head gaskets vary with cylinder liner design. Cylinder
head gasket made for flat-top cylinder liners can not be used with
groove-top cylinder liners and vice versa.
Signature and ISX engines use two different valve guides and valve guide seals.
1. Engines manufactured prior to engine serial number 14010274 employ non-grooved valve
guides and small valve guide seals. Valve Stem Seal Installer (3163294) is required for these
engines to install valve guide seals.
2. Engines built with serial number 14010274 and after employ a larger valve guide seal.
Installation of these seals should be done by hand without using seal
New seals snap into a groove machined on valve guide. Remember new style seals are not
compatible with old style non-grooved valve guides.
CYLINDER HEAD VALVE GUIDE SEAL
General Information
2 different valve guides and valve guide seals are used on Signature and ISX engines. Engines built
prior to engine serial number 14010274 use non-grooved valve guides and small valve guide seals.
These engines require Valve Stem Seal Installer, (3163294), to be used when installing valve guide
seals.
Engine serial number (ESN) 14010274 and all engines built after, use a larger valve guide seal. These
seals are designed to be installed by hand without seal driver. NEW seals snap into a groove
machined on valve guide. Seals introduced into engines built after ESN 14010274 with grooved
valve guides are incompatible with engines built with non-grooved valve guides and vice versa.
NOTE: Seals mating with grooved valve guides had 2 iterations.
1. Engines built from 15 May 2000 to February end 2002 had

separate intake and exhaust valve guide seals which were color
coded. Intake valve guide seals had a brass-colored garter spring
and three raised dots molded into rubber; exhaust valve guide
seals had a silver-colored garter spring and no raised dots.
2. Engines built after March 2002 had only one valve guide seal for
both intake and exhaust valve guides. These seals can be used
on any engines built after ESN 14010274.
ROCKER LEVERS
General Information
In order for engine to work efficiently, adjust valves, injectors, and engine brakes (if equipped)
correctly using values given in this section.
It is recommended to adjust valves, injectors, and engine brakes every 500,000 mi (800,000 km),
10,000 hours, or 5 years (whichever comes first).
Be sure to made adjustments after any major repair, and adjustment interval again becomes every
500,000 mi (800,000 km), 10,000 hours, or 5 years (whichever comes first).
For information about adjustment values, see Overhead Set-Adjustment.
COMPRESSED AIR SYSTEM
General Information
Common components of a compressed air system are:
l Air compressor (Gear-driven)

l Air governor
l Air tanks
l All necessary plumbing.
Fig. 11: Air Compressor
Single Cylinder
Common components of a single cylinder air system are:
l Air Governor
l Discharge line
l Air dryer
l Supply tank
l Check valve
l Primary tank
l Secondary tank
l Check valve
l Air compressor.
ENGINE TESTING
General Information
Recommendations provided are for engine testing and run-in. Ensure engines are run in after a
rebuild or a repair that involves replacement of one or more piston ring sets, cylinder liners, or
pistons.
NOTE: Early oil consumption or high-blowby are symptoms for running

engine with incorrect or insufficient break-in of piston rings. Use
following run-in guidelines to obtain full durability of new pistons,
liners, and rings.
Engine must have correct coolant in proper level before operating. Engine oil system must also be
filled and primed.
In Service Run-In
Use In service run-in guidelines for engines after repair has been made to piston ring sets, cylinder
liners, or pistons where engine or an engine dynamometer and/or chassis dynamometer run-in can not
be performed.
Under normal loaded operations almost all heavy-duty diesel applications provides sufficient run-in.
However, avoid high-RPM engine operation with light-load during run-in period.
Engine Dynamometer Run-In
Use this method for engines that have been rebuilt out of chassis. Removing an engine from
application to perform run in after a rebuild or cylinder repair that has been made in-chassis, is time
consuming and unreasonable. For an engine which has been run-in and tested on an engine
dynamometer, it does not make any sense to run it again after reinstallation in vehicle or equipment.
Avoid both of these practices.
Chassis Dynamometer, Portable Dynamometer, or Load Bank Run-In
For those applications where an engine loading immediately after rebuild or repair is not possible,
run in engine on a chassis dynamometer, portable dynamometer, or load bank. Use recommendations
outlined in attached procedures.
EXAMPLE: A standby generator or fire pump that can not be operated because of customer
restrictions, on-highway tractor that must be "bobtailed" for delivery.
MAINTENANCE
AIR COMPRESSOR CARBON BUILDUP
Initial Inspection
WARNING: Wear eyes and face protection gears to avoid damage from flying
debris and dirt while using compressed air.
Shut OFF engine and release compressed air by opening drain cock on wet tank.
WARNING: Allow air discharge lines to cool before handling to prevent

injury.
Remove air inlet and outlet connections from air compressor.
Measure total carbon deposit thickness inside air discharge line.
NOTE: Ensure carbon deposit thickness is not beyond 0.06 in. (1.6 mm).
WARNING: Air discharge line must be able to bear extreme heat and
pressure else injury and property damage can result.
NOTE: Remove and clean, or replace air discharge line if total carbon deposit
thickness is more than specification.
Inspect carbon buildup in air discharge line connections up to first connection or wet tank.
Clean or replace any lines and fittings if carbon deposits exceeds thickness of 0.06 in. (1.6 mm).
Cleaning
WARNING: Caustic solutions can cause injury to skin and eye. Exercise
precaution in handling them.
CAUTION: DO NOT remove carbon with a sharp object as they can damage
sealing surfaces.
CAUTION: Never allow debris and solvents in clearance between piston and
bore.
CAUTION: DO NOT use abrasive products like ScotchBrite. Any abrasive grit
left after cleaning will reduce life of air compressor.
Remove compressor head and valve assembly. See Air Compressor Cylinder Head-Single
Cylinder.
Use solvent and a nonmetallic brush to remove carbon from compressor head and valve assembly and
blow dry with compressed air.
Clean compressor cylinder.
Rotate crankshaft until piston is at top of cylinder bore.
Remove deposited carbon and varnish by scraping and light application of solvents.
Install compressor head and valve assembly. See Air Compressor Cylinder Head-Single Cylinder.
AIR COMPRESSOR UNLOADER & VALVE ASSEMBLY
Initial Inspection
Remove air governor or air governor signal line from air compressor.
Operate engine to activate air compressor.
Replace compressor cylinder head if air compressor is not pumping. See AIR COMPRESSOR
CARBON BUILDUP.
CYLINDER BLOCK
Inspect Condition
1. Inspect cylinder block for cracks, replace cylinder block if required.

2. Upper bore wear during block inspection should be ignored as it is not a failure and use of
NEW "O" rings on cylinder liner provides an adequate seal.
3. Liner ledge pitting found during block inspection, block can be reused if no leak found in liner-
to-liner ledge (block) interface.
Repair
WARNING: Some solvents are flammable and toxic. Use manufacturer

recommendation while using solvents, acids, or alkaline
materials for cleaning. Wear protective clothing and glasses to
avoid personal injury.
WARNING: To avoid personal injury from flying debris and dirt, use proper
eye and face protection when using compressed air.
This repair is used to retrieve bolt holes that are missing a portion of threads or have cracks extending
into threaded sidewall from upper counterbore.
NOTE: This procedure will not retrieve cracks that extend into bolt bosses or
coolant cavity below upper counterbore.
NOTE: Design of thread salvage kit allows to use with cylinder liner removed.
If cylinder liner remains in block, install shims to both sides of base
equally to bridge liner.
NOTE: Spacer (3376206) must be used on some engines, between mounting

base and drilling fixture.
1. Use a 12 inch flat surface mill file to remove any burrs from top deck surface of cylinder block.
This is necessary to get proper fixture location.
2. Select 2 bolt holes to position failed bolt nearly in middle. Install mounting plate assembly
onto bolt holes with proper spacers, 4 plain washers, and existing cylinder head bolts.
3. Using a heavy washer and 5/8-18 x 3 inch hex head bolt, connect drilling fixture to mounting
plate assembly.
4. For main bearing bolt thread repair, Mounting Plate (3164014), will not accommodate all
engines. Those cases required repair by a machine shop.
5. Slide locating pin through proper drilling fixture bushing hole until it rests in failed bolt hole of
cylinder block.
6. Drilling fixture guide bar and bushing must be centered over failed bolt hole.
7. Tighten 3 bolts to secure fixture assembly to 50 Ft. Lbs (68 N.m)
8. Remove locating pin.
9. Setting stop collar is required only for repairs using drills.
10. Drills are used in some kits for quick removal of waste material; but ensure depth of repaired
bolt hole is not beyond specification.
11. Following steps allows drill to stop short of original hole depth. Remaining material is then
removed with reamer.
A. Position 0.030 in (0.76 mm) feeler gauge over hole to be repaired.
B. Insert drill through drill bushing until its tip rests against feeler gauge.
C. Position thread insert to be installed between drill bushing and stop collar.
D. Move stop collar down until is rests against insert. Tighten stop collar.
E. Position drill through drill fixture bushing and let it rest over top of failed bolt hole.
F. Using a drill motor with a clutch and a maximum operating speed of 300 RPM, or using
a suitable cutting fluid, operate drill motor until stop collar contacts drill bushing.
12. Remove chips using chip vacuum.
13. Use reamer to clean material from bolt hole:
A. Position reamer through drill fixture bushing and let it rest over top of failed bolt hole.
B. Stop operation frequently while reaming to clean hole with chip vacuum.
C. Using drill motor with a clutch and a maximum operating speed of 300 RPM, or using
suitable cutting fluid, operate drill motor until reamer reaches bottom of original bolt
hole.
D. Reamer will stop cutting when reaches at bottom of hole.
14. Remove chips with using chip vacuum.
15. Cut NEW threads in bolt hole with tap.
A. Stop tapping operation frequently to clean bore with chip vacuum.
B. Install a 1/2 inch square drive socket on end of proper tap.
C. Keep tap well lubricated while tapping.
D. Install tap, and using proper tapping fluid, hand-tap to bottom of failed bolt hole.
E. Remove tap.
16. Remove chips with a chip vacuum.
17. Remove mounting bolts, spacers, 4 plain washers, and mounting plate assembly.
18. Thread tap in and out of newly-cut threads numerous times to ensure thread condition and
clean debris from threads.
19. Inspect bolt hole for leaks and cracks.
20. Clean threads and flush any debris from tapped hole with solvent-degreasing agent.
21. Remove solvent-degreasing agent from hole with a chip vacuum.
22. Position proper jam nut on an proper bolt.
23. Install proper thread insert onto cylinder head mounting bolt until it nears bottom of insert.
24. Rotate jam nut until it contacts thread insert. This will lock insert and jam nut together.
25. Using a solvent-degreasing agent, remove preservative coating from circumference of thread
insert.
26. Install thread insert, jam nut, and bolt into newly-tapped hole. Ensure thread insert threads
freely into hole.
27. Inspect for protrusion. Ensure thread insert protrusion is 0-0.040 in (0-1.0 mm) above cylinder
block surface.
NOTE: For applications with a counterbore, measure protrusion depth
beginning at counterbore face (which is recessed into hole).
28. Ensure minimum required thread depth is maintained after thread repair. If insert protrusion is
more than 0.040 in (1 mm), cylinder head bolt can bottom out when tightened.
29. Record amount insert protrudes and increase depth of original bolt hole.
A. If insert protrusion is correct, install insert.
B. If not correct, record measurement and adjust bore depth.
30. Inspect following before increasing bolt hole depth:
A. Ensure correct thread insert is being used. 2 inserts are available, 2 inserts are identical
except for their length.
B. Ensure insert used is correct length.
C. Ensure bolt hole is threaded all way to bottom.
D. Ensure there are no burrs or other damage that would prevent insert from threading to
bottom of bolt hole.
31. After inspecting these items, if thread insert protrusion still beyond 0.040 in (1.0 mm), increase
depth of original bolt hole depth.
NOTE: Design of thread salvage kit allows to use with cylinder liner
removed. If cylinder liner remains in block, install shims to both
sides of base equally to bridge liner.
NOTE: Use of Spacer is required on some engines; between mounting

base and drilling fixture.
32. Increase depth of bolt hole:

A. Install mounting plate assembly. DO NOT tighten fasteners at this step.
B. Slide drill through drill bushing and into threaded hole until it rests at bottom of hole.
C. Tighten all fasteners to 50 Ft- Lbs (68 N.m)
D. Ensure drill slides freely in bushing and threaded hole, indicating it is centered in hole.
E. Depth of original bolt hole must be up to 0.120 in (3.0 mm).
F. Slide stop collar over drill bit and subtract 0.020 in (0.50 mm) from insert protrusion.
Select a feeler gauge equivalent to this value.
G. With drill resting at bottom of hole, insert feeler gauge between stop collar and drill
bushing. Tighten stop collar.
H. Using drill motor with a clutch and a maximum operating speed of 300 RPM, a suitable
cutting fluid, operate drill motor until stop collar contacts drill bushing.
33. Remove chips with a chip vacuum.
34. DO NOT ream hole before second tapping.
35. Install a 1/2 inch square drive socket on end of appropriate tap and keep tap well lubricated.
36. Install tap, and using a suitable tapping fluid, hand-tap to bottom of failed bolt hole.
37. Remove tap.
38. Inspect bolt hole for leaks and cracks.
39. Clean threads, and flush any debris from tapped hole using a solvent-degreasing agent.
40. Remove chips and solvent-degreasing agent from hole with a chip vacuum.
41. Install thread insert on a cylinder head bolt and secure using jam nut.
42. Temporarily install thread insert and inspect protrusion. Ensure protrusion is 0-0.040 in (0-1
mm) above cylinder block surface.
43. Remove insert.
44. Lubricate thread insert and threaded hole with light coat of Primer (3824715). Allow 3-5
minutes to dry.
45. Lubricate circumference of thread insert with 4 beads of Thread Locking Compound
(3824038).
46. Each bead must be 0.03 in (0.8 mm) wide down entire length of thread insert and beads must
be 90 degrees apart.
47. Install thread insert until it is flush with cylinder block surface or it bottoms in hole. Allow to
dry for at least 3 hours.
48. Remove bolt and jam nut.
49. If required, file or machine top of thread insert so it is flush with cylinder block surface.
50. Ensure inner diameter of thread insert have no burrs. Using chip vacuum, remove any file
shavings or debris.
51. For applications where thread insert is recessed into a counterbore, an end mill or a machine
cutter may required to remove excess length of insert and restore alignment of counterbore.
ENGINE MOUNTS
Inspection
Inspect all rubber-cushioned mounts for cracks or damage. Inspect all mounting brackets for cracks
or damaged bolt holes.
NOTE: If damaged engine mounts and brackets are used:
l Engine can move out of alignment

l Driveline components in equipment can become damaged
l Vibration complaints may result
ADJUSTING
OVERHEAD SET
NOTE: BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4 are marked on
previous engine vibration dampers. Engine brakes need to set at
proper mark on these engines. Latest engine vibration dampers are
marked only with A, B, or C, and are adjusted with valves and injector
on same cylinder.
1. Locate valve set marks on outside of vibration damper.
Fig. 12: Identifying Mark On Vibration Damper
2. Set marks are A, B, and C:

A. Set to mark A to adjust cylinder 1 or 6.
B. Set to mark B to adjust cylinder 2 or 5.
C. Set to mark C to adjust cylinder 3 or 4.
D. Set all valves, engine brakes, and injectors 2 complete revolutions.
3. If engine is equipped with an air compressor:
A. Remove oil fill connector from lower gear case cover.
B. Insert a 3/4 inch drive ratchet and extension into air compressor drive.
C. Turn air compressor drive clockwise as viewed from front of engine.
Fig. 13: Rotating Crankshaft Using Barring Adapter
WARNING: DO NOT manually rotate engine by pulling or prying

on fan. This could damage fan blades causing earlier
fan failures that result in serious personal injury or
property damage.
4. Direction of rotation of crankshaft when viewed from front of engine: Clockwise.

5. Cylinders are numbered from front of engine (1-2-3-4-5-6).
6. Engine firing order: 1-5-3-6-2-4.
7. If air compressor is not equipped in engine:
A. Loosen bolts and rotate cover or remove oil fill tube, if equipped.
B. Using 1 1/2 inch socket, push barring gear into gear mesh and rotate barring adapter
counterclockwise to bar engine.
C. Rock barring device back and forth until it disengages.
Fig. 14: Identifying Rocker Levers
8. Each cylinder has 4 rocker levers:

A. Exhaust valve rocker lever
B. Injector rocker lever
C. Intake valve rocker lever
D. Engine brake rocker lever
9. Intake valve rocker lever is always long lever on valve rocker lever shaft.
10. BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4 are marked on previous engine
vibration dampers. Engine brakes need to set at proper mark on these engines. Latest engine
vibration dampers are marked only with A, B, or C, and are adjusted with valves and injector
on same cylinder.
11. Valves, brakes, and injectors on same cylinder are adjusted at same index mark on vibration
damper.
NOTE: For instructional purposes, position A is indicated as first step.

As long as proper sequence is followed, starting with position A
is not needed.
INJECTOR & VALVE ADJUSTMENT SEQUENCE

Turn Engine in Pulley Position Set Cylinder Set Cylinder Set Cylinder
Direction of Injector Valve Brake
Rotation (1)
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
(1) Firing Order: 1-5-3-6-2-4
12. Using compressor drive or barring device, bar engine over in direction of engine rotation
(clockwise as viewed from front of engine). A mark on vibration damper must be line up with
pointer on gear cover.
13. Inspect valve rocker levers on given cylinder to see if both intake and exhaust valves are
closed. Both sets of valves are closed if rocker levers and brake lever are loose. If not closed,
rotate compressor drive gear 1 complete revolution, and align A mark on front damper with
pointer again.
14. Loosen injector adjusting screw locknut on cylinder. DO NOT use click-type torque wrench.
15. Using dial-type torque wrench of 0-150 in-lb, tighten injector rocker lever adjusting screw. If
screw chatters during setting, repair screw and lever as needed. Back out adjusting screw 1 or 2
turns.
16. Position torque wrench so you can look in a direct line at dial. This will ensure correct reading
of dial.
17. Ensure parts are aligned, and tighten adjusting screw to squeeze oil out of valve and injector
train.
18. Preload valve train and injector with following initial adjustment:
A. Tighten injector lever adjusting screw to 71 in-lb (8 N.m)
B. Back adjusting lever screw out 1 or 2 turns.
C. Tighten injector lever adjusting screw to 71 in-lb (8 N.m)
D. Hold injector lever adjusting screw and tighten adjusting screw locknut to 55 ft-lb (75
N.m)
19. When injector is set on a cylinder for adjustment, adjust valves and engine brake on same
cylinder.
NOTE: BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4 are marked
on previous engine vibration dampers. Engine brakes need to set
at proper mark on these engines. Latest engine vibration
dampers are marked only with A, B, or C, and are adjusted with
valves and injector on same cylinder.
20. When set mark aligned with pointer on gear cover and both sets of valves closed on cylinder,
loosen locknuts on intake and exhaust valve adjusting screws. Back out adjusting screws 1 or 2
turns.
Fig. 15: Identifying Adjusting Screws
21. Select feeler gauge for correct valve lash specification.
VALVE LASH SPECIFICATION

Valve Specification In (mm)
Intake Nominal 0.014 (0.36)
Exhaust Nominal 0.027 (0.69)
22. Insert feeler gauge between top of crosshead and rocker lever nose pad. Ensure feeler gauge is
completely under pivoting rocker lever nose pad.
Fig. 16: Inserting Feeler Gauge
23. Tighten adjusting screw to 5 In. Lbs (0.6 N.m)

24. Using torque wrench and crows foot adapter, tighten locknut.
25. Hold adjusting screw in this position. DO NOT turn adjusting screw when locknut is tightened.
Torque locknut to 33 Ft. Lbs (45 N.m)
26. Now remove feeler gauge.
27. Locate engine brake set marks on outside of vibration damper for older engines. Set marks are
BRAKE SET 1-6, and BRAKE SET 2-5, and BRAKE SET 3-4.
A. BRAKE SET 1-6: Cylinder 1 or 6 adjust
B. BRAKE SET 2-5: Cylinder 2 or 5 adjust
C. BRAKE SET 3-4: Cylinder 3 or 4 adjust
CAUTION: Follow brake adjustment instructions to get maximum
brake operating efficiency and to prevent engine

damage.
NOTE: See Fig. 12
28. Using compressor drive or barring device, bar engine over in direction of rotation (clockwise
as viewed from front of engine). A mark on vibration damper must be line up with pointer on
gear cover.
NOTE: For illustrative purposes, position A is indicated as first step. As

long as proper sequence is followed, starting with position A is
not needed.
29. Inspect valve rocker levers on given cylinder to see if both intake and exhaust valves are
closed.
30. Both valves are closed if rocker levers and brake lever are loose. Rotate compressor drive gear
1 complete revolution, and realign A mark on front damper with pointer if valves are not
closed.
31. Press engine brake lever down to ensure camshaft follower is in contact with camshaft.
32. Loosen locknut on brake lever adjusting screw, and back out adjusting screw 1 turn.
33. Insert Feeler Gauge, (3163530), between bottom of engine brake piston and top of exhaust
valve pin on exhaust valve crosshead.
ENGINE BRAKE SPECIFICATION

Specification In (mm)
Lash 0.276 (7.00)
34. Tighten adjusting screw until drag on feeler gauge is felt. Proper drag indicates no motion of
brake lever camshaft follower against cam lobe.
A. Hold engine brake lever adjusting screw and tighten locknut to 177 In. Lbs (20 N.m)
B. Remove feeler gauge.
CAUTION: Engine could damage if running clearance is not within

specifications.
35. Inspect running clearance:

A. Turn engine brake rocker lever to detente (neutral) position.
B. Inspect clearance between engine brake lever actuator piston and crosshead guide pin.
ENGINE BRAKE ROCKER RUNNING CLEARANCE

Minimum 0.025 (0.635)
Maximum 0.110 (2.790)
36. If running clearance is not within specification, loosen rocker shaft bolts (but DO NOT
remove) and rotate shaft in direction necessary to bring running clearance within listed
specification. Setting this clearance and verifying on all 6-brake levers is critical. This task
must be completed to avoid engine damage.
37. Inspect brake running clearance.
38. Adjust rocker lever shafts so that all 3 engine brake levers fall within given running clearance
specification.
39. Repeat process to adjust all injectors, engine brakes, and valves. See INJECTOR & VALVE
ADJUSTMENT SEQUENCE table.
TROUBLE SHOOTING
AIR GOVERNOR-AIR COMPRESSOR WILL NOT PUMP
Removal
Remove air governor or air governor signal line from air compressor.
Inspect Condition
Operate engine to activate air compressor:
1. If air compressor is pumping, air governor is malfunctioning. Replace it.

2. If compressor does not pump with governor removed, unloader valve is malfunctioning.
Replace compressor cylinder head. See Air Compressor Carbon Buildup.
AIR GOVERNOR-AIR COMPRESSOR PUMPS CONTINUOUSLY
Initial Inspection
1. Remove air accessory air lines from air compressor governor and install pipe plugs in air
governor unloader ports. Operate engine to activate air compressor.
2. A leak in an accessory or an accessory air line is indicated if air compressor stops pumping (air
pressure stops rising) at governed air pressure.
3. Connect a regulated shop air pressure line to air compressor unloader valve port if air
compressor does not stop pumping (air pressure continues to rise) at governed air pressure.
NOTE: Use an accurate air pressure gauge. Supply lines and fittings
must be okay before performing any air pressure inspections.
4. Use an accurate master gauge to inspect air pressure gauge.

5. Apply 100 psi (690 kPa) air pressure to unloader port. If air compressor stops pumping (air
pressure stops rising), air governor is malfunctioning. Repair or replace it, or air governor
mounting gasket is leaking.
6. If air compressor continues to pump (air pressure continues to rise), unloader valve is
malfunctioning, replace it. See Air Compressor Unloader Valve.
7. Remove pipe plugs from unloader ports used for accessory air lines. Install and tighten
accessory air lines and connect line to unloader valve.
8. Operate engine and inspect for air leaks.
AIR PRESSURE RELIEF VALVE
Initial Inspection
CAUTION: Keep hands away from intake port of air compressor to avoid
injury.
1. Remove air governor or air governor line from air compressor. Remove air intake line from air
compressor cylinder head.
2. Operate engine to activate air compressor.
3. Keep hands 2 in. (5 cm) away from air compressor intake port. If air is coming out of intake
port, pressure relief valve is malfunctioning. Replace air compressor cylinder head. See Air
Compressor Cylinder Head-Single Cylinder.
4. If air is not leaking from intake port, inspect downstream air system components for damage or
restrictions.
5. Install air intake line to cylinder head. Install air governor or air governor line to air
compressor.
SYSTEM TESTS
ENGINE TESTING
Dynamometer Worksheet
Worksheet
With EGR
DYNAMOMETER WORKSHEET
Date: Repair Order No.: Operator:
ESN: CPL: ECM Code:
Complaint:
DYNAMOMETER WORKSHEET
ESN: CPL: ECM Code:
Complaint:
PARAMETER CODE SPECIFICATIONS

Parameter Code Specifications Actual Reading
Intake Air Restriction (in H2
O)(1), (2)
Exhaust Restriction (in Hg)(1),
(2)
Fuel Inlet Restriction (in Hg)

(1), (2)
Fuel Drain Line Restriction (in

Hg)(1), (2)
Engine Blowby (in H2 O)(2)
(1) Record at advertised horsepower RPM and full load
(2) See ENGINE TESTING.
Use correct fuel rate for temperature, see FUEL QUANTITY SPECIFICATIONtable below.
FUEL QUANTITY SPECIFICATION

Engine Set up for Dyno with Electronic Service Tool? (Circle one) YES/NO
Oil Level (Circle one)
LOW/HIGH/OKAY Fuel Quality (Circle one) OKAY/NOT OKAY
Road Speed Limit
Engine Speed
Horsepower
or Torque
EGR Valve
Position
Turbocharger
Control
Valve
Command
Fuel Rate
(lb/hr)3
Rail Fuel
Pressure (psi)
Fuel
Temperature
Intake
Manifold Air
Temperature
Intake
Manifold
Pressure (in
Hg)
Coolant
Temperature
Coolant
Pressure (psi)
Engine Oil
Pressure (psi)
FUEL TEMPERATURE SPECIFICATION

Fuel Temperature Correction for Flow Rate
Less than 45° F (7° C) Flow meter is not accurate
45-55° F (7-13° C) Subtract 2% from flow rate reading
68-85° F (20-29° C) No Correction
85-108° F (29-42° C) Add 1 % to flow rate reading
108-132° F (42-56° C) Add 2% to flow rate reading
132° F (56° C) above Flowmeter not accurate
PRESSURE CONVERSIONS
Pressure Conversions
1 in H2 O = 0.074 in Hg = 0.036 psi
1 in Hg = 13.600 in H2 O = 0.491 psi
1 psi = 2.036 in Hg = 27.680 in H2 O
Without EGR
WORKSHEET - WITHOUT EGR

ESN: CPL: ECM Code:
Complaint:
PARAMETER CODE SPECIFICATIONS

Parameter Code Specifications Actual Reading
Intake Air Restriction (in H2
O)(1), (2)
Exhaust Restriction (in Hg)(1),
(2)
Fuel Inlet Restriction (in Hg)

(1), (2)
Fuel Drain Line Restriction (in

Hg)(1), (2)
Engine Blowby (in H2 O)(2)
(1) Record at advertised horsepower RPM and full load
(2) See ENGINE TESTING.
Use correct fuel rate for temperature, see FUEL QUANTITY SPECIFICATIONtable.
FUEL QUANTITY SPECIFICATION

Engine Set Up for Dyno with EST? (Circle one) YES/NO
Oil Level (Circle one)
LOW/HIGH/OKAY Fuel Quality (Circle One) Okay/Not Okay
Road Speed Limit
Engine
Speed
Horsepower
or Torque
Fuel Rate
(lb/hr)3
Fuel
Temperature
Intake
Manifold
Air
Temperature
Intake
Manifold
Pressure (in
Hg)
Coolant
Temperature
Coolant
Pressure
(psi)
Engine Oil
Pressure
(psi)
FUEL TEMPERATURE SPECIFICATION

Fuel Temperature Correction for Flow Rate
Less than 45° F (7° C) Flow meter is not accurate
55-68° F (13-20° C) Subtract 1 % from flow rate reading
68-85° F (20-29° C) No correction
132° F (56° C) above Flowmeter not accurate
PRESSURE CONVERSIONS
Pressure Conversions
1 in H2 O = 0.074 in Hg = 0.036 psi
1 in Hg = 13.600 in H2 O = 0.491 psi
1 psi = 2.036 in Hg = 27.680 in H2 O
Engine Testing (Chassis Dynamometer)
Setup
An engine installed in "on-highway" vehicles can be tested for performance on a chassis

dynamometer.
NOTE: Rated horsepower will be reduced by 20% for single-axle vehicles, 25%
for tandem-axle vehicles. This is because of driveline inefficiencies
and engine-driven accessories.
NOTE: Wheel horsepower is also known as net horsepower.
NOTE: Use these percentages only for engine run-in. They are not absolute
figures.
WARNING: Adhere to vehicle manufacturer's safety precautions while

installing or operating a vehicle on a chassis dynamometer.
CAUTION: Bias ply tires are less sensitive to heat than low-profile radial
tires. These tires can get damaged due to overheating on
excessive operation at full load. Read manufacturers'
recommendations to know maximum allowable chassis
dynamometer operating time.
CAUTION: To prevent damage to chassis dynamometer "tie-down" chains

must have slack.
1. Observe following precautions while operating chassis dynamometer:

A. Use tires which are not used for more than 100 mi (160 km). DO NOT use NEW tires.
B. DO NOT use recapped tires or tires of different sizes or designs.
C. Ensure tires are inflated as per specifications.
D. Remove all dirt and debris from tires to be used on dynamometer rollers.
E. Ensure correct overhead clearance for exhaust stacks, air deflectors, or other attachments
above cab.
2. Carefully position vehicle on rollers.
3. Connect "tie-down" chains to rear of vehicle, and put wheel chocks in front of front wheels.
4. Adjust vehicle and dynamometer room exhaust system to vent exhaust gases from room.
5. Follow chassis dynamometer and vehicle manufacturer's recommendations and specifications
for testing.
6. Inspect engine coolant level to ensure it is filled to proper level.
WARNING: Allow coolant temperature to reduce to 120° F (50° C)

before removing pressure cap because heated coolant
spray or steam can cause personal injuries.
CAUTION: Engine casting can get damaged if cold coolant is added to

a got engine. Allow engine to cool to 120° F (50° C).
7. Inspect engine oil level ensure it is filled to proper level.
NOTE: Use good quality Number 2 diesel fuel. Number 1 diesel fuels and most
other alternate fuels, are lighter (lower specific gravity, higher API
gravity) than Number 2 diesel fuel. Lighter fuel reduce energy content
(BTU) per gallon (liter).
Test
Record following parameters to monitor engine performance correctly. To limit dynamometer

operating time, instrument engine or use EST to perform maximum possible inspections:
1. Engine speed (RPM)

2. Fuel rate
3. Intake manifold air temperature
4. Engine blowby
5. Engine coolant pressure
6. Engine coolant temperature
7. Rail fuel pressure.
8. Engine fuel temperature (if needed to correct fuel rate).
9. Fuel inlet restriction.
10. Fuel drain line restriction.
11. Intake manifold pressure.
12. Intake air restriction.
13. Exhaust restriction.
14. Engine oil pressure.
Engine Speed (RPM)
Use EST to monitor engine speed. Record engine speed.
Fuel Rate
Follow Fuel Flow Measurement on Engine or Chassis Dynamometer in following section.
NOTE: To compensate for temperature variation, adjust fuel rate reading.
Maximum Fuel Inlet Temperature should be 132° F (55.5° C) and minimum should be 45° F (7.2°
C).
Intake Manifold Air Temperature Control - Chassis Dynamometer Test
1. Lock cooling fan ON while operating an engine on a chassis dynamometer.

2. Use EST/Set Up for Dynamometer feature to lock fan in ON position if unit has no manual fan
switch. See Engine Testing-In Chassis.
3. Use EST to monitor intake manifold air temperature. Record temperature.
4. Temperature must not be more than maximum allowable limit. See Specifications on Engine
Testing page. If temperature exceeds specifications performance will be disrupted due to
engine protection system. Maintain temperature less than maximum limit during operation.
5. Unload dynamometer and allow engine to cool if temperature exceeds maximum limit.
6. Shut OFF engine and inspect charge air cooler fins for obstructions to airflow.
7. Inspect fan drive. Fan must be is locked ON.
8. Remove obstructions like winterfront or debris. Manually lock shutters (if equipped) in OPEN
position.
9. There should be adequate supply of suitably cool or outside air in dynamometer room.
Engine Blowby
Measure engine crankcase pressure using Blowby Checking Tool (3822567), and Water Manometer
(ST-1111-3).
Install tool to end of blowby tube and install water manometer to this tool. Operate engine at
mentioned horsepower RPM at full load and observe and record blowby.
Engine blowby must not exceed maximum limits, see Engine Testing-Specifications.
Engine Coolant Pressure
Measure engine coolant pressure using Pressure Gauge (3822995) and record pressure. See Engine
Testing-Specifications.
Engine Coolant Temperature
Use EST to monitor engine coolant temperature. Record temperature. See Engine Testing-
Specifications.
Unload dynamometer and allow engine to cool if coolant temperature exceeds maximum limits.
Shut OFF engine and inspect radiator fins for obstructions to airflow.
Inspect fan drive to ensure fan is locked ON.
Remove obstructions like winterfront or debris. Manually lock shutters (if equipped) in OPEN
position.
There must be adequate supply of suitable cool or outside air in dynamometer room. Dynamometer
room air recirculation must not be obstructed.
Engine Fuel Temperature
Monitor fuel temperature using Immersion Probe (3824965) with a Digital Multimeter (3377161),
and a Thermocouple Module (3824963). Record engine fuel temperature.
Engine Run-in (Chassis Dynamometer)
Instructions
NOTE: See Engine Testing (Chassis Dynamometer).
1. Operate vehicle in a gear which produces a road speed of 55-60 mph (90-100 Km/h) at
mentioned horsepower RPM.
2. Record all engine performance parameters using Dynamometer Worksheet in Procedure 014-
001. Monitor block coolant pressure during run-in to get early indication of a cooling system
problem.
3. Obtain ECM code and fuel pump code from ECM dataplate using EST.
NOTE: Use EST to confirm that ECM code on ECM is same as one
installed in ECM. All ECM codes have an associated fuel pump

code.
4. If a sudden increase in blowby occurs or if blowby exceeds maximum limit during any run-in,
go to previous step and continue run-in. Discontinue run-in if blowby does not reach an
acceptable level during next step. Determine cause.
5. Proceed to next step only when a steady, acceptable blowby reading is obtained.
NOTE: Measure blowby with Blowby Checking Tool, and Water

Manometer.
6. DO NOT idle engine for more than 5 minutes during first 100 mi (160 Km) of operation.
7. Adjust engine speed to 1200 RPM. Apply a test load which can develop 25% of advertised
horsepower of engine.
8. Operate engine at this speed and load level until coolant temperature reaches 160° F (70° C).
A. Repair all leaks.
B. Inspect all gauges and record data.
C. Allow blowby to stabilize and be within specifications before proceeding to next step.
9. Open throttle to get engine speed at which advertised horsepower is developed, and adjust
dynamometer load to achieve 75% of mentioned horsepower on engine.
A. Operate engine at this speed and load level for 3 minutes.
C. Allow blowby to stabilize and maintain specifications before proceeding to next step.
10. Maintain engine speed at which advertised horsepower is developed. Move throttle lever to
fully opened position. Increase dynamometer load until 100% mentioned horsepower of engine
is developed.
11. Increase dynamometer load until engine speed reduces to engine's peak torque RPM.
12. Reduce dynamometer load until engine speed increases to engine speed at which mentioned
horsepower is developed.
13. Fully remove dynamometer load and reduce engine RPM to idle.
14. Shut OFF engine.
CAUTION: DO NOT shut OFF engine immediately after completing run-

in. Allow engine to cool by operating it at 700-900 RPM for at
least 3-5 minutes. This will prevent internal damage and
allow turbocharger and other components to cool.
15. Remove all instruments before removing vehicle from dynamometer.
Engine Run-in (Without Dynamometer)
Run-In Instructions
On-Highway Applications
WARNING: To avoid internal component damage, see ENGINE TESTING at

front of this section before operating engine.
Pull heaviest available trailer allowed for first 50-100 mi (80-160 Km) after rebuild. Operate vehicle
in highest gear within normal operating RPM range of engine at or near full throttle at 75-85% of
maximum horsepower RPM mentioned on dataplate.
DO NOT idle engine for more than 5 minutes during first 100 mi (160 Km) of operation.
Off-Highway Applications
WARNING: To avoid internal component damage see ENGINE TESTING at

front of this section before operating engine.
Operate engine under highest load at full throttle within normal operating RPM range for first 3 hours
of operation after rebuild.
DO NOT idle engine for more than 5 minutes during first 3 hours of operation after a rebuild.
Engine Testing (Engine Dynamometer)
Setup
NOTE: Dynamometer should have a capacity to permit testing at 100% of

engine's rated horsepower. If not, modify testing procedure to
restrictions of dynamometer.
Install engine test stand using Engine Lifting Fixture (3162871). Align and connect dynamometer.
Coolant Plumbing
Connect coolant supply to water inlet connection and coolant return to water outlet connection.
Install drain plugs and close all water drain cocks.
Intake Manifold Air Temperature Control - Chassis Dynamometer test
Use a remote aftercooler to connect a charge air cooled engine to an engine dynamometer for engine
run-in, performance testing and engine diagnostics. DO NOT run this engine without means of
controlling intake manifold air temperature. Dynamometer-room Charge Air Cooler (3823978),
utilizes twin Big Cam III aftercooler assemblies for parallel air and water flow to cool intake air to
acceptable levels.
Parallel airflow circuit heat exchangers deliver air to mixer at 151° F (66° C) and with less than
maximum allowable intake air pressure drop to provide optimum performance. Remote aftercooler
removes energy from intake air which is compressed and heated by turbocharger to 410° F (210° C)
and cooled to 151° F (66° C) using city water at 61° F (16° C).
Water from a city tap line flows to aftercooler via a 1 inch (25.4 mm) inner diameter neoprene hose.
12 gal (45.4 liter) per minute city water flow is required (6 gal (22.7 liter) per minute per aftercooler
core) to properly cool intake air for 435-500 horsepower-rated engine. DO NOT use a normal garden
hose due to excessive restriction. Instead a low-restriction ball-type or gate valve can be used,
provided that required flow rates are achieved.
From aftercoolers water returns to drain or reservoir via a 1 inch (25.4 mm) inner diameter hose. Put
a low-restriction gate valve or ball valve on drain line(s) to regulate water flow through aftercoolers
to maintain optimum intake air temperature during test or run-in procedure.
Condensate will develop when intake air is cooled in remote aftercooler. These vapors are drained
through a hole at bottom of tubular steel manifold between aftercoolers. Ensure this fitting is
unobstructed.
NOTE: Air also escapes through condensate drain opening, but it is

insignificant since total airflow is high.
Airflow piping requires a 4 in. (101.6 mm) inner diameter aluminum steel piping. Flow circuit must
contain fewer bends and long length of straight sections. Use long elbows when bends are required.
DO NOT use square elbows or anything that changes airflow direction quickly. This will increase
intake air restriction.
Air Compressor
NOTE: All air compressors must operate during engine run-in. All air
compressors must be in unloaded or non-operating mode during
performance inspection.
Connect a source of compressed air which can produce 96 psi (665 kPa) to air compressor unloader.
This air line must have a valve between air source and unloader.
NOTE: Connect compressed air load to air compressor outlet.
Use an air tank to install an Air Regulator which can maintain 50-75 psi (345-517 kPa) air pressure at
both minimum and maximum engine RPM.
Install a steel tube or high temperature hose. Specification for Hose Temperature is 500° F (235° C)
at minimum.
Connect tube or hose to air compressor outlet.
Starting Motor
Before installing electrical wiring, inspect voltage rating on starting motor.
WARNING: Batteries emit gases which can cause explosion resulting in

injuries. Ensure proper ventilation before servicing batteries.
Remove negative (-) battery cable first and connect it last to
prevent arcing.
Install electrical wiring to starting motor and batteries (if used).
If using an alternate method for starting engine, follow manufacturer's instructions to make necessary
connections.
Engine Throttle Control

prevent arcing.
For engines operating on an engine dynamometer install engine harness and connect it to engine.
Also, use Engine Controller Harness (3164242), and Engine Controller (3163890) to properly control
engine during dynamometer run.
Connect engine controller harness Deutsch connector to ECM, OEM port.
When test or run-in is complete return parameters to their original value.
Connect battery power to starter.
Connect dynamometer test OEM wiring harness starter solenoid lead (yellow) to starter solenoid.
Connect ground lead (black) to starter or battery negative (-) or ground side. Connect + 12 Volt dc
power lead (red) to either starter or battery positive (+ 12-Volt dc) side.
Connect Ignition switch panel data link cable to electronic service tool.
Use EST electronic service tool to set engine up for dynamometer. See Engine Testing-In Chassis.
Now setup is complete, and auto/manual throttle can be used to control engine speed.
Test
Record following parameters for correct monitoring of engine performance. To limit dynamometer
operating time, instrument engine or use EST electronic service tool to make maximum number of
inspections.
l Engine speed (RPM)

l Fuel rate
l Intake manifold air temperature
l Engine blowby
l Engine coolant pressure
l Engine coolant temperature
l Rail fuel pressure.
l Engine fuel temperature (if needed to correct fuel rate).
l Fuel inlet restriction.
l Fuel drain line restriction.
l Intake manifold pressure.
l Intake air restriction.
l Exhaust restriction.
l Engine oil pressure.
Engine Speed (RPM)
Monitor engine speed with EST electronic service tool and observe and record engine speed.
Fuel Rate
See Engine Testing-Specifications.
Adjust fuel rate reading to compensate for temperature variation if required. Maximum Fuel Inlet
Temperature should be 132° F (55.5° C) and minimum should be 45° F (7.2° C).
Intake Manifold Air Temperature Control - Chassis Dynamometer Test
1. Lock cooling fan in ON position while operating an engine on a chassis dynamometer.

2. Use EST electronic service tool/Set Up for Dynamometer feature to lock fan ON when unit has
no manual fan switch. See Engine Testing-In Chassis.
3. Monitor intake manifold air temperature using EST electronic service tool and observe and
record temperature. It must not exceed maximum allowable limit. See Engine Testing-
Specifications.
4. Unload dynamometer and allow engine to cool if temperature exceeds maximum limit.
5. Shut OFF engine and inspect charge air cooler fins for obstructions to airflow.
6. Inspect fan drive to ensure fan is locked ON.
7. Remove obstructions like winterfront or debris. Manually lock shutters (if equipped) in OPEN
position.
8. There should be adequate supply of suitably cool or outside air in dynamometer room.
Dynamometer room air recirculation must be fine.
Engine Blowby
Measure engine crankcase pressure using Blowby Checking Tool and Water Manometer.
Install tool to end of blowby tube and install water manometer to blowby checking tool. Operate
engine at mentioned horsepower RPM at full load. Observe and record blowby. It must not exceed
maximum allowable specifications. See Engine Testing-Specifications.
Engine Coolant Pressure
Measure engine coolant pressure using Pressure Gauge (3822995) and observe and record pressure.
Engine Coolant Temperature
Monitor engine coolant temperature using EST electronic service tool and observe and record
temperature.
Unload dynamometer and allow engine to cool when coolant temperature exceeds maximum
allowable limit.
Shut OFF engine and inspect radiator fins for obstructions to airflow.
Inspect fan drive to ensure fan is locked ON.
Remove obstructions like winterfront or debris. Manually lock shutters (if equipped) in OPEN
position.
There should be adequate supply of suitably cool or outside air in dynamometer room. Dynamometer
room air recirculation must be fine.
Engine Fuel Temperature
Monitor fuel temperature using Immersion Probe with a Digital Multimeter, and a Thermocouple
Module. Observe and record temperature.
Engine Run-in (Engine Dynamometer)
Run-In Instructions
See ENGINE DYNAMOMETER-SETUP, for general operating procedures and safety precautions.
Record all engine performance parameters using Dynamometer Worksheet.
Monitor block coolant pressure during run-in to detect a cooling system problem at early stage.
NOTE: Use EST to confirm that ECM code on ECM is same as one installed in
ECM. All ECM codes have an associated fuel pump code.
Obtain ECM code and fuel pump code from ECM dataplate using EST.
If a sudden increase in blowby occurs or if blowby exceeds maximum limit during any run-in, got to
previous step and continue run-in. Discontinue run-in if blowby does not reach an acceptable level
during next step. Determine cause.
Proceed to next step only when a steady, acceptable blowby reading is obtained.
NOTE: Measure blowby with blowby Checking Tool, and water manometer.
DO NOT idle engine for more than 5 minutes during first 3 hours or 100 mi (160 km) of operation.
Adjust engine speed to 1200 RPM. Apply a test load which can develop 25% of mentioned
horsepower of engine.
Operate engine at this speed and load level until coolant temperature is 160° F (71° C).
Repair all leaks.
Inspect all gauges and record data.
Allow blowby to stabilize and be within specifications before proceeding to next step.
Open throttle to obtain engine speed at which mentioned horsepower develops, and adjust
dynamometer load to achieve 75% of mentioned horsepower on engine.
Operate engine at this speed and load level for 3 minutes.
Maintain engine speed at which mentioned horsepower is developed. Move throttle lever to fully
opened position, and increase dynamometer load until 100% mentioned horsepower of engine is
developed.
Operate engine at this speed and load level for five minutes.
Increase dynamometer load until engine speed reduces to engine's peak torque RPM.
Operate engine at this speed and load level for 7 minutes.
Reduce dynamometer load to increase engine speed to point at which advertised horsepower is
developed.
Operate engine at this speed and load level for five minutes.
Fully remove dynamometer load.
CAUTION: DO NOT shut OFF engine immediately after completing run-in.

Allow engine to cool by operating it at 700-900 RPM for at least 3-
5 minutes. This will prevent internal damage and allow
turbocharger and other components to cool.
Shut OFF engine.
Remove all instruments before removing engine from engine dynamometer.
Engine Testing-In Chassis
Setup
1. Setup for Dynamometer function prepares engine ECM for an advanced diagnostic test run on
chassis dynamometer. Following are set for this test:
A. Maximum engine speed without Vehicle Speed Sensor (VSS)
B. Maximum vehicle speed in top gear
C. Maximum vehicle speed in lower gear
D. Idle shutdown feature is disabled
E. Fan is locked ON
2. When engine Ignition switch is turned OFF these values are automatically reset.
A. Max. Engine Speed without VSS: 2500 RPM for testing purposes, this speed is
temporarily set to maximum value allowed.
B. Max. Vehicle Speed in Top Gear: 120 mph for testing purposes, this speed is temporarily
set to maximum value allowed.
C. Max. Vehicle Speed in Lower Gear: 120 mph for testing purposes, this speed is
temporarily set to maximum value allowed.
D. Gear-Down Protection: This feature is temporarily disabled for testing purposes.
E. Fan Clutch: On.
F. Idle Shutdown: Temporarily disabled for testing.
3. Disable some SAE (J1939) electronic subsystems. User can enable or disable SAE (J1939)
data link with service tool.
Engine Testing (Portable Dynamometer or Load Bank)
General Information
Run-in engine on a chassis dynamometer, portable dynamometer, or load bank using

recommendations of preceding procedures when it can not be loaded immediately after rebuild or
repair (for example, on-highway tractor which should be "bobtailed" for delivery, a standby generator
or fire pump that can not be operated due to customer restrictions, a fire truck which can not be
loaded with water pump, etc.).
Specifications
CM870
Maintain following limits during engine test and run-in procedures:
NOTE: Since different engine models have different ratings, use engine data
plate to identify specific engine model and horsepower rating.
CM870 TESTING SPECIFICATIONS

Charge Air Cooler Restriction (maximum)
Mercury 3.0 in Hg (76.2 mm Hg)
Pounds Force 1.5 psi (10.3 kPa)
Intake Restriction (maximum at advertised horsepower)
Clean Air Filter 10.0 in H2 O (254.0 mm H2 O)
Dirty Air Filter 25.0 in H2 O (635.0 mm H2 O)
Exhaust Back Pressure (maximum) 3.0 in Hg (76.2 mm Hg)
Oil Pressure
Low Idle (minimum) 20.0 psi (138.0 kPa)
Oil Pressure Range 35.0-40.0 psi (241.0-276.0 kPa)
Cylinder Block Coolant Pressure (closed 38.0 psi (262.0 kPa)
thermostat, maximum)
Fuel Inlet Temperature (maximum) 160° F (71° C)
Fuel Inlet Maximum Restriction
Pressure Side Fuel Filter Restriction 75.0 psi (517.0 kPa)
(maximum)
Fuel Drain Line Restriction (maximum) 9.0 in Hg (228.6 mm Hg)
Blowby (maximum at advertised or torque peak RPM) with 0.354-in (9-mm) orifice
New or rebuilt engines (maximum) less than 12.0 in H2 O (305 mm H2 O)
100,000 miles
Used Engine (maximum) greater than 100,000 18.0 in H2 O (457 mm H2 O)
miles
CM871
Maintain following limits during engine test and run-in procedures:
NOTE: Since different engine models have different ratings, use engine data
plate to identify specific engine model and horsepower rating.
CM871 TESTING SPECIFICATIONS

Charge Air Cooler Restriction (maximum)
Mercury 3.0 in Hg (76.2 mm Hg)
Pounds Force 1.5 psi (10.3 kPa)
Intake Restriction (maximum at advertised horsepower)
Clean Air Filter 10.0 in H2 O (254.0 mm H2 O)
Dirty Air Filter 25.0 in H2 O (635.0 mm H2 O)
Exhaust Back Pressure (maximum) 12.0 in Hg (304.8 mm Hg)
Oil Pressure
Low Idle (minimum) 20.0 psi (138.0 kPa)
Oil Pressure Range 35.0-40.0 psi (241.0-276.0 kPa)
Cylinder Block Coolant Pressure (closed 48 psi (331 kPa) @ 1600 RPM
thermostat, maximum)
Coolant Temperature Operating Temperature (maximum)
Fuel Inlet Temperature (maximum) 160° F (71° C)
Fuel Inlet Maximum Restriction

Pressure Side Fuel Filter Restriction 75.0 psi (517.0 kPa)
(maximum)
Fuel Drain Line Restriction (maximum) 9.0 in Hg (228.6 mm Hg)
Blowby (maximum at advertised or torque peak RPM) with 0.354 in (9 mm) orifice
New or rebuilt engines (maximum) less than 12.0 in H2 O (305 mm H2 O)
100,000 miles
Used Engine (maximum) greater than 100,000 18.0 in H2 O (457 mm H2 O)
miles
COMPRESSED AIR SYSTEM
Air Leaks
1. Shut OFF engine and release air by opening drain cock on wet tank and then close drain cock
after releasing.
2. Operate engine to activate air compressor.
3. When air compressor is pumping between 80-100 psi (550-690 kPa), use a solution of soapy
water to inspect for air leaks at:
A. Air compressor head gasket
B. Air compressor cover gasket
C. Hose and fitting leaks.
4. If leaks are detected, verify that air compressor head and cover bolts and hoses and fittings are
tight. Make necessary replacements.
COMPONENT TESTS
CONNECTING ROD
Bend & Twist Inspection
Calibration Procedure
NOTE: Reference connecting rod is rod of known length, bend, and twist
which is necessary to calibrate fixture. You can also use a NEW
connecting rod for which distance from center of crankshaft bore to
center of piston pin bore (rod length) is known.
1. Install and tighten connecting rod cap to correct specifications or calibration will be incorrect.
2. Install proper connecting rod checking guide into reference connecting rod piston pin bore and
center guide.
3. Install proper connecting rod checking guide into reference connecting rod crankshaft bore.
4. Ensure pin on guide is down and centered in connecting rod. Rotate end of guide to lock it in
position.
5. Install reference connecting rod into connecting rod checking fixture.
6. Loosen knob and move indicator bracket until both indicators contacts top of piston pin guide.
7. Move bracket toward guide until indicator needles have moved about 0.010 in (0.25 mm).
8. Turn knob to tighten bracket.
9. Adjust indicator needles to zero and to confirm move connecting rod in and out.
10. Remove reference connecting rod from fixture. Rotate connecting rod 180 degrees horizontally
and install it into fixture.
11. Ensure indicators are at 0 setting. If indicator needles do not return to 0, adjust indicator so
zero moves 1/2 of indicated difference from needle to 0 established during previous step.
12. If needle is more than 0.004 in (0.10 mm) from 0 established during previous step, inspect for
dirt or burrs on connecting rod checking guides and fixture. If still not in specification, ensure
reference connecting rod is not damaged.
13. After completing this step there is no need to adjust indicators or measurements will be
incorrect. When calibration of fixture is completed, remove reference connecting rod.
Testing
CAUTION: Calibrate connecting rod testing fixture before testing connecting

rod to prevent engine damage.
Install appropriate mandrel in piston pin end of connecting rod. Locating pin in mandrel for crank pin
end must contact connecting rod cap directly opposite beam of connecting rod.
Install mandrel in crank pin bore of master connecting rod.
Tighten mandrel so it is centered in bore correctly. Install master connecting rod in testing fixture.
Loosen knob and move indicator bracket until both indicators contact top of piston pin end mandrel.
Move bracket toward mandrel until indicator needles have moved about 0.010 in (0.25 mm). Turn
knob to tighten bracket.
Adjust indicator needles to 0. Move master connecting rod in and out to confirm 0 setting. Remove
master connecting rod from fixture.
Rotate connecting rod 180 degrees horizontally and install it in checking fixture.
Note indicator reading. Add or subtract difference calibrated "0" of indicator from known length of
master connecting rod to find length of connecting rod being measured.
CONNECTING ROD LENGTH

Minimum 10.293 (261.45)
Maximum 10.297 (261.55)
Replace connecting rod if connecting rod length is not within specifications.
CAUTION: DO NOT use heat or force to straighten a connecting rod. Rod can
eventually break and cause extensive engine damage.
Note indicator readings and remove connecting rod from fixture. Rotate connecting rod 180 degrees
horizontally and install it into checking fixture.
Compare indicator readings with previous step readings. Difference between indicator readings is
amount of bend in connecting rod.
CONNECTING ROD BEND-BUSHING INSTALLED

Maximum 0.0008 (0.021)
Replace connecting rod if connecting rod bend is not within specifications.
CAUTION: DO NOT use heat or force to straighten a connecting rod. Rod can
eventually break and cause extensive engine damage.
Inspect fixture and mandrel in piston pin end for a gap between 2. Mandrel will only touch 1 side of
fixture if any twist exist in connecting rod. Hold end of mandrel that is touching fixture firmly
against fixture. Measure gap between mandrel and fixture using feeler gauge. Amount of gap
between mandrel and fixture is amount of connecting rod twist.
CONNECTING ROD TWIST-BUSHING INSTALLED

Maximum 0.002 (0.05)
Replace connecting rod if connecting rod twist is not within specifications.
Magnetic Crack Inspection
Connecting Rod
1. Use a magnetic particle testing machine and assemble connecting rod and connecting rod cap
during this process.
2. Use residual method. Apply head shot amperage and adjust amperage to 1500 ampere direct
current or rectified alternating current.
3. Inspect for cracks, replace connecting rod if any cracks are visible.
4. Use residual method and apply coil shot amperage.
AMPERAGE
Minimum Maximum
2600 amps direct current 2800 amps direct current
5. Ampere turn is an electrical current of 1 ampere flowing through coil, multiplied by number of
turns in coil.
6. Inspect for cracks.
7. Replace connecting rod if any indications are apparent in critical (shaded) areas.
8. Demagnetize connecting rod and clean it with solvent or steam.
WARNING: Hot steam can cause personal injury when using steam
cleaner. Wear proper clothing and eye protection.
WARNING: Use manufacturer recommendation while using solvents,

acids, or alkaline materials for cleaning. Wear protective
clothing and glasses to avoid personal injury.
CAUTION: Clean and demagnetized connecting rod completely as even

a small metal particles can cause engine damage.
Connecting Rod Bolt
1. Use a Magnaflux or similar magnetic particle testing machine.

2. Use continuous method and apply a head shot of 300-400 amperes direct current or rectified
alternating current.
3. Use an ultraviolet light and inspect for crack signs. DO NOT confuse sharp corner and edges
formed by magnetic particles as cracks.
4. Any indications of cracks are not acceptable.
5. Prepare machine for a coil shot.

6. Ensure bolt is near one side of coil and not in center.
7. Apply 1000-1350 ampere-turns.
8. Use an ultraviolet light and inspect for crack signs. Any indications of cracks are not
acceptable.
9. Demagnetize bolt thoroughly and clean it with solvent. Blow compressed air to dry.

CAUTION: Clean and demagnetized connecting rod completely as even

small metal particles will cause engine damage.
CRANKSHAFT
Rotation Check
Rotate crankshaft clockwise through 2 complete revolution with compressor drive or barring device
only.
If engine rotation is blocked, equipment may have a failure or was assembled incorrectly.
Bend & Twist Inspection
WARNING: Have assistance or lift this component with proper equipment as

it weighs more than 50 lb (23 kg). This will prevent serious
personal injury.
1. Runout is measured when crankshaft is turned 1 revolution with recording of total movement
of dial indicator. Crankshaft alignment limits are based on total indicator runout
2. Measure following when measuring crankshaft alignment:
A. Full length alignment
B. Bearing to bearing runout
C. Rear oil seal flange diameter runout
D. Front oil seal crankshaft adapter diameter runout.
CAUTION: Measuring from top of main bearing journal causes

wrong alignment measurements due to crankshaft sag.
3. To inspect crankshaft full length alignment, support crankshaft on No. 1 and No. 7 main
bearing journals.
4. Set up dial indicator so indicator is located on side of No. 4 main bearing journal. Set up dial
indicator.
5. Turn crankshaft 1 complete revolution and record total indicator runout.
CRANKSHAFT RUNOUT
Maximum 0.008 (0.200)
6. Replace crankshaft if crankshaft total indicator runout is not within specifications.

7. Bearing to Bearing Runout: It is also referred as step runout, adjacent runout or journal to
journal runout. This is relationship of total indicator runout of a main bearing journal as it is
rotated on a common axis to total indicator runout of an adjacent journal.
8. Clock Position: Location of journal at highest total indicator runout point. Compare its angular
relationship with No. 1 crankshaft pin as viewed from front of crankshaft.
9. Secure crankshaft on number No. 1 and No. 7 main bearing journals to inspect crankshaft full
length alignment.
WARNING: Have assistance or lift this component with proper

equipment as it weighs more than 50 lb (23 kg). This will
prevent serious personal injury.
CAUTION: Measuring from top of main bearing journal causes incorrect

alignment measurements due to crankshaft sag.
10. Set dial indicator up on side of main bearing journal.

11. Turn crankshaft and measure total indicator runout at each bearing journal. Note value and
clock position for each location.
12. For each journal, plot total indicator runout value at its clock position on a polar chart. Plot end
journals, supported by V-blocks, at center of chart.
13. Following table indicates plot points.
JOURNAL INDICATOR RUNOUT SPECIFICATION

Journal Total Indicator Runout Clock Position
1 0 0
2 0.002 12
3 0.003 12
4 0.004 1
14. Draw a straight line between plotted points. From journal No. 1, to journal No. 2, to journal
No. 3, until all journals are plotted on chart.
15. To determine adjacent journal runout, measure length of line from each journal to its
corresponding journal point.
16. In above table journal No. 3 and No. 4 are 2 in (51 mm). This represents a runout of 0.002 in
(0.051 mm).
17. Record adjacent runout for each main bearing journal.
ADJACENT JOURNAL RUNOUT

Maximum 0.003 (0.075)
18. If alignment between adjacent journals is not in specifications, it can not be repaired by
grinding. Replace crankshaft. ISX crankshafts can not be straightened as it fully fillet
hardened.
19. To achieve rear oil seal flange diameter runout measurement:
A. With crankshaft supported on No. 1 and No. 7 main bearing journals, position a dial
indicator 1.0 in (25.4 mm) from flywheel mounting face of crankshaft.
20. Turn crankshaft 1 complete revolution and record total indicator runout.
21. Replace crankshaft if crankshaft rear oil seal flange total indicator runout is not within
specifications.
REAR OIL SEAL FLANGE RUNOUT

Maximum 0.0012 (0.03)
22. To achieve front oil seal crankshaft adapter diameter runout measurement:
A. With crankshaft supported on No. 1 and No. 7 main bearing journals, position a dial
indicator 1.0 in (25.4 mm) from balancer mounting face of crankshaft.
23. Rotate crankshaft 1 complete revolution and note total indicator runout.
24. Replace crankshaft if front oil seal crankshaft adapter diameter runout is not within
specifications.
FRONT OIL SEAL CRANKSHAFT ADAPTER DIAMETER RUNOUT

Maximum 0.002 (0.05)
Head Shot Method
For head shot (longitudinal magnetization) process: Apply magnetic bath solution and magnetize
crankshaft by applying 3800 amperes with Vdc or rectified Vac.
1. Test crankshaft using "continuous method": Apply magnetic bath solution to wet entire surface
before and during flow of magnetic current through crankshaft.
2. Each section of crankshaft requires minimum 3 successive head shots.
3. Flow magnetic solution over first 1/3-length of crankshaft.
A. Apply 2 head shots of magnetizing current.
B. Turn magnetic solution flow off to prevent washing metal particles off crankshaft.
C. Apply a 3rd head shot of magnetizing current and inspect crankshaft for open signs.
4. Flow magnetic solution over second 1/3-length of crankshaft.
5. Flow magnetic solution over last 1/3-length of crankshaft.
Coil Shot Method
For coil shot (circumferential magnetization) method: Use magnetic solution and magnetize
crankshaft in a 20.249 in (51.35 mm) inside coil or equivalent, by applying 3,600-4,000 ampere-turns
with Vdc or rectified Vac.
NOTE: Ampere-turn is amperage flowing through coil multiplied by number of

turns in coil.
1. To magnetize crankshaft correctly, minimum 3 coil shots are required for each 18 in (457 mm)
length.
2. Flow magnetic solution over crankshaft in 1/3 sections.
3. Apply 2 coil shots, when wetted with magnetic solution, with coil placed at 1/4-length points
along crankshaft.
4. Turn magnetic solution flow off to prevent washing metal particles off crankshaft.
5. Apply 3rd coil shot with coil positioned at 1/4-length points along crankshaft.
6. Inspect each 18 in (457 mm) section after completing 3rd coil shot.
A. An open indication is a crack open to surface that can be observed without using optical
enhancement.
B. DO NOT mistake forging trim lines for crack indications as sometimes open indication
may be felt with a fingernail.
C. Replace crankshaft if open indications are observed in hardened fillet area or critical
areas.
7. Open indications longer than 1/4 in (6 mm) are not acceptable, also open indications in any
filter or critical areas are not acceptable.
8. Open indications on crankpin or main bearing journal surfaces extending closer than 1/8 in (3
mm) to fillet but never enter fillet are acceptable.
9. Open indications in longitudinal direction up to 2 in (12.5 mm) in length, but not closer than
1/8 in (3 mm) to oil hole chamfer are okay.
10. Open indications entering oil hole chamfer or intersecting oil hole at 45 degrees ±10 degrees
are not acceptable.
11. Any open indication in crankpin bearing hole entrance chamfer is not acceptable.
12. Open indications in counterweights inside critical area are not acceptable.
13. Open indications extending over face of crankshaft or extend into damper mounting bolt holes
are not acceptable.
14. Inspect for subsurface indications.
15. After removal of magnetic particles, you can not see subsurface with naked eye. These are
indications of open areas or foreign objects below surface.
CAUTION: Thoroughly clean crankshaft and remove all magnetism

from it, even small metal particles may cause engine
damage.
16. Demagnetize crankshaft.

A. Use reverse D.C. -30 point step down equipment, or equivalent, to remove magnetism.
B. Maximum residual magnetic field on any pin or main bearing journal is 8 gauss.
17. Steam clean crankshaft and dry with compressed air.
WARNING: To avoid personal injury from flying debris and dirt, use
proper eye and face protection when using compressed air.
18. Lubricate crankshaft with preservative oil to prevent rust.

19. Use plastic cover to protect crankshaft when not in use. This will prevent dirt sticking to oil.
CYLINDER BLOCK & LINER SEATS
Leak Test
WARNING: Avoid direct contact of hot oil with skin to prevent personal
injury.
WARNING: Ensure that fluids are contained while inspecting, maintaining,
testing, adjusting and repairing. When opening or disassembling

any component containing fluids, collect it in appropriate
containers. Properly dispose of all fluids.
1. Drain engine oil. See ENGINE OIL SYSTEM .

2. Remove engine oil pan. See ENGINE OIL PAN .
3. Remove engine oil suction tube. See ENGINE OIL SUCTION TUBE-(BLOCK
MOUNTED) .
4. Remove block stiffener plate. See BLOCK STIFFENER PLATE.
5. Pressurize engine cooling system.
A. System Pressure: 20 psi (138 kPa)
6. Inspect outside circumference of cylinder liners and area below cylinder liner seats in cylinder
block for coolant leaks.
NOTE: Before inspecting cylinder liner seats, pressurize for 15 minutes.

Ensure system is holding air pressure before beginning
inspection.
7. If a leak is found:
A. Remove and inspect cylinder liners. See CYLINDER LINER.
B. If fretting or wear is found in cylinder block liner area, replace cylinder block.
8. Install block stiffener plate. See BLOCK STIFFENER PLATE.
9. Install engine oil suction tube. See ENGINE OIL SUCTION TUBE-(BLOCK
MOUNTED) .
10. Install engine oil pan. See ENGINE OIL PAN .
11. Add oil to engine.
12. Prime engine oil system. See ENGINE OIL SYSTEM .
13. Operate engine to normal operating temperature and inspect for leaks.
14. If failure resulted in coolant, oil, excessive fuel or excessive BLACK smoke entering exhaust
system, inspect aftertreatment system. See AFTERTREATMENT SYSTEM .
CYLINDER HEAD
Leak Test
Fuel Passage
Fuel system is divided into front bank which is for cylinder 1 through 3 and another is rear bank
which is for cylinder 4 through 6. Banks are tested independently of each other, left 3 male
connectors on plate are for front bank and right 3 male connectors are for rear bank. Metering,
Timing and Return are male connectors on plate.
1. Lubricate male connectors with thread sealant and install them into plate, if not installed.
2. Install gasket, plate, 2 short bolts, and 2 long bolts. Tighten bolts to 20 Ft Lbs (27 N.m)
3. Install injector cavity plugs into proper injector borer and center injector cavity plugs in
injector bores.
4. Install injector hold down clamps and bolts. Tighten bolts to 30 Ft Lbs (41 N.m)
5. Connect Leak Test Kit (3164231), or equivalent to 1 of male connectors on plate and
pressurize with 30 psi (207 kPa).
6. Ensure test hardware is not leaking.
7. Shut off air pressure supply, it should not be below 28 psi (193 kPa) in 30 seconds.
8. Replace cylinder head if fuel passages are leaking.
9. Remove test kit.
Coolant Passage

personal injury.
1. Position cylinder head on a work bench with intake side down.

2. Install gasket onto combustion face of cylinder head.
3. Install plate, with marking "exhaust" toward exhaust side of cylinder head.
NOTE: See Fig. 27
4. Install cylinder head bolts and nuts.

5. Tighten bolts to 50 Ft Lbs (68 N.m)
6. Apply thread sealant and install male connector into plate if it is not installed.
7. Install gasket and plate onto cylinder head at thermostat location.
8. Install bolts and washers.
10. Connect Leak Test Kit (3164231), or equivalent to male connector.
11. Install injector cavity plugs into injector bores and center injector cavity plugs in injector bores.
12. Install injector hold down clamps and bolts.
14. Position cylinder head into a tank of water and pressurize with 30 psi (207 kPa)

A. Inspect for bubbles to confirm leakage of test assembly.

B. Replace cylinder head if bubbles are present.
15. Use of a water and soap solution is an alternate method to position cylinder head into a tank of
water.
A. Pressurize cylinder head with 30 psi (207 kPa) and spray a mild water and soap solution
on it
B. Inspect for bubbles to confirm leakage in test assembly.
C. Ensure test assembly is not leaking.
D. Replace cylinder head if bubbles are present.
16. Remove test kit.
Valve Seat
1. Set head down with intake ports on bottom. Add fuel into exhaust port until it is full. Set
container of fuel down and start timer.
l If a drop of fuel drips or runs down face of head within 30 seconds, inspect valves and
seats to determine if parts required replacement. Inspect valve and valve seat using
vacuum test procedure.
l If a drop of fuel has not run down face of head in 30 seconds, it indicates proper sealing
of valves and seats.
2. Drain fuel from exhaust side of head and turn head over so exhaust port is on bottom. Add fuel
into intake ports until full. Set container of fuel down and start timer.
l If a drop of fuel drips or runs down face of head within 30 seconds, inspect valve and
valve seat interface using vacuum test procedure.
l If a drop of fuel has not run down face of head in 30 seconds, indicates proper sealing of
valves and seats.
Vacuum Test
Inspect seal between valve and valve seat using Valve Vacuum Tester (ST-1257). To perform this
test, sit cylinder head either on its side or turned upside down so combustion face can be accessed.
Test engine using valve vacuum tester. Seal cylinder head inserts using Seal Ring (ST-1257-35), and
Vacuum Cup (ST-1251-6).
Install seal ring and vacuum cup to vacuum line (hose).
Clean and dry valves and valve seats if vacuum testing.
Clean and dry combustion face of cylinder head and ensure there is no loose debris in valve recess.
This will provide good vacuum cup to cylinder head sealing surface.
Turn ON toggle switch.
Turn vacuum control valve to OPEN position, valve is in OPEN position if vacuum gauge needle
moves clockwise.
Operate vacuum pump until specified vacuum is indicated by gauge.
VALVE-TO-VALVE SEAT VACUUM

Specification In Hg (mm Hg)
Minimum 20 (508)
Maximum 25 (685)
Turn vacuum control valve to close position.
Turn OFF toggle switch.
Use a stopwatch and start timing when needle on gauge indicates 18 in Hg (457 mm Hg) and stop
timing if gauge indicates 8 in Hg (203 mm Hg).
Elapsed time for needle to move between specified gauge readings should be 10 seconds or more.
If elapsed time is less than 10 seconds, perform following inspections:
l Repeat test to ensure proper operation of equipment.

l Use mallet, hit valve stem lightly to ensure valve is seated. Repeat test.
l Coat outside diameters of insert and valve head with thin film of grease. Repeat test. Grease
pattern will indicate point of leakage.
Break in grease seal pattern indicates leakage between valves and valve seat or valve seat insert and
cylinder head.
CAUTION: Use Small Plugs (4089255), to prevent debris and magnetic

powder from entering lubrication system during magnetic crack
inspection. This will cover oil supply holes at cylinder head ends.
Follow this without failure before magnetic crack inspection of

combustion face of cylinder head. This way you can avoid
connecting rod bearing failure, crankshaft failure, or both.
1. You can find cracks in combustion face, in areas around valve ports and injector bores with
magnetic Crack Detector (ST-1166).
2. To inspect for cracks running across cylinder head, place magnetizing head on combustion face
as shown.
3. Fill powder spray bulb one-third (1/3) full with metal powder.
4. Spray powder lightly on combustion face.
5. Remove excess metal powder with compressed air 40 psi (276 kPa).
6. Powder will remain in cracks, if present, and show as a white line.
7. Cylinder heads with cracks on combustion face should NOT be used.
8. Inspect for cracks running lengthwise of cylinder head by placing magnetizing head on
combustion face as shown. Repeat for each cylinder.

CAUTION: Insert oil passage plugs to avoid connecting rod bearing

failure, crankshaft failure, or both.
9. Remove all magnetism and clean cylinder head with solvent and dry with compressed air.
10. Thoroughly clean cylinder head after using magnetic crack detector to remove all of iron
fragments.
11. Inspect valve for cracks by using magnetic particle residual method.
12. Exhaust valves contain 2 types of metal. To inspect use coil shot method.
13. There will be a magnetic leakage apparent at point where two metals are welded together.
Leakage will appear as a wide pattern of magnetic particles.
14. Magnetize valves in a coil of 100 - 200 amperes.
15. Inspect valves with residual magnaglo.
16. A broad fuzzy pattern will appear at welded joint on exhaust valves. Replace valve if there is a
distinct line in pattern.
17. Intake valves are made of one type of metal, so magnetize and inspect them in 2 directions.
18. Same as exhaust valves use magnetic coil method and inspect with residual magnaglow.
19. Magnetize intake valves again with a headshot at 500 - 700 amperes.
20. Inspect valves with residual magnaglow.
21. A broad fuzzy pattern will appear at welded joint on exhaust valves. Replace valve if there is a
distinct line in pattern.
FLYWHEEL
Bore Runout
1. Inspect flywheel bore and face runout using Dial Indicator Gauge (3376050), or equivalent,
and Dial Gauge Attachment (ST-1325).
2. Install attachment to flywheel housing and install gauge on attachment.
3. Install contact tip of indicator against inside of flywheel bore.

4. Use compressor drive or barring device to rotate crankshaft one complete revolution (360°).
5. Measure bore runout. Maximum Flywheel Bore Runout should be 0.005 in. (0.127 mm).
6. Remove flywheel if total indicator reading is more than specification.
7. Inspect flywheel mounting surface and crankshaft for dirt or damage.
8. Install flywheel and inspect bore runout again.
9. Replace flywheel if runout does not meet specifications.
Face Runout
1. Install contact tip of indicator against flywheel face close to outside to inspect face runout.
2. Remove crankshaft end thrust by pushing flywheel forward.
3. Use compressor drive or barring device to rotate crankshaft one complete revolution (360°)
while keeping crankshaft end thrust pushed forward.
4. Total indicator reading must not be more than specification listed in Flywheel Face Runout
Total Indicator Reading table.
FLYWHEEL FACE RUNOUT TOTAL INDICATOR READING

Maximum (Total Indicator Reading) of
Flywheel Radius (A)
Flywheel Face
8 in. (203 mm) 0.008 in. (0.203 mm)
10 in. (254 mm) 0.010 in. (0.254 mm)
12 in. (305 mm) 0.012 in. (0.305 mm)
14 in. (356 mm) 0.014 in. (0.356 mm)
16 in. (406 mm) 0.016 in. (0.406 mm)
VISCOUS VIBRATION DAMPER
Eccentricity Check
1. Clean outside surface of vibration damper. Install a dial indicator onto gear cover to measure
vibration damper eccentricity (out of round).
2. Rotate crankshaft with accessory driveshaft 1 complete revolution (360 degrees), and note total
indicator movement.
3. Replace vibration damper if not within specifications.
VIBRATION DAMPER ECCENTRICITY

Maximum 0.011 (0.28)
Wobble Check
1. To measure wobble (face alignment), install a dial indicator as shown.

2. Push crankshaft to front or rear of engine. Set indicator to "0".
3. Rotate crankshaft 1 complete revolution (360 degrees) while maintaining position of
crankshaft, either toward front or rear of engine.
4. Record total indicator movement.
5. Replace vibration damper if not within specifications.
VIBRATION DAMPER WOBBLE MEASUREMENT

Maximum 0.011 (0.28)
REMOVAL & INSTALLATION

ACCESSORY BRACKET
Removal
NOTE: A combination of push on and slide in tabs connects each nylon cover
to engine. To remove top 2 covers, first pull (at location marked "Pull
Here") bottom of covers away from engine until tabs are released then
sliding upward to remove them from accessory bracket. To remove
lower cover, pull (at location marked "Pull Here") top of cover away
from engine until tabs are released then sliding downward.
1. Remove 3 composite nylon covers.

2. Remove OEM wiring harness and accessories connected to accessory bracket. See Fig. 17.
Fig. 17: Identifying OEM Wiring Harness & Accessories
3. Disconnect and remove camshaft position sensor with retaining bolt. See Fig. 17.
4. Remove 4 bolts, studded bolt, and accessory bracket.
Inspect Condition
Inspect bracket for cracks in bend radius.
Installation
NOTE: Tighten bolts and studded bolt hand-tight initially.
1. Install accessory bracket, 4 bolts and studded bolt to cylinder head hand-tight.
2. Tighten 2 bolts to gear housing. See TORQUE SPECIFICATIONS.
3. Tighten 2 bolts and studded bolt to cylinder head. See TORQUE SPECIFICATIONS.
4. Install camshaft position sensor and bolt. See TORQUE SPECIFICATIONS.
5. Connect camshaft position sensor.
6. Install OEM wiring harness and accessories to accessory bracket. See Fig. 17
7. Install 3 composite nylon covers.
NOTE: To install top 2 covers, slide cover down into slots on accessory
bracket then push bottom of cover toward engine onto cover
mounting tabs. To install bottom cover, slide cover upward into
slots on accessory bracket, mounted on IFSM, then push top of
cover toward engine onto cover mounting tabs.
AIR COMPRESSOR CYLINDER HEAD-SINGLE CYLINDER
Removal
1. Drain cooling system.

2. Remove coolant lines, air governor or air governor signal line (if equipped).
3. Remove air inlet and outlet connections from air compressor.
4. Remove four 8 mm bolts and remove air compressor head and gasket.
Installation
1. Use a NEW gasket to assemble air compressor.

2. Install head and gasket and install 4 8-mm bolts.
3. Tighten bolts as follows using torque plus angle method.
NOTE: See Fig. 18.
A. Step 1: 18 Ft. Lbs (25 N.m)

B. Step 2: 90°
4. If installing a NEW head assembly, tighten 5 small head cover bolts in sequence shown in Fig.
18.
A. Step 1: 53 INCH Lbs. (6 N.m)
B. 90°
Fig. 18: Air Compressor Cylinder Head Cover Bolt Torque Sequence - (Single Cylinder)
5. Fill cooling system.

6. Operate engine and inspect for leaks and proper operation.
AIR COMPRESSOR
Removal
CAUTION: Ensure that fluids are contained while inspecting, maintaining,

WARNING: Wear safety glasses or a face shield and protective clothing to

avoid injury from a steam cleaner or high-pressure water.
1. Drain engine coolant.

2. Use steam to clean air compressor. Dry with compressed air.
3. Remove coolant lines and air connections from air compressor.
4. Remove or disconnect air governor.
5. Remove air compressor support bracket and bolts.
6. Remove 4 mounting bolts and air compressor.
7. Dispose of gasket.
Cleaning & Inspect Condition
Inspect compressor housing and compressor drive gear for cracks or damage.
Ensure gasket surfaces of front gear housing and air compressor are clean and not damaged.
Installation
1. Pin engine crankshaft. See ENGINE BASE TIMING.

2. Rotate gear on air compressor until mark on gear aligns with V-notch on air compressor
housing, located at 3 o'clock position as viewed from front.
3. Use Loctite, (3824040) or equivalent on bolts mounting air compressor to gear housing. This
seals threads in housing.
4. Place a line of sealant along length of bolt to evenly distribute sealant as bolt is tightened.
5. Install air compressor and 4 bolts on front gear housing, see TORQUE SPECIFICATIONS.
6. Install air compressor mounting brace and 4 bolts on block under air compressor. Tighten all 4
bolts, see TORQUE SPECIFICATIONS.
7. Use 2 elbows and run locking nuts up before installation
8. Thread elbows in cylinder head.
9. Use a 24 mm open-ended wrench to position elbows.
10. Install U-shaped water inlet tube in left elbow, start threading compression nut.
11. Install other end of water inlet tube in grommet in cylinder block.
12. Insert water outlet tube in other elbow and thread compression nut.
13. Install other end of water inlet tube into grommet in cylinder block.
14. Begin threading bolts into engine block, see TORQUE SPECIFICATIONS.
15. Tighten compression nuts and elbow locking nuts.
16. Install air discharge line and tighten, see TORQUE SPECIFICATIONS.
17. Install air inlet line and tighten hose clamp, see TORQUE SPECIFICATIONS.
18. Install air governor (if removed). Connect air governor pressure signal line.
19. Fill engine cooling system.
20. Operate engine and inspect for leaks.
ALTERNATOR/REFRIGERANT COMPRESSOR MOUNTING BRACKET
Removal
CM 870
1. Remove turbocharger control valve. See TURBOCHARGER CONTROL VALVE .

2. Remove alternator drive belt.
3. Remove alternator.
4. Remove alternator spacers.
5. Remove refrigerant compressor drive belt. See REFRIGERANT COMPRESSOR DRIVE
BELT.
6. Remove refrigerant compressor. See REFRIGERANT COMPRESSOR.
7. Remove refrigerant compressor mounting bracket.
8. Remove refrigerant compressor belt tensioner. See REFRIGERANT COMPRESSOR
AUTOMATIC BELT TENSIONER.
9. Remove refrigerant idler pulley. See REFRIGERANT COMPRESSOR IDLER PULLEY.
10. Remove water pump belt tensioner.
11. Disconnect wire harness jumper from EGR valve motor, EGR valve position sensor and main
engine wire harness.
12. Remove 5 mounting bolts from alternator/refrigerant compressor mounting bracket and pry out
bracket from gear housing.
NOTE: Split washers generate slight friction fit between bracket and gear
housing.
13. Remove wire harness jumper from alternator/refrigerant compressor mounting bracket.
CM 570
1. Remove refrigerant compressor and alternator belt.

2. Remove refrigerant compressor. See REFRIGERANT COMPRESSOR.
3. Remove upper belt tensioner.
4. Remove lower belt tensioner.
5. Remove 6 mounting bolts from alternator/refrigerant compressor mounting bracket and gently
pry out bracket from gear housing.
NOTE: Split washers generate slight friction between bracket and gear
housing.
Inspect Condition
CM 870
Replace bracket if alternator/refrigerant compressor mounting bracket has cracks.
Replace alternator bracket if wear is found underneath refrigerant compressor, alternator spacer,
water pump belt tensioner, and refrigerant compressor belt tensioner.
CM 570
Replace bracket if alternator/refrigerant compressor mounting bracket has cracks.
Replace belt tensioners if they are excessively worn.
Installation
CM 870
1. Install wire harness jumper to alternator/refrigerant compressor mounting bracket and tighten.
See TORQUE SPECIFICATIONS.
2. Tap split washers out slightly to facilitate installation.
3. Install alternator/refrigerant compressor mounting bracket to gear housing.
4. Install 5 mounting bolts and tighten them to following sequence:
A. Bolts No. 1, 2, 3, and 4: 27 Ft Lbs. (36 N.m)
B. Bolt No. 5: 41 Ft Lbs. (56 N.m)
Fig. 19: Mounting Bolt Torque Sequence
5. Install water pump belt tensioner.

6. Install refrigerant compressor idler pulley. See REFRIGERANT COMPRESSOR IDLER
PULLEY.
7. Install refrigerant compressor belt tensioner See REFRIGERANT COMPRESSOR
AUTOMATIC BELT TENSIONER.
8. Install refrigerant compressor mounting bracket. See REFRIGERANT COMPRESSOR
MOUNTING BRACKET.
9. Install refrigerant compressor. See REFRIGERANT COMPRESSOR.
10. Install refrigerant compressor drive belt.
11. Install alternator spacers.
12. Install alternator.
13. Install alternator drive belt.
14. Install turbocharger control valve. See TURBOCHARGER CONTROL VALVE .
CM 570
1. Alternator/refrigerant compressor mounting bracket is installed on gear housing at top and

water pump at bottom.
2. Install bracket and 6 mounting bolts.
3. Tighten bolt that threads into gear housing first to 41 Ft. Lbs (56 N.m)
4. Tighten short bolt to 25 Ft. Lbs. (34 N.m).
5. Then tighten remaining bolts to 25 Ft. Lbs. (34 N.m).
6. Install upper belt tensioner.
7. Install lower belt tensioner.
8. Install refrigerant compressor. See REFRIGERANT COMPRESSOR.
9. Install refrigerant compressor and alternator drive belt.
BLOCK STIFFENER PLATE
Removal
injury.


2. Remove oil pan. See ENGINE OIL PAN .
MOUNTED) .
4. Remove 10 bolts and block stiffener plate.
Fig. 20: Removing/Installing Bolts & Block Stiffener Plate
Installation
1. Install block stiffener plate and 10 bolts.

2. Tighten bolts, see TORQUE SPECIFICATIONS.
MOUNTED) .
4. Install oil pan. See ENGINE OIL PAN .
6. Add oil to fill engine. See ENGINE OIL SYSTEM .
7. Operate engine until 180° F (82° C) is achieved, and inspect for engine oil leaks.
CONNECTING ROD
Disassembly
NOTE: Remove piston and connecting rod as an assembly on Signature and

ISX engines.
1. Remove piston and connecting rod assembly. See PISTON & CONNECTING ROD
ASSEMBLY.
2. Disassemble piston and connecting rod.
Clean & Inspect Condition
CAUTION: Avoid nicks in body of bolt, it can cause an area of stress that
may fail during engine operation. Damaged threads will cause
incorrect torque values and will damage mating parts.
WARNING: Hot steam can cause personal injury when using steam cleaner.
Wear proper clothing and eye protection.
WARNING: Use manufacturer recommendation while using solvents, acids,

or alkaline materials for cleaning. Wear protective clothing and
glasses to avoid personal injury.
CAUTION: DO NOT use thread die to repair rolled threads. Die may form a
sharp corner on minor diameter (root) of threads causing an area
of increased stress.
1. Clean bolts, connecting rod, and connecting rod cap with solvent or steam. Blow dry with
compressed air and clean oil drilling using a soft bristle brush.
2. Inspect bolts for damaged threads, rust or corrosion-caused pitting and nicks, bent, stretched, or
galled. Replace if any of damaged found.
3. Inspect connecting rod and connecting rod cap for damage, replace if I-beam or connecting rod
cap is damaged.
CAUTION: Hold connecting rod using vise with brass jaws. Notches,
scratches, or dents in I-beam area can cause engine failure.
Fig. 21: Inspecting Connecting Rod For Damage-Typical Example
4. Inspect connecting rod and connecting rod cap for fretting damage on mating surfaces. If
damage is apparent on either piece replace both rod and rod cap as an assembly.
CAUTION: To prevent damage to connecting rods and crankshaft,

ensure connecting rod cap alpha characters matches alpha
characters on connecting rod and installed with characters
aligned.
5. Inspect bearing surface for nicks or burrs. Fine emery cloth can not remove nicks or burrs, so
replace connecting rod.
6. Inspect rod pin bushing for damage. Replace piston pin bushing with any signs of scoring,
galling, or scuffing. Replace any bushing that has turned in bore using special tools and
precision machining. Replace connecting rod if special tools and procedures are not available.
7. Position connecting rod into a vise with brass jaws. Install connecting rod cap onto connecting
rod.
8. Apply clean engine oil to lubricate threads of bolts. Thread bolts into connecting rod and hand
tighten.
CAUTION: Tightening procedure for used bolts is different than

tightening NEW bolts.
Fig. 22: Connecting Rod Bolts Torque Sequence
9. For used connecting rod bolts, tighten bolts in numerical order and see TORQUE
SPECIFICATIONS.
NOTE: See Fig. 22.
A. Step 1: Torque rod bolts to 52 Ft Lbs. (70 N.m)

B. Step 2: Turn bolts 60°
10. For NEW connecting rod bolts, tighten bolts in numerical order and see TORQUE
SPECIFICATIONS.
NOTE: See Fig. 22.

B. Step 2: Loosen rod bolts
C. Step 3: Retorque rod bolts to 52 Ft Lbs. (70 N.m)
D. Step 4: Turn bolts 60°
11. Measure connecting rod crankshaft bore inside diameter using bore dial indicator.
CONNECTING ROD CRANKSHAFT BORE DIAMETER

Minimum 3.890 (98.801)
Maximum 3.891 (98.839)
12. Replace connecting rod if connecting rod crankshaft bore inside diameter is not within
specifications.
Fig. 23: Measuring Piston Pin & Crankshaft Journal Inside Diameter-Typical Example
13. Measure connecting rod piston pin bushing inside diameter.
CONNECTING ROD PISTON PIN BUSHING INSIDE DIAMETER

Minimum 2.502 (63.55)
Maximum 2.503 (63.57)
14. Replace connecting rod if connecting rod piston pin bushing inside diameter is not within
specifications.
Assembly
NOTE: Install piston and connecting rod as an assembly on Signature and ISX
engines.
1. Assemble piston and connecting rod.

2. Install piston and connecting rod assembly. See PISTON & CONNECTING ROD
ASSEMBLY.
CONNECTING ROD BEARINGS
Removal
WARNING: Avoid direct contact of heat with skin to prevent personal injury.
WARNING: Avoid prolonged contact, vapor inhalation of used engine oil,

used oil could be carcinogenic and causes reproductive toxicity
as per research of some state and federal agencies. Follow local
environmental regulations to dispose of if not reused.

MOUNTED) .
4. Remove engine oil pump. See ENGINE OIL PUMP .
6. Remove piston cooling nozzles. See PISTON COOLING NOZZLE .
7. Rotate crankshaft so that 2 of connecting rods are at bottom dead center. But DO NOT remove
bolts.
8. Loosen connecting rod bolts and hit them with a rubber hammer, this will loosen rod caps from
dowels.
9. Remove bolts and rod cap. Remove bearing shell from rod cap and mark cylinder number and
letter "L" on flat surface of bearing tangs.
10. Install 2 Guide Pins (3163097), in connecting rod.
11. Using T-handle pusher, push rod up far enough to remove upper bearing shell. After removal
mark cylinder number and letter "U" on flat surface of bearing tangs.
Steam-clean parts and dry with compressed air.
Inspect rod caps, connecting rod bearing saddles, and bolts for nicks, cracks, burrs, scratches, or
fretting.
Inspect connecting rod journal of crankshaft for scratches or nicks, remove with crocus cloth.
Inspect bearings for following damage:
l Pitting
l Flaking
l Corrosion
l Lock tang damage
l Scratches (deep enough to be felt with a fingernail).
Replace bearings if any of these are found.
Normal bearing wear generates smooth finish that will wear into lining.
Inspect bearing seating surface for nicks or burrs, replace bearings if nicks/burrs can not be removed
with crocus cloth.
Using outside micrometer that has a ball tip, measure rod bearing shell thickness. Dispose of bearing
shell if thickness is below minimum specification.
CONNECTING ROD BEARING THICKNESS

Minimum 0.093 (2.366)
Maximum 0.094 (2.378)
Crankshafts that are ground undersize in connecting rod or main bearing journals are marked on front
counterweight. If crankshaft is marked, inspect bearing shell part number to ensure correct bearing
size is used.
Installation
CAUTION: Ensure connecting rod bearings matches connecting rod design,

drilled rods use drilled rod bearings and non-drilled rods use
non-drilled bearings. Mismatches will cause engine damage.
CAUTION: When bearing shells are installed ensure connecting rod and
bearing shell mating surfaces are clean and dry. Install used
bearings in their original location to avoid engine damage.
1. Ensure connecting rod design is matched with proper connecting rod bearing, drilled
connecting rods are fitted with drilled connecting rod bearings and non-drilled connecting rods
are fitted with non-drilled connecting rod bearings.
2. Drilled and non-drilled connecting rods can be mixed in same engine if 2 piece piston is used.
Whereas engines using 1-piece piston can not use non-drilled connecting rods.
3. Lubricate crankshaft journal mating surface of upper bearing shell with clean Lubriplate 105
multipurpose lubricant, or its equivalent.
4. Install upper bearing shell into connecting rod with tang of bearing in slot of rod.
5. Install bearing shell into connecting rod cap with tang of bearing in slot of cap.
6. Lubricate bearing shell to crankshaft journal mating surface and connecting rod bolts with
clean Lubriplate 105 multipurpose lubricant, or its equivalent.
CAUTION: Rod cap alpha characters must match alpha characters on

connecting rod and it is important to install it with
characters aligned. This will prevent damage to connecting
rods and crankshaft. Ensure locking tang of connecting rod
cap face towards intake side of cylinder block. Clean rod
and cap mating surfaces to avoid engine damage.
7. Install cap onto connecting rod.

8. Apply clean engine oil to lubricate threads of bolts. Thread bolts into connecting rod and hand
tighten.
9. For used connecting rod bolts, tighten bolts in numerical order and see TORQUE
SPECIFICATIONS.
NOTE: See Fig. 22.

B. Step 2: Turn bolts 60°
10. For NEW connecting rod bolts, tighten bolts in numerical order and see TORQUE
SPECIFICATIONS.
NOTE: See Fig. 22.

B. Step 2: Loosen rod bolts
C. Step 3: Retorque rod bolts to 52 Ft Lbs. (70 N.m)
D. Step 4: Turn bolts 60°
11. Measure connecting rod side clearance. See PISTON & CONNECTING ROD ASSEMBLY.
12. Repeat these steps again to install remaining bearing shells and connecting rod caps.
CAUTION: To avoid internal component damage, prime engine oil

system before operating engine after any internal engine
repairs.
13. Install piston cooling nozzles. See PISTON COOLING NOZZLE .

14. Install oil pump. See ENGINE OIL PUMP .
MOUNTED) .
19. Operate engine until it reaches 180° F (82° C), and inspect for engine oil leaks.
CRANKCASE BREATHER ELEMENT
Removal
1. After loosening all cover mounting captive bolts, remove element cover.
2. Remove crankcase breather element and dispose of.
3. Clean excess dirt and oil from cover interior.
Installation
1. Install NEW crankcase breather element in breather housing.

2. Install cover.
3. Tighten all captive mounting bolts:
A. Breather Cover 46 in-lb (5.2 N.m)
B. Sensor Clamp 20 in-lb (2 N.m)
CRANKCASE BREATHER-EXTERNAL
Removal
CM870
1. Remove breather tube and rubber grommet from engine.
Fig. 24: Removing Breather Tube & Rubber Grommet From Engine
2. Remove 4 p-clips securing hose to front cover and block.

3. Disassemble breather tube.
CM871
1. Disconnect wiring connector from breather pressure sensor.

2. Loosen 2 hose clamps on inlet hose.
3. Disconnect hose from breather and loosen outlet hose clamp.
4. Disconnect outlet hose and breather oil drain line.
5. Remove drain line inline with connection nipple, DO NOT bend.
6. Remove 4 mounting bolts from crankcase breather element housing to breather housing
bracket. Remove housing assembly.
Disassembly
CM871
Disassemble crankcase breather assembly. See CRANKCASE BREATHER ELEMENT.
NOTE: All bolts are captive bolts.
CM870

1. Clean inside of crankcase breather tube with solvent. Dry with compressed air.
2. Blow through vent tube using air pressure.
3. Replace clogged vent tube.
WARNING: To avoid personal injury from flying debris and dirt, use
proper eye and face protection when using compressed air.
4. Use soap water to clean rubber grommet and dry with compressed air. Avoid using solvents for
cleaning.
5. Inspect breather tube, hose and rubber grommet for cracks/other damage. Replace if needed.
CM871
1. Use solvent to clean breather crankcase housing and breather crankcase cover.
2. Dry with compressed air.
3. Inspect for cracks in crankcase breather element housing and crankcase breather cover.
Replace if needed.
Assembly
CM871
Assemble crankcase breather assembly. See CRANKCASE BREATHER ELEMENT.
Installation
CM870
1. Assemble breather tube.

2. 2 p-clips attach vent hose to gear housing and 2 p-clips attach vent hose to side of block. Hose
should extend lower than flywheel housing with breather hose installed on NEW cover.
3. Install crankcase vent hose and secure crankcase vent hose to engine with 4 p-clips.
4. Tighten P-clips, see TORQUE SPECIFICATIONS.
CM871
1. Connect inlet and outlet rubber hoses, oil drain line, and install 3 hose clamps to housing. Push
hose on until it stops on housing connector. Ensure hose clears fan blade.
2. Connect breather sensor wiring connector to breather sensor. Install and tighten 4 mounting
bolts. See TORQUE SPECIFICATIONS.
3. Remove and install crankcase pressure sensor.
CRANKSHAFT
Removal
WARNING: To avoid personal injury from hot coolant, remove pressure cap
when coolant temperature is less than 120° F (50° C).
WARNING: Keep coolant away from children or pets as it is poisonous.

Follow local environmental regulations to dispose of if not
reused.
injury.

1.Drain cooling system.

2.Drain engine oil. See ENGINE OIL SYSTEM .
3.Remove engine. See ENGINE-REMOVAL.
4.Remove cylinder heads. See CYLINDER HEAD.
5.Remove flywheel. See FLYWHEEL.
6.Remove flywheel housing. See FLYWHEEL HOUSING.
7.Remove front gear housing. See FRONT GEAR HOUSING.
8.Remove engine oil pan. See ENGINE OIL PAN .
9.Remove engine oil suction tube. See ENGINE OIL SUCTION TUBE-(BLOCK
MOUNTED) .
11. Remove block stiffener plate.
12. Remove piston and connecting rod assemblies.
13. Remove main bearing caps.

14. Use a lifting strap that will not damage crankshaft and remove crankshaft with hoist and sling.


CAUTION: DO NOT clean bolt threads in crankshaft with thread chaser,

severe engine damage can cause.
1. Remove discoloration or light scratches from machined surfaces of crankshaft using crocus
cloth or a ScotchBrite pad.
2. Clean all of crankshaft oil passages with bristle brush and solvent.
3. Steam clean crankshaft and dry with compressed air.
4. ISX uses rolled bolt threads in bolt holes of crankshaft.
5. Flush rolled threads with solvent, and dry with compressed air. Brush with a nylon bristle
brush if more cleaning is required.
6. Position tape over threaded bolt holes.
7. Inspect machined surfaces for scratches or nicks and use crocus cloth to remove them. Replace
crankshaft if scratches or nicks still felt with a fingernail after polishing with crocus cloth.
8. Inspect threaded bolt holes for damage, replace crankshaft if holes are damaged.
9. Inspect crankshaft gear and tone wheel for excessive wear or damage.
10. Replace crankshaft if any teeth on crankshaft gear are missing, chipped, or pitted and if any
teeth on tone wheel are missing.
11. Measure crankshaft connecting rod journal outside diameter.
CONNECTING ROD JOURNAL OUTSIDE DIAMETER

Minimum 3.700 (93.98)
Maximum 3.702 (94.02)
12. Replace crankshaft if crankshaft connecting rod journal outside diameter is not within
specifications.
13. Measure crankshaft main bearing journal outside diameter.
CRANKSHAFT MAIN BEARING JOURNAL OUTSIDE DIAMETER

Minimum 4.999 (126.98)
Maximum 5.001 (127.02)
14. Replace crankshaft if crankshaft main bearing journal outside diameter is not within
specifications.
15. Measure crankshaft thrust face width.
CRANKSHAFT THRUST FACE WIDTH

Minimum 2.163 (54.95)
Maximum 2.167 (55.05)
16. Replace crankshaft if crankshaft thrust face width is not within specifications.
17. Measure crankshaft rear oil seal flange outside diameter.
CRANKSHAFT REAR OIL SEAL OUTSIDE DIAMETER

Outer Flange Diameter Minimum 6.495 (164.964)
Maximum 6.497 (165.035)
Inner Flange Diameter Minimum 6.515 (165.475)
Maximum 6.517 (165.525)
18. Replace crankshaft if crankshaft rear oil seal flange outside diameter is not within
specifications.
19. Inspect crankshaft rear oil seal flange for nicks, burrs, and grooves. Replace crankshaft if nick,
burrs, or groove felt with fingernail. Damage to sealing surface can cause a seal leakage.
20. Measure crankshaft front oil seal flange outside diameter.
CRANKSHAFT FRONT OIL SEAL FLANGE OUTSIDE DIAMETER

Specifcation In (mm)
Outer Flange Diameter (1) Minimum 5.482 (139.24)
Maximum 5.497 (139.63)
Inner Flange Diameter (1) Minimum 5.507 (139.89)
Maximum 5.513 (140.04)
(1) See Fig. 25
21. Replace crankshaft if crankshaft front oil seal flange outside diameter is not within
specifications.
22. Inspect crankshaft front oil seal flange for nicks, burrs, and grooves. Replace crankshaft if a
fingernail catches in a nick, burr, or groove. Damage to sealing surface can cause seal leakage.
Fig. 25: Identifying Crankshaft Front Oil Seal Flange
23. Measure crankshaft damper pilot outside diameter.
CRANKSHAFT DAMPER PILOT OUTSIDE DIAMETER

Minimum 1.968 (49.985)
Maximum 1.969 (50.015)
24. Replace crankshaft if crankshaft pilot outside diameter is not within specifications.
25. Apply 15W-40 oil to entire crankshaft to prevent rust.
Installation

personal injury.
CAUTION: Use a lifting strap that may not harm crankshaft. Avoid falling
crankshaft on bearings.
1. Install main bearings. See MAIN BEARINGS.

2. Position end of crankshaft with smallest diameter points toward front of cylinder block.
3. Install main bearing caps. See MAIN BEARINGS.
4. Install piston and connecting rod assemblies. See PISTON & CONNECTING ROD
ASSEMBLY.
6. Install engine oil pump. See ENGINE OIL PUMP .
MOUNTED) .
9. Install front gear housing. See FRONT GEAR HOUSING.
10. Install flywheel housing. See FLYWHEEL HOUSING.
11. Install flywheel. See FLYWHEEL.
12. Install cylinder heads. See CYLINDER HEAD.
13. Install engine. See ENGINE-INSTALLATION.
14. Add engine oil to fill engine.
CRANKSHAFT ADAPTER
Removal
CAUTION: Remove engine oil pan to prevent debris from falling into it, this
will reduce possibility of engine damage.
Remove radiator, charge air cooler, and hood if applicable.
Remove crankshaft pulley and vibration damper. See CRANKSHAFT PULLEY.
Remove engine oil pan. See ENGINE OIL PAN .
NOTE: Tools used for this repair are contained in Crankshaft Adapter and
Gear Removal Kit (4918530)
NOTE: When threaded hole adjacent to dowel pin is selected, remove dowel
pin before drilling.
NOTE: Position a threaded hole at 12 o'clock position to make this procedure

easier to perform.
Use a 1/2 in (12.7 mm) Drill Bit (4918535) or equivalent, to ream out threaded hole so 1/4 in (6.35
mm) Bushing (4918538) or equivalent, will insert easily.
Install Stop Collar (4918541) or equivalent, onto a 1/4 in (6.35 mm) Drill Bit (4918533) or
equivalent, at a depth of 2.375 in (60.3 mm).
CAUTION: Drilling holes completely through crankshaft adapter or gear can

damage engine, crankshaft, and or tools.
Use a generous amount of cutting fluid to increase tool life and ease drilling operation. Maximum
recommended drill speed is 850 RPM.
Insert 1/4 in (6.35 mm) Drill Bushing (4918538) or equivalent, into reamed hole. Drill a 1/4 in (6.35
mm) hole to preset depth.
Clean out debris using low pressure air and a shop towel to cover hole as needed.
Install Stop Collar (4918542) or equivalent onto a 1/2 in (12.7 mm) Drill Bit or equivalent, at a depth
of 2.125 in (54 mm).

Use generous amount of cutting fluid to increase tool life and ease drilling operation. Maximum
Remove 1/4 in (6.35 mm) Drill Bushing or equivalent. Drill 1/2 in (12.7 mm) hole to preset depth
using previously drilled 1/4 in (6.35 mm) hole as a pilot.
Clean out debris using low pressure air and a shop towel to cover hole as required.
Install Drill Guide Adapter (4918276), onto crankshaft nose so raised drill guide bushing is aligned
with previously drilled 1/2 in (21.7 mm) hole.
NOTE: Drill Guide Adapator has 4 bolts holes and 2 guide bushings. 1 guide
bushing is raised higher then other.
Install and tighten 2 existing damper bolts through drill guide adapter to 120 In. Lbs (13.6 N.m)

Use generous amount of cutting fluid to increase tool life and ease drilling operation. Maximum
Install 3/4 in (19.05 mm) Drill Bushing (4918540) or equivalent, into raised drill guide bushing
position.
Drill 3/4 in (19.05-mm) hole using Drill Bit (4918536) or equivalent, to a depth of previous 1/2 in
(21.7 mm) hole. Remove 3/4 in (19.05 mm) drill bit.

Use generous amount of cutting fluid to increase tool life and ease drilling operation.
A right angle, clutched, 1/2 inch drive drill at a maximum drill speed of 300 RPM is recommended.
Drill 1 in (25.4 mm) hole using Drill Bit (4918537) or equivalent, to a depth of previous 3/4 in (19.05
mm) hole. Remove 1 in (25.4 mm) drill bit.
Remove drill guide adapter from crankshaft and turn adapter 180 degrees so that other drill guide
bushing is lined up with previously drilled hole.
Install and tighten 2 existing damper bolts through drill guide adapter to 120 In. Lbs (13.6 N.m)
Install Stop Collar (4918543) or equivalent, onto a 3/4 in (19.05 mm) End Mill (4918532), at a depth
of 4.375 in (111 mm).

Use generous amount of cutting fluid to increase tool life and ease drilling operation. A right angle,
clutched, 1/2 inch drive drill at a maximum drill speed of 300 RPM is recommended.
Bore a 3/4 in (19.05 mm) hole to preset depth and remove 3/4 in (19.05 mm) end mill, 2 damper
bolts, and drill guide adapter.
Clean out debris with low pressure air and a shop towel to cover hole as required.
Remove front crankshaft seal. See FRONT CRANKSHAFT SEAL.
Remove lower gear cover. See LOWER GEAR COVER.
Insert Wedge (4918546), into 3/4 in (19.05 mm) drilled hole. Securely hit wedge with a hammer until
crankshaft adapter splits.
After splitting it is easy to remove crankshaft adapter by hand, however, a proper puller can be used
to facilitate removal.
1. Inspect crankshaft, tone wheel, and crankshaft gear for damage.
2. Inspect machined surface for scratches or nicks, use crocus cloth to remove them.
3. Replace crankshaft if scratches or nicks still felt with a fingernail after polishing crankshaft
with crocus cloth.
4. Inspect crankshaft gear and tone wheel for excessive wear or damage.
5. Replace crankshaft if any teeth on crankshaft gear are missing, chipped, or pitted. Replace tone
wheel of any teeth of tone wheel are missing.
Installation
WARNING: Handle heated part by wearing protective gloves to prevent

personal injury.
NOTE: When installing crankshaft adapter, align pin on backside of

crankshaft adapter with slot on front surface of tone wheel.
1. DO NOT lubricate crankshaft before installing crankshaft adapter.

2. Heat crankshaft adapter for 6 hours at 500° F (260° C) before installation.
NOTE: Install crankshaft adapter within 15 seconds when removed from

oven.
3. Install crankshaft adapter. Use a twisting motion until pin is aligned in slot on tone wheel. Hold
crankshaft adapter against tone wheel for about 30 seconds.
4. To inspect installation, insert a 0.010 in (0.25 mm) feeler gauge between crankshaft gear and
tone wheel at 4 locations about 90 degrees apart. Remove or replace tone wheel if feeler gauge
can be inserted.
6. Install lower gear cover. See LOWER GEAR COVER.
7. Statically time engine. See ENGINE BASE TIMING.
8. Install radiator, charge air cooler, and hood, if applicable.
NOTE: If Timing Pin (3163020), can not be inserted when damper marking
"Insert Pin" is aligned with marking on lower gear, it indicates tone
wheel or crankshaft adapter is not properly aligned with crankshaft.
NOTE: Lower gear cover, crankshaft seal, and vibration damper must be
removed and inspect for missing dowel pins and or misalignment in
crankshaft adapter or tone wheel.
CRANKSHAFT PULLEY
Removal
1. Remove fan and water pump drive belt.

3. Remove fan and water pump drive belt tensioner.
4. Remove 2 vibration damper and crankshaft pulley retaining bolts.
CAUTION: Damper can damage if removed with hammer or a

screwdriver, never use these tools.
5. Install 2 guide studs into holes.
6. Remove remaining 10 bolts and remove pulley and damper.
Fig. 26: Crankshaft Pulley Retaining Bolts
Inspect Condition
Inspect pulley for cracks, excessive wear in belt grooves, or other damage.
Installation
NOTE: Mounting surfaces of crankshaft nose, vibration damper, and pulley

must be clean, dry, and free of burrs.
1. Install 2 guide studs into crankshaft nose.
NOTE: Dowel pin in crankshaft must be aligned with dowel hole in

damper.
2. Install vibration damper(s) and pulley on guide studs.

3. Lubricate bolt threads with clean 15W-40 oil.
4. Install 10 bolts.
5. Remove 2 guide studs and install remaining bolts.
6. Tighten bolts in a star pattern. See TORQUE SPECIFICATIONS.
7. Install fan and water pump belt tensioner.
NOTE: Align dowel of tensioner to bracket.
8. Install fan and water pump drive belt.

CRANKSHAFT TONE WHEEL
Removal
1. Remove vibration damper. See VISCOUS VIBRATION DAMPER.

2. Remove crankshaft. See CRANKSHAFT.
3. Remove lower front gear cover. See LOWER GEAR COVER.
4. Using a suitable pry bar or a lady's foot, remove tone wheel from crankshaft and dispose of
tone wheel. DO NOT damage crankshaft gear when removing tone wheel.
Inspection
1. Inspect crankshaft, crankshaft gear, and tone wheel alignment dowel for damage and replace
components as required.
2. Inspect machined surfaces for scratches or nicks.
3. Inspect tone wheel alignment dowel hole for damage. If dowel hole or area surrounding hole is
damaged, replace crankshaft.
4. Remove scratches or nicks with crocus cloth. After polishing crankshaft with crocus cloth if
scratches or nicks still felt with a fingernail, replace crankshaft.
5. Inspect crankshaft gear for excessive wear or damage.
6. Replace crankshaft if any teeth on crankshaft gear are missing, chipped, or pitted.
Installation
WARNING: Handle heated parts by wearing protective gloves to prevent

personal injury.
1. Heat tone wheel for 2 hours at 350° F (177° C) before installation. Install tone wheel so face
labeled "FRONT" faces away from crankshaft gear.
2. Tone wheel is keyed to crankshaft with a dowel. Ensure tone wheel alignment dowel slot on
inside diameter of tone wheel is aligned with crankshaft pin for proper installation.
3. Install tone wheel within 30 seconds when removed from oven.
4. Install tone wheel so slot on inside diameter of tone wheel aligns with tone wheel alignment
pin.
5. Hold tone wheel in position for about 90 seconds to allow shrink fit to properly hold
components.
6. To inspect installation, try to insert a 0.010 inch (0.25 mm) feeler gauge between crankshaft
gear and tone wheel at 4 locations about 90 degrees apart. If feeler gauge can be inserted,
remove and replace tone wheel.
7. Install lower front gear cover. See LOWER GEAR COVER.
8. Install crankshaft. See CRANKSHAFT.
9. Install vibration damper. See VISCOUS VIBRATION DAMPER.
CYLINDER HEAD
Initial Check
Clean exterior of engine using steam or high-pressure water.
Run engine at low idle. Inspect for oil or coolant leaks between cylinder head and engine block.
Inspect for chirping sound between cylinder head and engine block. Cause of this sound (usually
during acceleration) is a combustion leak.
Inspect leak using a transparent bottle half filled with water, immerse overflow tube from coolant
tank and run engine at high idle until thermostat opens. Inspect for a stream of bubbles in water to
ensure combustion leak.
Remove and inspect cylinder head and all related components if leak is found.
Removal
WARNING: Always ventilate compartment before servicing batteries as

batteries can emit explosive gases causing injury. Remove
negative (-) battery cable first and connect negative (-) battery
cable last to prevent arcing.
WARNING: Keep coolant away from children and pets as it is poisonous.

Dispose of as per local environmental regulations when not
reused.

personal injury.
1. Disconnect batteries or air supply to air starter to prevent accidental engine starting.
3. Remove turbocharger. See TURBOCHARGER .
4. Remove exhaust manifold. See EXHAUST MANIFOLD .
5. Remove thermostat housing. See COOLANT THERMOSTAT HOUSING .
6. Remove air intake connection.
7. Remove integrated fuel system module. See INTEGRATED FUEL SYSTEM MODULE
(IFSM) .
8. Remove ECM.
9. Remove air compressor air inlet hose.
10. Remove rocker lever cover. See ROCKER LEVER COVER.
11. Remove rocker lever shaft assemblies. See ROCKER LEVER ASSEMBLY.
12. Remove injectors. See INJECTOR .
13. Remove upper front gear cover. See UPPER GEAR COVER.
14. Remove valve and injector camshaft gears. See ENGINE BASE TIMING.
15. Remove retaining brace bracket. See RETAINING BRACE BRACKET.
16. Remove accessory bracket. See ACCESSORY BRACKET.
17. Remove overhead valve camshaft. See OVERHEAD CAMSHAFT-VALVE.
18. Remove overhead injector camshaft. See OVERHEAD CAMSHAFT-INJECTOR.
19. Using chip vacuum, remove excess oil from top of cylinder head.
20. Remove cylinder head bolts to remove cylinder head. Remove and dispose of gasket.
21. Remove fire rings from cylinder liners, if equipped.
22. Reusable Plugs (4089255), are included in Master Plug Kit (4918319).
23. Install plugs in cylinder block and cylinder head oil passages.
CAUTION: Install plugs into oil passages in both cylinder head and
block immediately when cylinder head is removed. Plugs are
required to prevent debris from into lubrication system
during repair. Insert oil passage plugs to avoid connecting
rod bearing failure, crankshaft failure or both.
24. Before removing cylinder head gasket and sealing rings (if installed), inspect gasket for carbon
tracks across sealing ring to confirm combustion leak.
NOTE: DO NOT use this step if 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.
25. Remove cylinder head gasket and ensure cylinder liner recession or protrusion (based on liner
style) is within specification. See CYLINDER LINER.
Inspect Condition
Use Depth Gauge (3164438), to measure valve recess in cylinder head.
VALVE RECESS
Intake Valve Minimum 0.040 (1.02)

Maximum 0.190 (4.82)
Exhaust Valve Minimum 0.021 (0.53)
Maximum 0.036 (0.91)
Recondition cylinder head if valve recess is not within specifications.
Before cleaning cylinder head combustion surface, inspect for a leak path between cylinder and
cylinder head bolt holes.
NOTE: DO NOT use this step if 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.
Inspect cylinder head combustion surface for pitting or erosion. Pitting or erosion on cylinder head
combustion surface located in area where cylinder liner fire dam contacts head is not okay. However,
it is acceptable if pitting or erosion on cylinder head combustion surface located inside fire ring.
Cleaning
Before cleaning combustion face of cylinder head, Small Rubber Plugs (4089255), and use tape to
plug or cover oil supply holes at ends of cylinder head to prevent debris from entering oil passages.
Clean cylinder head combustion face using ScotchBrite 7448 (3823258), or equivalent. Ensure there
is no loose debris in valve pockets around head of valve.
DO NOT clean combustion face of cylinder head using power tools.
CAUTION: Crankshaft could fail if oil passages are not plugged or covered
before cleaning.
Install plugs in oil passages of cylinder block deck and cover coolant passages in cylinder block deck.

Clean cylinder block deck surface using gasket scraper.
Remove any residual gasket material from cylinder block deck surface using ScotchBrite 7448
(3823258), or equivalent, and solvent.
Remove excess oil and coolant from bolt holes using chip vacuum.
Ensure cylinder head bolt holes are clean and free of debris, oil, and coolant. Never use power tools
to clean combustion face.
Disassembly

personal injury.
1. Before disassembly, ensure valve recess has been recorded.

2. Position cylinder head combustion face down on a clean, smooth and level work surface that is
sturdy enough to support weight of cylinder head.

3. Use 4 Valve Spring Compressor (3162986), to compress valve springs.
4. Mandrel pilots in injector bore and use injector hold down clamp to secure.
5. Using pencil magnet, remove and dispose of valve collets.
6. Relieve pressure slowly on valve spring.
7. Remove these components:
A. Valve spring retainer
B. Valve spring
C. Valve spring guide
8. Using lifting device, roll head up on its side to gain access to valves. Remove valves.

9. Using electric pencil (engraving tool) to mark valves for position as they are removed.
10. Different materials are used to made intake and exhaust valves and are not interchangeable.
11. Remove valve seals from valve guides. See CYLINDER HEAD VALVE GUIDE SEAL.
12. Remove old valve guides using Valve Guide Removal Tool (3163321)
NOTE: Remove valve guides only if they are not within specification
from previous step. An air hammer can be used to drive guides
out, however it is okay to use dead blow hammer.
13. Remove intake valve seat inserts from cylinder head using Slide Hammer Assembly
(3376617), and Valve Seat Extractor (ST-1279-1).
NOTE: Remove valve seats only if they were not within specification
from step.
14. Exhaust valve seat insert does not have a lower inside diameter chamfer for exhaust seat puller
to grip. Cut a groove in inside diameter of exhaust valve seat inserts using valve seat grooving
tool.
15. Set up cutting tool with cutting edge 0.3 in (7.75 mm) from base of grooving tool motor.
16. During entire cutting groove operation, ensure base of tool remains flat on cylinder head
combustion face. Set tool on head surface with cutter in valve bore.
17. Contact valve seat insert inside diameter with grooving tool on. Apply adequate pressure to
prevent tool chatter. DO NOT over-pressurize to avoid overheating of tool or seat insert.
18. Follow inside diameter circumference in a clockwise direction for 3 complete rotations.
19. Remove tool and inspect groove for uniformity of depth. Recut shallow areas.
20. Remove exhaust valve seat inserts from cylinder head using Seat Extractor (ST-1276-1).

CAUTION: DO NOT clean cylinder head bolts with caustic or acid solutions,
it could damage bolts.
CAUTION: Plug or cover oil passages before cleaning to avoid crankshaft

failure.
If valve seat insert is removed during disassembly, inspect insert bore for cracks or damage. DO
NOT use cylinder head if insert bore has cracks or damage. Use petroleum-based solvent to clean
cylinder head. Thoroughly clean bolts with a wire brush, wire wheel (soft), or nonabrasive bead blast
to remove deposits from shank and threads. Steam clean cylinder head and dry with compressed air.
Clean out all bolt holes with a chip vacuum.
DO NOT clean combustion face of cylinder head with power tools. Before cleaning, insert Small
Rubber Plugs (4089255), in oil supply holes at ends to prevent debris into oil passages. Clean
cylinder head combustion face using ScotchBrite, or equivalent, and solvent. Clean exhaust manifold
gasket surface and air intake gasket surface. Clean valve guide bores in cylinder head using a flexible
brush and solvent. Dry with compressed air. Clean deposits from valve seat insert bores using wire
brush and solvent. Dry with compressed air.
Inspect fuel passages and water passages for blockage or foreign material. Remove any obstructions.
Inspect valves and valve springs for cracks, bent or broken valve stems, broken valve spring collets,
or other damage. Inspect valves for leakage or burning. Rebuilt or replace cylinder head if cracked,
damaged, leaking or burnt valves. Inspect cylinder head for cracks or damage. Inspect combustion
face for ring-shaped wear or erosion that encircles valves.
Wear in area where cylinder liner fire dam contacts head is acceptable. But wear in area that fire ring
combustion seal contacts head is not acceptable.
Use inspection gauges to help differentiate.
Install Inspection Gauge (3164442), on cylinder head combustion face with dowel pin in injector
bore for cylinder being evaluated. Inspect area within 1/8 inch of outside diameter of tool all way
around its perimeter. Any wear felt with a fingernail within 1/8 inch area is not okay that makes
cylinder head not reusable. If wear is outside this area, it have no effect on future combustion sealing
and reusability of cylinder head.
Install Inspection Gauge (3165071), on cylinder head combustion face with dowel pin in injector
bore for cylinder being evaluated. Inspect area within narrow slots cut into tool and rotate tool to see
entire wire ring area on cylinder head combustion face. Any wear felt by fingernail within these slots
is not acceptable that makes cylinder head not reusable. If wear is outside slots, it have no effect on
future combustion sealing and reusability of cylinder head. Inspect valve spring retainers and valve
spring guides for damage or worn areas. Dispose of damaged and worn parts.
Bolt is positioned beyond yield point and stretches permanently using flange-head bolts with torque-
plus-angle method of installation. You can use these bolts during engine life if bolt does not exceeds
specified free length.
Inspect free length to avoid bottoming in block during installation.
Using Head Bolt Stretch Gauge (3163162), measure bolt free length by positioning head of bolt in
proper slot, long or short, with flange against base of slot.
l If end of bolt contacts foot of gauge, bolt is too long and should be disposed of.
l If there is clearance between end of bolt and bottom base of tool, bolt can be used.
Measure
1. Inspect bolt length.

l Maximum allowable free length is measured from bottom of flange to end of bolt.
CYLINDER HEAD BOLT MAXMIMUM LENGTH

Bolt In. (mm)
Short Bolts 6.93 (176)
Long Bolts 9.09 (231)
() Cylinder head bolt length is measured from underside of bolt head to tip of
threaded end. Replace bolts if they exceed maximum length.
2. Measure flatness of cylinder head combustion face surface as follows:

A. A to A and B to B (corner to corner)
B. C to C (across combustion face).
3. Inspect dimensions for C to C at multiple positions from front to rear of cylinder head.
CYLINDER HEAD FLATNESS

Specification Location In (mm)
Maximum A to A 0.006 (0.15)
Maximum B to B 0.006 (0.15)
Maximum C to C 0.006 (0.15)
4. Replace cylinder head if it is pitted, grooved, or not within specifications.

5. Using Valve Spring Tester (3375182), measure valve spring load at valve spring working
height.
VALVE SPRING SPECIFICATION

Valve Spring Load at 2.431 in (61.75 mm)
Specification Lbs. (N)
Minimum 339.5 (1511)
Maximum 360.5 (1604)
6. Replace valve spring if valve spring load for working height is less than minimum specified.
7. Inspect valves for damage and collet grooves for wear and measure valve stem outside
diameter.
8. Take 3 measurements of each valve stem at 1.57 in (40 mm), 3.54 in (90 mm), and 5.51 in (140
mm) from tip end.
VALVE STEM OUTSIDE DIAMETER

Minimum 0.378 (9.593)
Maximum 0.379 (9.627)
9. Replace valves if found damaged and not within specification. Inspect valve guides for
chips/cracks and measure inside diameter of valve guides in locations 1/2 in (13 mm) from
each end and at center.
USED VALVE GUIDE INSIDE DIAMETER-(INSTALLED)

Minimum 0.380 (9.663)
Maximum 0.382 (9.713)
10. Replace valve guide inside diameter if not within specifications.

11. Measure valve guide installed height.
VALVE GUIDE HEIGHT-(INSTALLED)

Minimum 1.763 (44.77)
Maximum 1.802 (45.77)
12. Replace valve guide if found damaged or beyond specification.

13. Measure valve recess in cylinder head using Depth Gauge (3164438).
NOTE: See VALVE SPECIFICATION table.
14. Replace valve if valve seat and valve recess is not within specification.
15. Measure inside diameter of valve guide bore.
VALVE GUIDE BORE INSIDE DIAMETER

Minimum 0.649 (16.48)
Maximum 0.650 (16.50)
16. Replace cylinder head if valve guide bore is not within specifications.
17. Measure valve seat insert bore depth in cylinder head.
VALVE SEAT INSERT BORE DEPTH

Intake Valve Minimum 0.367 (9.32)
Maximum 0.373 (9.48)
Exhaust Valve Minimum 0.406 (10.32)
Maximum 0.413 (10.48)
18. Replace cylinder head if valve seat insert bore is not within specifications.
19. Measure inside diameter of valve seat insert bore.
VALVE SEAT INSERT BORE INSIDE DIAMETER

Intake Minimum 1.949 (49.51)
Maximum 1.950 (49.54)
Exhaust Minimum 1.870 (47.51)

Maximum 1.872 (47.54)
20. If valve seat insert bore inside diameter is not within specifications, replace cylinder head.
Assembly
1. Install NEW valve guides with Valve Guide Installer, (3163294). Valve guides can be driven
in using a dead blow hammer.
2. Measure valve guide installed height above cylinder head top deck surface.
NOTE: See VALVE GUIDE SPECIFICATION table.
NEW VALVE GUIDE INSIDE DIAMETER-(INSTALLED)

Minimum 0.380 (9.66)
Maximum 0.382 (9.71)
3. Measure valve guide inside diameter.

4. Replace valve guide if not within specifications.
5. Install insert chamfer toward bottom of counterbore. Drive intake seat insert into counterbore
with Intake Valve Seat Installer, (3163318). Whereas to drive exhaust valve seat insert into
counterbore, use Exhaust Valve Seat Installer, (3163319).
6. These 2 service tools pilot in valve guide. Install NEW seat inserts using a dead blow hammer
with seat drivers.
7. Install NEW valve stem seals onto valve guides. See CYLINDER HEAD VALVE GUIDE
SEAL.
8. Lubricate valve stems with clean 80W, or higher, gear lube with EP additives. Install valves in
valve guides and after valves are installed place cylinder head on a flat surface which will not
damage cylinder head surface. Install valve spring guide, valve springs and valve spring
retainers.
9. Use 4 valve Spring Compressor to compress valve springs. Whenever you need NEW cylinder
head, use collets.
10. Install NEW valve spring retainer collets.
11. Inspect collets for proper seating and installation. Once cylinder head is assembled, it will be
necessary to run vacuum test to assure good valve to seat sealing.
12. See VACUUM TEST.
13. Remove oil plugs from cylinder head and cylinder block.
CAUTION: Remove all oil passage plugs if cylinder head is assembled

onto block or engine will damage.
Installation
1. 2 different styles of head gaskets are used on Signature and ISX engines based on style of liner
used in engine. Inspect cylinder liner to correctly identify which style of liner is used.
2. Install cylinder head gasket.
Fig. 27: Cylinder Head Gasket
WARNING: Have assistance or lift this component or assembly with

proper equipment as it weighs more than 50 lb (23 kg). This
will prevent serious personal injury.
3. Lift cylinder head with Engine Lifting Fixture.

4. 2 long cylinder head bolts placed toward each end of cylinder head serve as convenient guides
when lowering cylinder head into place.
5. Align cylinder head over dowel pins and lower into position.
6. Lubricate cylinder head bolts with clean 15W-40 oil.
7. Drain excess oil from threads.
8. Install 26 bolts into cylinder head.
CAUTION: To avoid engine damage place 4 longer bolts in correct

location.
Fig. 28: Cylinder Head Bolt Torque Sequence
9. Tighten bolts in sequence:

A. Step 1: 148 Ft Lbs (200 N.m)
B. Step 2: 300 Ft Lbs (405 N.m)
C. Step 3: Rotate 90°
NOTE: Use an Air Impact Wrench and Socket, Tool Number

(3163059) and (3163484), to rotate bolt 90 degrees.
10. Install overhead injector camshaft. See OVERHEAD CAMSHAFT-INJECTOR.

11. Install overhead valve camshaft. See OVERHEAD CAMSHAFT-VALVE.
12. Install accessory bracket. See ACCESSORY BRACKET.
13. Install retaining brace bracket. See RETAINING BRACE BRACKET.
14. Install valve and injector camshaft gears. See ENGINE BASE TIMING.
15. Install upper front gear cover. See UPPER GEAR COVER.
16. Install injectors. See INJECTOR .
17. Install rocker lever shaft assemblies. See ROCKER LEVER ASSEMBLY.
18. Adjust overhead settings. See OVERHEAD SET-ADJUSTMENT.
19. Install rocker lever cover. See ROCKER LEVER COVER.
20. Install air compressor air inlet hose.
21. Install ECM.
22. Install integrated fuel system module. See INTEGRATED FUEL SYSTEM MODULE
(IFSM) .
23. Install air intake connection.
24. Install thermostat housing. See COOLANT THERMOSTAT HOUSING .
25. Install exhaust manifold. See EXHAUST MANIFOLD .
26. Install turbocharger. See TURBOCHARGER .
28. Install batteries or air supply to air starter.

negative (-) battery cable first and connect negative (-)
battery cable last to prevent arcing.
29. Inspect aftertreatment system if failure resulted in coolant, oil, excessive fuel or excessive
black smoke entering exhaust system. See AFTERTREATMENT SYSTEM .
CYLINDER HEAD HEATER PIPE (VT)
This information includes proper procedure for cab heating system heater pipe replacement
(connected to cylinder head) on VT chassis with Cummins ISX engine.
NOTE: Information may change without notice. Illustrations are meant for
reference and hence may vary from actual vehicle version. However,
this article is developed with main components as accurately as
possible.
WARNING: Avoid burns from hot fluids by allowing components to cool and
observe appropriate safety precautions when relieving
pressurized systems containing hot fluids. When working on
cooling systems, release cooling system pressure by slowly
loosening radiator cap.
Removal
1. Drain engine coolant by connecting coolant extractor to drain fitting at bottom of radiator.
NOTE: Connect drain hose to drain fitting and drain coolant into an
approved container. This is an alternate method.
2. Remove air filter housing and fresh air pipe from turbo.
3. From metal coolant pipe, remove heater hose after loosening clamp.
4. Remove metal coolant pipe bracket-to-cylinder head bolt, then loosen fitting and remove pipe
from right rear of cylinder head.
Installation
1. Install metal coolant pipe into of cylinder head (right rear) and tighten fitting.
2. Connect metal coolant pipe bracket to cylinder head with bolt.
3. Place heater hose on coolant pipe and tighten hose clamp.
4. Install air filter housing and fresh air pipe to turbo.
5. Add recommended coolant system up to specified level with Coolant Extractor (DBT2V700).
6. With engine ON, inspect for leaks.
CYLINDER HEAD-TO-TRANSMISSION OIL COOLER PIPE (VT)
Procedure for replacing cylinder head-to-transmission oil cooler pipe on VT chassis with Cummins
ISX engine is covered here.
possible.
Removal
1. Drain coolant by connecting Coolant Extractor (DBT2V700) to drain fitting at bottom.

2. Remove air filter housing and fresh air pipe.
3. Loosen clamp, then apart coolant hose of transmission oil cooler from coolant pipe of cylinder
head.
4. Remove metal coolant pipe-to-transmission (top) clamp.
5. Loosen metal coolant pipe-to-cylinder head clamp and remove pipe.
Installation
1. Install metal coolant pipe to rear of cylinder head and tighten fitting.
2. Install metal coolant pipe clamp to top of transmission and secure.
3. Connect coolant hose of transmission oil cooler to coolant pipe of cylinder head. Use clamp to
secure.
4. Add recommended coolant to system up to specific level using Coolant Extractor
(DBT2V700).
5. Install air filter housing and fresh air pipe.
6. With engine ON, inspect for coolant leaks.
CYLINDER HEAD VALVE GUIDE SEAL
Removal
Off-Engine Repair
WARNING: Have assistance or lift this component or assembly with proper

equipment as it weighs more than 50 lb (23 kg). This will prevent
serious personal injury.
Remove cylinder head and set it on a bench or table. See CYLINDER HEAD.
On-Engine Repair
WARNING: Properly release valve springs else valve springs will be under
tension and can act as projectiles. Wear safety glasses with side
shields to avoid eye injury. Ensure collets are properly seated
before releasing valve spring tension.
1. Remove rocker lever cover, if not previously removed. See Rocker Lever Cover.
2. Turn engine over so cylinder you are working on is at top dead center (TDC). See Overhead
Set-Adjustment. Repeat this step for each cylinder.
NOTE: See Fig. 13
3. Compress valve springs using Valve Spring Compressor (3162986) and remove spring retainer
collets.
4. Remove following:
A. Spring retainer
B. Valve spring
C. Valve spring guide
NOTE: DO NOT remove valve spring guides on cylinder heads having

grooved style valve guides. Valve without groove should have
valve spring guides removed for use of installation tool.
Fig. 29: Removing/Installing Spring Retainer & Valve Spring
5. Remove valve guide seal with Valve Guide Seal Remover, (3163293).
Installation
1. Grooved Valve Guide Seals:
NOTE: Seals mating with grooved valve guides had 2 iterations:
A. Engines built from 15 May 2000 to end of February 2002 had

separate intake and exhaust valve guide seals which were
color coded. Intake valve guide seals had a brass-colored
garter spring and 3 raised dots molded into rubber, exhaust
valve guide seals had a silver-colored garter spring without
raised dots.
B. Engines built after March 2002 had only 1 valve guide seal
for both intake and exhaust valve guides. These seals can
be used on any engines built after ESN 14010274.
2. Snap seal by hand into groove on valve guide, to install intake and exhaust valve.
3. Non-Grooved Valve Guide Seals:
NOTE: Remove valve spring guides before installing non-grooved valve

guide seals.
Install valve guide seals with an unmodified Valve Seal Installer,

(3163294). Ensure seal installer makes contact with cylinder head
at installation which correctly locates valve guide seals.
4. Install:
A. Valve spring guide
B. Valve spring
C. Spring retainer
NOTE: See Fig. 29
5. Compress valve springs using Valve Spring Compressor, (3162986). Install valve spring
retainer collets and remove valve spring compressor.
WARNING: Properly release valve springs else valve springs will be

under tension and can act as projectiles. Wear safety
glasses with side shields to avoid eye injury. Ensure collets
are properly seated before releasing valve spring tension.
Off-Engine Repair

Install cylinder head and see CYLINDER HEAD.
On-Engine Repair
1. Install rocker lever cover and see ROCKER LEVER COVER.

2. Operate engine to normal operating temperature and inspect for leaks. Inspect aftertreatment if
failure resulted in coolant, oil, excessive fuel or excessive black smoke entering exhaust
system. See AFTERTREATMENT SYSTEM .
CYLINDER LINER
Removal
WARNING: Keep coolant away from children and pets as it is toxic. Dispose
of as per local environmental regulations when not reused.

injury.

environmental regulations to dispose of, if not reused.
CAUTION: Install cylinder puller and use as described to minimize chances

of damage to cylinder block. Ensure puller plate is parallel to
main bearing saddles and not overlap cylinder liner outside
diameter.

3. Remove cylinder head. See CYLINDER HEAD.
MOUNTED) .
8. Remove piston and connecting rod assemblies. See PISTON & CONNECTING ROD
ASSEMBLY.
9. Remove cylinder liners by using either:
A. Cylinder Liner Puller (universal) (3163745) and Puller Plate (3162462).
B. Cylinder Liner Puller (universal) (3376015).
10. Insert cylinder liner puller onto top of cylinder block.
11. Center cylinder liner puller on top of cylinder block.
12. Turn puller jackscrew clockwise to loosen cylinder liner from cylinder block.
13. Remove cylinder liner using hands. Remove and dispose of "O" ring seals.
14. Use Dykem, or equivalent, to mark on intake air side of cylinder liner to indicate cylinder liner
orientation.
15. Use Dykem, or equivalent, to mark cylinder number on each cylinder liner.
CAUTION: Emery cloth or sand paper contain aluminum oxide or silicon

particles that may cause serious engine damage. Avoid use of
them to remove carbon from cylinder liners. DO NOT use any

abrasives in ring travel area, cylinder liner can be damaged.

WARNING: To avoid personal injury, wear proper clothing and eye

protection when using a steam cleaner or high pressure water.
1. Clean flange seating area using soft wire brush.

2. Remove remaining scale and rust using fine fibrous, abrasive pad such as ScotchBrite or
equivalent.
3. Use solvent or steam clean cylinder liners and dry with compressed air. Lubricate inside
circumference of cylinder liners with clean 15W-40 oil and keep for 5-10 minutes.
4. Clean oil from inside of cylinder liners with lint-free paper towels. Keep lubricating inside of
cylinder liners and clean until paper towel indicates no GRAY or BLACK residue.
5. Inspect cylinder liners for cracks on inside and outside circumferences.
6. Inspect for cracks under cylinder liner flange, use either magnetic inspection or dye method to
detect crack.
7. Inspect outside circumference for excessive corrosion or pitting. It is not recommended to use
cylinder liners with pitting, however if pitting is light and can be removed with fine emery
cloth, cylinder liner can be used.
CYLINDER LINER PITTING DEPTH

Maximum 0.060 (1.60)
8. Inspect inside circumference for vertical scratches to be felt with a fingernail. Replace cylinder
liner if scratches are felt with fingernails
9. Inspect inside circumference for scuffing or scoring.
10. Inspect inside diameter for cylinder liner bore polishing:
A. A moderate polish generates a mirror finish in worn area with traces of original hone
marks or an indication of an etch pattern.
B. A heavy polish generates a bright mirror finish in worn area with no traces of hone
marks or an etch pattern.
11. If a heavy polish is present over 20% of piston ring travel area, replace cylinder liner. 30% of
piston ring travel has both moderate and heavy polish and one half (15%) is heavy polish.
12. Using dial bore gauge, measure cylinder liner inside diameter in 4 places, 90 degrees apart at
top and bottom of piston travel area.
CYLINDER LINER INSIDE DIAMETER

Maximum 5.40 (137.14)
13. Measure cylinder liner top press fit area outside diameter.
CYLINDER LINER TOP PRESS FIT OUTSIDE DIAMETER
Maximum 6.34 (160.98)
Installation
CAUTION: DO NOT mix cylinder liners of different design within an engine.

Ensure all 6 cylinder liners have same design.
1. Cylinder liners uses 2 different designs. Design used in a particular engine is dependent on
engine's production vintage.
A. Engines assembled before engine serial number 14022615 have groove-top cylinder
liners, characterized by a groove machined into top surface of cylinder liner flange.
B. Engines with serial number 14022615 and after are assembled with flat-top cylinder
liners, characterized by a cylinder liner flange that is flat, except for fire dam.
2. Clean cylinder block and all components, and lubricate 2 cylinder liner "O" ring seals with
vegetable oil before assembly.
3. Install 2 "O" ring seals onto cylinder liner.
CAUTION: DO NOT mix cylinder liners of different design within an

engine. Ensure all 6 cylinder liners have same design.
4. Install cylinder liner into cylinder block. Now rotate cylinder liner 90 degrees from its original
position in engine. Ensure thrust and anti-thrust surfaces face front and back of cylinder block.
5. Seat liner using Cylinder Liner Installation Kit (3162461). If it does not seat properly, remove
and inspect cylinder liner bore seat and cylinder liner for nicks, burrs, or dirt.
6. Install cylinder liner again.
WARNING: Have assistance or lift this component or assembly with

proper equipment as it weighs more than 50 lb (23 kg). This
will prevent serious personal injury.
7. Measure cylinder liner to ensure correct installation, see Cylinder Lining-Measuring.

8. Install piston and connecting rod assemblies. See Piston & Connecting Rod Assembly.
10. Install block stiffener plate. See Block Stiffener Plate.
11. Install oil suction tube. See ENGINE OIL SUCTION TUBE-(BLOCK MOUNTED) .
13. Install cylinder head. See Cylinder Head.
14. Add clean engine oil to fill engine. See ENGINE OIL SYSTEM .
17. Operate engine and inspect for leaks.
Measuring
Liner Protrusion
1. Position of cylinder liner (relative to cylinder top deck) may not be similar due to different
design.
A. For groove-top cylinder liners: A recession measurement is taken, which measures depth
of groove relative to cylinder block deck besides flange or fire dam height.
B. For flat-top cylinder liners: Cylinder liner protrusion measurement is taken which is
height of cylinder liner flange above cylinder block surface besides flange or fire dam
height.
2. Measurement technique remain same besides cylinder liner design.
3. Inspect cylinder liner measurement before installing pistons and connecting rods.
4. Measure cylinder liner measurement with cylinder liners in clamped state.
5. Install and tighten cylinder liner installation tool to 50 Ft Lbs (68 N.m)
6. Using Depth Gauge (3823495), measure clamped state at intake side 3 times and average
readings.
7. Measure clamped state of exhaust side 3 times and record average readings.
GROOVE-TOP CYLINDER LINER PROTRUSION

Specifications In (mm)
Minimum 0.014 (0.36)
Maximum 0.019 (0.51)
FLAT-TOP CYLINDER LINER PROTRUSION

Minimum 0.014 (0.18)
Maximum 0.007 (0.33)
8. Replace cylinder liner if measurement on either intake or exhaust side does not follow
specifications.
9. For flat-top cylinder liners only:
A. Difference between lowest cylinder liner and highest cylinder liner should not be above
0.004 in (0.102 mm).
B. Maximum allowable difference between adjacent cylinders is (0.002 in) 0.51 mm.
C. Protrusion should be within 0.0015 in (0.0381 mm) around any cylinder.
10. Before installing piston and connecting rod assemblies, use clean cloth with 15W-40 oil to
clean inside of cylinder liners.
ENGINE
Removal
To identify individual locations on engine, place tag on all hoses, lines, linkages, and electrical
connections, as they are removed.
WARNING: Explosive gases from batteries may cause personal injury.

Ensure compartment is ventilated, before servicing batteries.
First remove negative (-) battery and lastly connect negative (-)
battery cable. This will avoid arcing.
WARNING: To avoid personal injury, never remove pressure cap from a hot
engine. Coolant temperature should be below 120° F (50° C),
before removing pressure cap.

WARNING: DO NOT let direct contact of hot oil with your skin, to avoid
personal injury.
1. Disconnect battery cables.

2. Drain engine coolant.
4. Disconnect starting motor cable, engine ground straps, cab- or chassis-to-engine hoses, tubing,
electrical wires, and hydraulic lines.
5. Disconnect intake and exhaust air pipes.
6. Disconnect all chassis-mounted, engine-driven accessories.
Fig. 30: Intake & Exhaust Air Pipes
7. Disconnect drive units from flywheel.

8. Disconnect OEM wiring harness from electronic control module (ECM).
NOTE: When rear engine mounts are attached to transmission, removal

of engine and transmission as an assembly may probably be
required.
9. Most cab-over configuration vehicles will have factory-installed rear engine lifting bracket still
installed.
WARNING: To avoid eye and skin injury from liquid refrigerant system
(A/C), wear eye and face protection. Wrap a cloth around
fittings before removing.
WARNING: Properly empty and fill liquid refrigerant systems using

equipment that prevents release of refrigerant gas into
atmosphere. This helps in protecting environment. Federal
law requires capturing and recycling refrigerant.
10. Remove all chassis components necessary to remove engine.
WARNING: Engine lifting equipment should be designed to lift engine

and transmission as an assembly without causing personal
injury.
WARNING: This component is heavy. Lift component with help of hoist

or assistance, to prevent personal injury.
11. Remove engine by using a correctly rated hoist. Attach Engine Lifting Fixture (3162871) to
engine-mounted lifting brackets.
12. To avoid transmission from falling, place a support under it, when transmission is not removed,
place a support under it.
13. Remove engine.
14. Engine opening must be covered to avoid dirt and debris from entering engine.
15. Place engine on proper engine support stands.
16. Remove any remaining accessories and brackets from old engine.
Installation
1. Install all accessories and brackets onto replacement engine.
2. When rear engine mounts are attached to transmission, removal of engine and transmission as
an assembly may probably be required.
WARNING: Ensure engine lifting equipment is designed to lift engine

and transmission as an assembly without causing personal
injury.
WARNING: This component is heavy. Lift component with help of hoist

or assistance, to prevent personal injury.
3. Remove engine by using a correctly rated hoist. Attach Engine Lifting Fixture to engine-
mounted lifting brackets.
CAUTION: To avoid damage, ensure all lines, hoses, and tubes are
correctly routed and fastened.
4. Align engine in chassis. Tighten engine mounting bolts.

5. Connect all engine and chassis-mounted accessories removed.
6. Connect OEM wiring harness to ECM.
7. Use clean 15W-40 oil to fill and prime engine. See ENGINE OIL SYSTEM .
8. Radiator and total system capacity depend on OE truck manufacturer installed equipment.
10. Inspect and ensure sure all hoses, wires, linkages, and components is properly installed and
tightened.
Fig. 31: Hose Linkage Points
WARNING: To avoid personal injury, never remove pressure cap from a

hot engine. Coolant temperature should be below 120° F
(50° C).
11. Operate engine at low idle for 2 - 3 minutes. Stop engine and wait 15 minutes for oil to drain to
oil pan. Again inspect oil and coolant levels.
12. Fill engine to correct coolant level, if needed.
13. Fill engine to correct oil level, if needed. See ENGINE OIL SYSTEM .
14. To inspect correct engine operation, unusual noises and leaks, operate engine for 8 - 10
minutes.
15. Repair any leaks or component problems.
ENGINE (VT)
Procedure for replacement of Cummins ISX engine in a VT chassis is covered in this information.
possible.
Removal
1. Remove ten retaining grille fasteners and remove grille.

2. Disconnect headlights wiring harness and remove nylon ties securing harness.
3. Disconnect fog/running lights wiring harness in bumper.

4. Mark bumper mounting flange nuts locations (four on each side).
5. From each side (one nut on each side), remove three of four bumper attachment nuts. Loosen
remaining nut. DO NOT remove.
6. While holding bumper with assistance, remove remaining fasteners and set bumper aside.
7. Mark hood hinge mounting flange nuts locations on frame mounts. This will aid in hood
alignment during reassembly.
8. Support hood in an open position after removing support struts.
9. Remove hinge-to-frame mounts mounting flange nuts. Once fasteners are removed, support
hood using protective covering.
NOTE: Assistance is required in this step.
10. Position hood.
WARNING: Disconnect negative battery cable first when disconnecting

batteries to avoid electrical shock and sparks that could
cause battery explosion. DO NOT disconnect batteries with
engine running. Disconnecting batteries with engine
running can cause electrical component failures.
11. Disconnect negative battery terminals.
WARNING: Avoid burns from hot fluids by allowing components to

cool and observe appropriate safety precautions when
relieving pressurized systems containing hot fluids. When
working on cooling systems, release cooling system
pressure by slowly loosening radiator cap.
12. Drain engine coolant by connecting Coolant Extractor (DBT2V700).
NOTE: Connect drain hose to drain fitting and drain coolant. This is an
alternate method.
WARNING: When working with refrigerants wear appropriate protective

clothing and only disconnect refrigerant lines in well
ventilated areas. Liquid refrigerant systems MUST be
properly filled and emptied using appropriate
capturing/recycling equipment that prevents the release of
fluorocarbons (refrigerant gases) into the atmosphere.
Refrigerants gas and vapors can be under high pressures.
Unintentional release of refrigerant under high pressure can
cause severe personal injury. Use caution when working
with refrigerant lines.
13. Use Refrigerant Recovery/Recycling/Recharging Unit (J-39500-A), recover A/C

refrigerant.
14. Disconnect condenser A/C lines. Remove single flanged nut (one on each location) that
connects pressure and suction metal lines to condenser side. Collect "O" rings at each fitting.
15. From top and left side of radiator, remove A/C line clamps.
NOTE: Cover openings in lines and condenser to prevent contamination.
16. Remove eight front closing cross member connecting bolts (four on each side) and remove
cross member.
17. From both ends of lower charge air pipe, loosen clamps, then push to collapse bellows on pipe.
Drop one end and release from charge air cooler and turbo outlet tube. Then from both ends of
pipe, collect "O" rings.
18. Loosen lower coolant hose clamps (on both ends) and remove hose from chassis.
19. Remove upper coolant hose and by-pass hose at engine end only by loosening clamps.
20. Loosen clamps and remove surge tank coolant hose at engine end only.
21. Disconnect harness of low coolant sensor.
WARNING: Carefully follow disassembly/assembly procedures and

safety precautions when working on components having
springs under pressure. Sudden release of spring pressure
can cause severe personal injury or death if proper
procedures and safety precautions are not followed.
22. Both ends of upper charge air pipe has spring-loaded clamps, loosen them and remove pipe.
23. Remove mount flange nuts of radiator frame and mounts of rubber/metal, then lift off top
section (both sides).
24. Cut wiring harness-to-radiator shroud nylon ties then connect lifting chain or strap to radiator.
25. Place proper capacity hoist over charge air cooler and radiator and connect it to lifting
chain/strap.
26. First lift straight up on radiator assembly, then move forward and away from chassis.
27. From side of chassis, remove side cover/step assemblies (both).
28. Remove passenger-side fender extender/inner fender assembly, and driver's-side fender
extender/inner fender assembly.
29. Remove mounting bracket of inner fender from both sides.
30. Remove center dash trim panel (directly over engine cover), and remove lower dash trim panel
(over accelerator pedal).
31. Remove both threshold plates, and remove trash basket and bracket from engine cover.
32. Remove upper section of engine cover and its mounting ring.
33. From fan drive, remove engine fan blade.
34. Remove fan ring-to-upper and lower mounts bolts then, remove ring from engine.
35. Remove two fan ring mounts (lower) from engine block.
36. Remove A/C and fan belts after releasing tension on belt tensioners, then remove fan belt idler
pulley.
37. Disconnect fan drive air line using Air Line Release Tool (J-44773).
38. Remove fan drive and mounting bracket as an assembly, then remove oil filler spout and frame
mounting bracket.
39. Disconnect filter minder harness and remove harness connecting screws.
40. From turbocharger, remove air filter housing and fresh air pipe.
41. Disconnect alternator and A/C compressor wiring harness.
42. Cut nylon ties that connects wiring harness to front of and down left side of valve cover.
43. Disconnect ECM electrical harness connectors.
44. From air compressor, supply line of air governor then ties connecting air governor and fan air
lines at front of engine.
45. At lower left side of engine, disconnect air line from turbocharger control valve.
46. Disconnect left side of cylinder block ground wires.
47. Remove clamp that connect battery cables (above left rear motor mount).
48. Mark all wires connecting to starter relating to corresponding terminals on starter. Disconnect
all starter wires.
49. Disconnect fuel lines at rear of fuel pump with Fuel Line Fitting Release Tool (20449325).
50. Cut nylon ties that connects engine electrical wiring harness to cylinder block (left side), then
place harness to out of frame rail.
51. Remove two power steering pump-to-engine block bolts. Ensure hoses remains connected to
pump if possible.
NOTE: Power steering pump is removed for clarity.
52. From underneath side of turbocharger, remove charge air pipe and bracket.
53. Remove exhaust temperature sensor after loosening fitting. Then, cut harness-to-side and rear
of engine connecting nylon ties.
54. Remove four heat shield-to-exhaust pipe flange nuts (at turbocharger), then remove shield.
55. Loosen exhaust pipe-to-turbocharger T-bolt clamp, slide clamp away from turbocharger flange.
56. Loosen four connecting exhaust pipe-to-flex exhaust pipe bolt clamp. Exhaust pipe is removed
between flex pipe and turbocharger.
57. Loosen two clamps that connects both heater hoses to metal tubes connecting engine. Then
apart hoses.
58. Remove two block heater connecting bolts and remove heater. Cut all ties securing harness.
59. Remove single bolt that connects shift lever to shift tower on transmission, then remove lever
from tower.
60. Drain air tanks and disconnect main air line at engine (rear side).
61. Disconnect transmission 2 speed air lines.
62. For supply line, remove clutch slave cylinder and bracket.
63. Disconnect wiring harness of transmission.
64. Remove driveshaft and center support bearing. Lower cross member is removed from under
transmission.
65. Remove front engine and rear engine mount bolts.
NOTE: Lifting chain and engine hoist should have ability to lift both
engine and transmission weight.
66. Connect lifting chain to engine lifting device, and position hoist over engine and connect chain
to lifting device.
Component Transfer
1. Remove twelve (six on each side) large bolts connecting rear mounts to cylinder block at both
rear mount locations, then remove engine mounts.
2. For NEW engine, install both rear engine mounts on side of cylinder block and tighten twelve
(each side has six) large mounting bolts to 202 ± 33 Ft. Lbs. (275 ± 45 N.m).
3. Remove air compressor main air line fitting and install it to NEW engine compressor.
4. Remove bolts that connect starter in bell housing and remove starter motor.
5. For NEW engine, install starter into opening of bell housing and torque fasteners to 44 ± 4 Ft.
Lbs. (60 ± 6 N.m).
6. Remove metal heater pipes (both inlet and outlet) from right side of block when fittings are
loosened.
7. On cylinder block (right side), install metal heater pipes (for NEW engine).
8. Remove clutch forks, transmission cooler hoses, then remove transmission.
9. From rear of engine, remove clutch, and from right side of engine, remove cooler lines of metal
transmission.
10. On right side of NEW engine, install metal transmission cooler lines.
11. Install clutch and transmission to rear of engine. Then connect transmission cooler pipes.
12. From right side of engine, remove by-pass coolant tube and fitting.
13. Remove alternator and A/C compressor from right front side of engine, and install A/C
compressor, alternator, by-pass tube and fitting on it.
14. By loosening hose clamp, remove lower coolant pipe and fitting from right front side of
engine, and install lower coolant pipe and fitting on it. Tighten hose clamp to secure.
Installation
1. Install engine in frame and torque engine mount bolts for front mount to 202 ± 33 Ft. Lbs.
(275 ± 45 N.m).
2. Install engine to line up with engine rear mounts and torque bolts to 202 ± 33 Ft. Lbs. (275 ±
45 N.m).
3. Remove engine hoist and lifting chain.
4. Install clutch forks into bell housing.
5. Install and secure clutch slave cylinder on clutch fork housing with four bolts.
6. Connect hydraulic clutch line and bracket to side of transmission.
7. Connect driveshaft to rear yoke on transmission and use center support bearing to secure.
8. While holding with one bolt on each side, install lower cross member underneath transmission.
Then tighten remaining three bolts on each side to specification. Torque fasteners to 103 ± 18
Ft. Lbs. (140 ± 25 N.m).
9. Connect and secure transmission wiring harness with nylon ties.
10. At left rear of engine, connect and secure main air line to bracket.
11. Install shift lever on transmission shift tower and secure with single bolt. Torque fasteners to
35 ± 6 Ft. Lbs. (48 ± 8 N.m).
12. Install block heater bolts and connect electrical connector. Use nylon ties to secure harness.
13. At bulkhead, connect heater hoses to metal tubes connecting to engine. Tighten clamps to
secure.
14. Connect exhaust pipe to turbocharger. Connect rear clamp to pipe and front clamp to
turbocharger.
15. Install and secure exhaust pipe heat shield with four flanged nuts.
16. Through heat shield, route exhaust heat sensor and connect it to exhaust pipe with sensor
fitting.
17. Install charge air pipe with brace. Connect pipe to turbocharger outlet.
18. Connect A/C suction line-to-compressor.
19. Clean power steering pump sealing area. Install pump with a NEW gasket on cylinder block
and secure with two pump fasteners. If removed, pressure and return lines needs to be installed
again.
NOTE: If power steering hoses were removed, refill steering reservoir.
20. Position wire harness behind fuel pump and secure. Use nylon ties and up left side of valve
cover.
21. Connect fuel lines to fuel pump rear surface.
22. As marked during disassembly, connect wires at starter and ground wires to left side of
cylinder block. Use nylon ties to secure.
23. All starter wires are secured and clamped.
24. Connect and secure air governor line at air compressor with nylon ties.
25. Connect turbocharger control valve air line.
26. Connect alternator and A/C compressor wires. Use nylon ties to secure harness across front of
valve cover.
27. Install oil filler spout and mounting bracket.

28. Install fan drive assembly and brackets, then connect air supply line.
29. Install fan belt idler pulley, fan and A/C belts.
30. Position lower fan ring mounts on engine block and tighten to specification.
31. Install fan ring on upper and lower mounts and tighten bolts to specification.
32. Install fan blade on fan drive and torque fasteners to 35 ± 6 Ft. Lbs. (48 ± 8 N.m).
33. Install radiator over frame opening with hoist and chain or strap. Lower it into alignment with
frame studs.
34. Install and secure radiator frame mounts.
35. Remove lifting chain or strap
36. Place upper coolant hose between radiator and engine on right side. Use two hose clamps to
secure.
37. Remove protective tape and install NEW "O" rings on both A/C condenser lines. Place lines
against condenser ports and tighten flanged nuts (one at each location) to 18 ± 3 Ft. Lbs. (24 ±
4 N.m).
38. At top and left side of radiator, install A/C line clamps.
39. Install lower coolant hose between radiator and engine. Tighten hose clamps to secure.
40. Install NEW "O" rings on air pipe, then collapse bellows and position pipe between charge air
inlet tube and turbocharger outlet tube. Tighten clamps to secure.
41. Install front closing cross member to front of frame and torque eight bolts (four on each side)
to specification.
42. Install upper charge air pipe between charge air cooler outlet and engine intake manifold.
Install and tighten clamp at each end of pipe.
43. Add recommended coolant to specified level using Coolant Extractor (DBT2V700).
44. Connect negative batteries.
45. Install air filter housing and fresh air pipe to turbocharger. Secure harness to filter minder.
46. Install left inner fender and fender extender and right inner fender and fender extender.
47. Evacuate A/C system and charge using Refrigerant Recovery/Recycling/Recharging Unit
(J-39500-A).
48. Install engine cover ring, and install cab engine cover and cup holder/package tray again.
49. Mount holder to install trash basket.
50. Install lower trim panel over accelerator pedal and center dash trim panel (directly over engine
cover).
51. Install threshold plates (both).
52. Move hood at front of vehicle to install.
Use assistance to lift and support hood. Protect and support hood using pallet with protective
covering.
53. Install hood hinge on frame mounts and line up studs with marks (made before removal).
Install and tighten flange nuts to specification. Close and inspect hood for alignment. Connect
wiring harness.
54. Use assistant to place and align bumper with bumper frame brackets.
55. Install one nut on each side (loosely) to retain bumper. Install and tighten all remaining bumper
nuts to specification.
56. With nylon ties, connect and secure wiring harness to fog/running lights.
57. Place grill into hood opening and tighten ten fasteners to secure.
58. Inspect for leaks with engine ON.
ENGINE BASE TIMING
Removal
1. Rotate crankshaft clockwise until "insert pin" mark on outside diameter of engine vibration
damper is aligned with mark on gear housing.
NOTE: See Fig. 12
2. Insert pin in hole in pin boss. Align Green band on timing pin with surface of timing pin boss
of block.
Fig. 32: Inserting Timing Pin In Hole In Pin Boss
CAUTION: Pin will not seat properly in crank notch if Green band is
either completely visible outside block, or completely
invisible.
3. Secure crankshaft in position with Timing Pin (3163020).

4. Remove rocker lever cover and gasket. See Rocker Lever Cover.
5. Disconnect and remove engine brake wiring harness.
6. Remove rocker lever shafts to remove load from camshafts. This will allow camshafts to be
rotated when installing timing wedges and camshaft gears are not installed.
7. Remove rocker lever shafts. See Rocker Lever Assembly.
8. Lower front cover does not require removal if setting gear backlash on engines that utilize all
non-scissor gears. There is an access hole to insert a shim between lower non-scissor idler gear
and adjustable idler gear. Access hole is sealed with a plug.
9. Push gear cover plug out from rear. Removal of lower gear cover is not necessary to push out
plug.
10. Remove upper gear cover. See Upper Gear Cover.
11. Remove lower gear cover, if required. See Lower Gear Cover.
Valve Camshaft Gear
1. Ensure injector camshaft scissor gear is unloaded during removal of valve camshaft gear. To
unload gear, Back out 2 of gear screws far enough to allow teeth on scissor gear to be aligned.
2. Unload injector camshaft scissor gear. Remove valve camshaft gear mounting bolt and washer.
3. Install Gear Puller (3163069).
NOTE: Earlier engines were not equipped with puller holes in valve
camshaft gear. Use a 3-jaw gear puller for gears that do not have
puller holes. Injector And Valve Gear Puller (3163069), can be
used for gears that have puller holes.
4. Install valve camshaft gear mounting bolt completely.

5. Loosen bolt 2 turns.
6. Using gear puller, remove valve camshaft gear from camshaft nose.
7. Remove puller.
8. DO NOT remove camshaft gear mounting bolt completely if 3-jaw puller is used.
NOTE: Bolt worked as a safety catch by preventing gear from shooting

off of camshaft nose.
9. Remove valve camshaft gear mounting bolt, valve camshaft gear.
Injector Camshaft Scissor Gear
CAUTION: Before removing injector camshaft gear or camshaft, remove rear

injector camshaft. Force required to remove camshaft gear
creates enough backwards movement of camshaft to crack rear
cover plate.
1. Remove injector camshaft rear cover plate.
NOTE: See Fig. 47
2. Remove injector camshaft scissor gear mounting bolt and washer.

4. Install injector camshaft scissor gear mounting bolt. Loosen bolt 1 turn.
5. Using gear puller, force injector camshaft scissor gear off camshaft taper.
6. Remove these items: gear puller, bolt and injector camshaft scissor gear.
Injector Camshaft Non-Scissor Gear
CAUTION: Before removing injector camshaft gear or camshaft, remove rear

injector camshaft. Force required to remove camshaft gear
creates enough backwards movement of camshaft to crack rear
cover plate.
1. Remove injector camshaft rear cover plate.
NOTE: See Fig. 47
2. Remove injector camshaft gear mounting bolt and washer.

4. Install injector camshaft gear mounting bolt and loosen bolt 1 turn.
5. Using gear puller, force injector camshaft gear off camshaft taper.
6. Remove these items: gear puller, bolt and injector camshaft gear.
Adjustable Idler Gear
1. Adjustable idler gear shaft may fall if adjustable idler gear is removed.
2. Remove retainer bolts, retainer, gear, and adjustable idler gear shaft.
3. Remove mounting spacer.
Lower Idler Scissor Gear
1. Unload lower idler scissor gear during removal. To unload gear, back out 2 of gear screws far
enough to allow teeth on scissor gear to be aligned.
2. Unload lower idler scissor gear and remove idler scissor gear bolts.
3. Remove retainer, gear, shaft, and thrust bearing.
Lower Idler Non-Scissor Gear
1. Remove idler non-scissor gear bolts and retainer.

2. Remove gear, shaft, and thrust bearing.
Inspect Condition
Inspect gear teeth on all gears for pitting, heavy wear, or breakage. Replace suspect gear and inspect
mating gear for resulting damage.
Inspect lower idler shaft and adjustable idler shaft for heavy wear.
Measure idler shafts outside diameter.
LOWER IDLER SHAFT OUTSIDE DIAMETER

Minimum 3.4992 (88.88)
Maximum 3.4997 (88.89)
ADJUSTABLE IDLER SHAFT OUTSIDE DIAMETER

Minimum 3.4992 (88.88)
Maximum 3.4997 (88.89)
Inspect lower idler gear bore and adjustable idler gear bore for heavy wear.
Measure inside diameter of lower idler and adjustable idler gear bores.
LOWER IDLER GEAR BORE INSIDE DIAMETER

Minimum 3.5024 (88.962)
Maximum 3.5035 (88.988)
ADJUSTABLE IDLER GEAR BORE INSIDE DIAMETER

Minimum 3.5024 (88.962)
Maximum 3.5035 (88.988)
Installation
1. Timing Wedges: located on engine dataplate.

l 1st number - injector wedge
l 2nd number - valve wedge.
Fig. 33: Identifying Timing Wedges
2. Ensure wedges with proper angles are used and wedges are properly seated in their installed
position.
Fig. 34: Camshaft Lobe Position & Timing Wedge
3. Insert correct timing wedge to lock injector camshaft. Using mallet, lightly tap top of timing
wedge to be sure it is properly seated.
4. Ensure wedges with proper angles are used and wedges are properly seated in their installed
position.
WARNING: DO NOT drive wedges into place, engine damage may

result.
5. Insert correct timing wedge to lock valve camshaft. Using mallet, lightly tap top of timing
wedge to be ensure it is properly seated.
Lower Idler Scissor Gear
1. Unload lower scissor idler gear during installation. To unload gear, back out 2 of gear screws
far enough to allow teeth on scissor gear to be aligned.
2. Apply Lubriplate to thrust bearing, shaft, and lower scissor idler gear.
3. Install thrust bearing, shaft, and lower scissor idler gear. Install shaft with word
"TOP" (stamped on end of shaft) toward top of engine.
4. Lower idler scissor gear front retainer plate is larger in diameter than adjustable idler retainer
plate. Slots in plate go toward scissor gear
5. Install retainer and bolts.
6. Tighten all bolts in a star pattern, see TORQUE SPECIFICATIONS.
7. Rotate each bolt an additional 60 degrees in similar order as above.
CAUTION: Tighten all scissor gear screws to proper torque to avoid

back out during engine operation and severe engine
damage.
8. Tighten all gear screws to load lower idler scissor. Torque to specifications.
Lower Idler Non-Scissor Gear
1. Apply Lubriplate to thrust bearing, shaft, and lower non-scissor idler gear.
2. Install thrust bearing, shaft, and lower non-scissor idler gear. Install shaft with word
"TOP" (stamped on end of shaft) toward top of engine.
3. Lower idler non-scissor gear front retainer plate is larger in diameter than adjustable idler
retainer plate. Slots in plate go toward scissor gear
4. Install retainer and bolts.
5. Tighten all bolts in a star pattern to specification
Spacer plate is doweled to block with 2 standard dowels. Install mounting spacer plate.
1. Apply Lubriplate to spacer, shaft, and adjustable idler gear.

2. Shaft may be installed in a different orientation, but setting gear backlash correctly is not
possible.
3. Install spacer, shaft and adjustable idler gear. Install shaft with word "TOP" (stamped on front
face of shaft) oriented toward top of engine.
4. Adjustable idler front retainer plate is smaller in diameter than lower idler scissor gear retainer
plate. Slots on retainer plate go toward gear.
5. Adjustable idler gear is installed loosely because it is moved into its final position later in
timing process.
6. Install retainer and bolts. Finger-tighten bolts and then loosen by 1 "flat," which is 60 degrees.
Install injector camshaft rear cover plate, see TORQUE SPECIFICATIONS.
NOTE: See Fig. 47
CAUTION: Before assembly, clean and dry injector camshaft nose and
injector camshaft scissor gear. Use lint-free cloth to clean taper
surface. DO NOT touch surfaces after wiping, engine damage may
occur.
Unload injector camshaft scissor gear during installation. To unload gear, back out 2 of gear screws
far enough to allow teeth on scissor gear to be aligned.
It is necessary to fully engage injector camshaft scissor gear on camshaft nose taper, however loose
enough so it can rotate on camshaft nose.
Install injector camshaft scissor gear loosely on camshaft nose taper. Injector camshaft scissor gear
mounting washer has larger diameter than valve camshaft mounting washer.
Install mounting washer and bolt.
Finger-tighten bolt and then loosen by 1 "flat," which is 60 degrees. Injector camshaft scissor gear is
still loose to allow adjustable idler gear to be positioned correctly.
NOTE: DO NOT seat gear.
CAUTION: Before assembly, clean and dry injector camshaft nose and
injector camshaft non-scissor gear. Use lint-free cloth to clean
taper surface. DO NOT touch surfaces after wiping, engine
damage may occur.
1. Install injector camshaft rear cover plate, see TORQUE SPECIFICATIONS.
NOTE: See Fig. 47
2. Install injector camshaft non-scissor gear loosely on camshaft nose taper. Injector camshaft
non-scissor gear mounting washer has larger diameter than valve camshaft mounting washer.
NOTE: It is necessary to fully engage injector camshaft non-scissor gear

on camshaft nose taper, however it should remain loose enough
so it can rotate on camshaft nose.
3. Install mounting washer and bolt.

4. Finger-tighten bolt and then loosen by 1 "flat," which is 60 degrees.
5. Injector camshaft non-scissor gear should still be loose to allow adjustable idler gear to be
positioned correctly.
Valve Camshaft Gear
CAUTION: Before assembly, clean and dry valve camshaft nose and valve
camshaft gear. Use lint-free cloth to clean shaft surface and gear.
DO NOT touch surfaces after wiping, engine damage may occur.
1. Loosely install valve camshaft gear on camshaft nose taper. Valve camshaft mounting washer
has smaller diameter than injector camshaft scissor gear mounting washer.
CAUTION: It is necessary to fully engage valve camshaft gear on

camshaft nose taper, yet should remain loose enough so it
can rotate on camshaft nose.
2. Install mounting washer and bolt.
CUMMINS - ISX - CM870/871 - MECHANICAL -2013 Volvo VNL - Series - VN... Стр. 100 из 174
3. Finger-tighten bolt and then loosen by 1 "flat" (60 degrees).

4. Valve camshaft gear is still loose to allow adjustable idler gear to be properly positioned.
Adjusting
Backlash (Non Gear Combinations)
CAUTION: Setting backlash between adjustable idler gear and lower scissor
idler gear may cause severe damage to engine.
NOTE: These backlash steps works with scissor type injector camshaft gear
and lower idler gear, and non-scissor injector camshaft gear with a
scissor type lower idler gear.
1. Ensure injector camshaft scissor gear is still unloaded. To unload gear, back out 2 of gear
screws far enough to allow teeth on scissor gear to be aligned.
2. Insert a narrow shim of 0.010 in (0.25 mm) into gear teeth mesh between adjustable idler gear
and wide (rear side) gear of injector camshaft scissor gear.
SHIM TOLERANCE
Minimum 0.009 (0.225)
Maximum 0.011 (0.275)
3. With hand pressure, turn adjustable idler gear toward center of engine (into mesh) so there is
no gap on either side of shim.
4. Both of camshaft gears will rotate slightly on camshafts during this step, while pulling shim in
and out, slight drag may be felt on shim.
Backlash (Non-Scissor Gear Combinations)
NOTE: Procedure of gear backlash set for engines with non-scissor injector
camshaft gear and a scissor type lower idler gear is similar that of
engines that use 2 scissor type gears.
CAUTION: DO NOT remove lower front cover when setting gear backlash on
engines that use all non-scissor gears. There is an access hole
(which is sealed with a plug) to insert a shim between lower non-
scissor idler gear and adjustable idler gear. Plug can be pushed
out from rear side without removal of gear cover.
1. Insert a shim of 0.010 in (0.25 mm) into gear teeth mesh between adjustable idler gear and
injector camshaft gear. Shim is inserted on load side of gear teeth.
2. Insert a shim of 0.010 in (0.25 mm) into gear teeth mesh between adjustable idler gear and
lower non-scissor idler gear. Shim is inserted on load side of gear teeth.
3. With hand pressure, turn adjustable idler gear so there is no gap between teeth and either side
of shims.
4. Both of camshaft gears will rotate slightly on camshafts during this step. While pulling shim in
and out, slight drag will be felt.
1. Tighten adjustable idler gear mounting bolts while holding adjustable idler gear in position.
See TORQUE SPECIFICATIONS.
2. Remove feeler gauge.
CAUTION: Tighten all scissor gear screws to proper torque to avoid back out
during engine operation and engine damage.
1. Tighten all gear screws to load injector camshaft scissor gear. See TORQUE
SPECIFICATIONS.
2. Valve camshaft gear will rotate slightly on valve camshaft during this step.
3. Tighten injector camshaft scissor gear retaining bolt. See TORQUE SPECIFICATIONS.
1. With hand pressure, rotate injector camshaft gear clockwise until gear train backlash is
removed. Tooth-to-tooth contact between crankshaft gear and injector camshaft gear must be
obtained.
2. Tighten injector camshaft non-scissor gear retaining bolt. See TORQUE SPECIFICATIONS.
Valve Camshaft Scissor Gear
Tighten valve camshaft scissor gear retaining bolt. See TORQUE SPECIFICATIONS.
Valve Camshaft Non-Scissor Gear
1. With hand pressure, rotate valve camshaft gear counterclockwise until backlash between
injector camshaft gear is removed. Tooth-to-tooth contact between injector camshaft gear and
valve camshaft gear must be obtained.
2. Tighten valve camshaft non-scissor gear retaining bolt. See TORQUE SPECIFICATIONS.
3. Lubricate entire gear train with clean 15W-40 oil.
4. Lubricate lower idler gear and crankshaft using access hole in lower gear cover.
Final Installation
1. Remove injector and valve camshaft timing wedges. Removing wedges with a sudden jerking
motion upwards is an effective method to remove.
NOTE: See Fig. 34.
2. Remove timing pin.
NOTE: See Fig. 32.
3. Install upper gear cover. See Upper Gear Cover.

4. Install lower gear cover. See Lower Gear Cover.
5. Install rocker lever shafts. See Rocker Lever Assembly.
6. Install and connect engine brake wiring harness.
7. Install rocker lever cover and gasket. See Rocker Lever Cover.
8. If coolant, oil, excessive fuel, or excessive black smoke, enter into exhaust system, inspect
aftertreatment system. See AFTERTREATMENT SYSTEM .
ENGINE LIFTING BRACKETS
Removal
NOTE: 3 mounting bolts are used in recent models.
1. Remove retaining brace bracket.

2. Remove 4 bolts and rear lifting bracket. Remove 4 bolts and front lifting bracket.
Fig. 35: Lifting Bracket Bolts
WARNING: Adhere to manufacturer's recommendations for using solvents,

acids, or alkaline materials. Also wear safety equipments like
goggles and clothing to avoid injury.
WARNING: Wear safety glasses or a face shield and protective clothing for
protection from hot steam of steam cleaner.
WARNING: To avoid damage from flying debris and dirt while using
compressed air, protect eyes and face.
1. Clean with steam or solvent and dry with compressed air.

2. Replace lifting brackets if they are cracked or damaged.
3. Replace bolt threads if they are damaged.
Installation
1. Install front bracket and 4 bolts.

2. Install rear bracket and 4 bolts.
NOTE: See Fig. 35
4. Install retaining brace bracket.
FLYWHEEL
Removal

prevent arcing.
WARNING: Approximate weight of this component is 50 lb (23 kg). Use hoist

or assistance for lifting this component to avoid injuries.
1. Disconnect batteries or air starter to prevent accidental start of engine.

2. Remove transmission, clutch, and all related components.
3. Use 2 M16 x 1.5 guide studs to prevent rotation of flywheel. Use a 21 mm Impact Socket
(3162813) to remove 2 bolts and install guide studs.
4. Use a hoist, 2 t-handles, and a lifting sling. Install tee-handles. Remove remaining 10 bolts and
flywheel.
5. Tap flywheel from crankshaft with a soft faced mallet, if necessary. DO NOT use a hard faced
hammer to prevent damage to clutch surface.
6. Remove and inspect pilot bearing spacer from rear of crankshaft. Replace if damaged.
7. Remove pilot bearing from flywheel using a mandrel and hammer.

1. Use a wire brush to clean crankshaft pilot bore and flywheel pilot bore clean with steam or
solvent and dry with compressed air.
2. If nicks or burrs are present remove them with fine crocus cloth.
WARNING: Use of a cracked or resurfaced flywheel can cause serious

injury or property damage when it breaks.
3. Inspect cracks in flywheel using Crack Detection Kit (3375432). Follow instructions provided
with kit.
4. Inspect flywheel ring gear teeth for cracks and chips.
5. Replace ring gear if ring gear teeth are cracked or broken. See Flywheel Ring Gear.
Installation

prevent arcing.
1. Install pilot bearing spacer into rear of crankshaft.
CAUTION: Flywheel mounting bolts must be at least SAE Grade 8 with

rolled threads. To avoid possible flywheel failure and
personal injury or property damage use identical
replacements.
2. Use clean 15W-40 oil to lubricate threads and underneath heads of bolts. Allow excess oil to
drain off parts. DO NOT lubricate threads of crankshaft.
WARNING: Approximate weight of this component is 50 lb (23 kg). Use

hoist or assistance for lifting this component to avoid
injuries.
3. Use 2 M16 x 1.5 guide studs during assembly.

4. Install flywheel firmly against crankshaft.
5. Use a 21 mm Impact Socket to install 10 bolts.
6. Remove t-handles and guide studs.

7. Install remaining two bolts into holes from which guide studs were removed.
8. Tighten bolts in two steps using sequence in Fig. 36. See TORQUE SPECIFICATIONS.
Fig. 36: Flywheel Bolt Torque Sequence
9. Install pilot bearing using a mandrel and hammer. Install it flush with pilot bore surface.
Fig. 37: Installing Pilot Bearing
10. Perform bore runout inspection and face runout inspection given in this procedure.
11. Install clutch discs, pressure plate, transmission, and driveline (if equipped) in reverse order of
removal.
12. Align universal joints on each end of driveshaft to prevent vibration.
13. Connect batteries and air starter.
14. Operate engine to inspect operation of equipment.
FLYWHEEL HOUSING
Removal

prevent arcing.


WARNING: DO NOT allow hot oil to touch skin, it can cause injury.
WARNING: Support engine properly to prevent damage and injury.
1. To prevent accidental engine starting disconnect batteries and air starter.

3. Remove flywheel. See Flywheel.
4. Drain oil.
5. Remove oil pan. See ENGINE OIL PAN .
6. Remove rear crankshaft seal. See Rear Crankshaft Seal.
7. Remove starting motor.
8. Remove rear engine mounts from flywheel housing.
9. Remove 2 top exterior bolts from flywheel housing.
10. Install 2 guide studs.

injuries.
11. Use a hoist and lifting sling. Install sling around both sides of upper housing and adjust hoist
until there is tension in lifting sling. Remove remaining bolts.
12. Tap flywheel housing off 2 locating dowels using a mallet.
13. Remove 2 bolts, cover plate, and gasket. Dispose of gasket.
CAUTION: Insert a plug into cylinder block oil passages immediately

after removing flywheel housing assembly to avoid bearing
failure, crankshaft failure, or both.
14. Reusable Plug (4918321), is provided in Protective Plug Kit (4918319). Use this plug to
prevent entry of debris in lubrication system during repair.
15. Plug block oil passage with Plug (4918321).
16. Firmly push plug in oil passage to prevent entry of debris in lubricating system when cleaning
gasket surface.
CAUTION: While cleaning gasket sealing surfaces dirt or foreign material

must not enter oil passages in cylinder block else main or
connecting rod bearing failures can occur. DO NOT use power
tools with abrasive pads to clean gasket surfaces.

WARNING: Wear appropriate eye and face protection when using

compressed air. Flying debris and dirt can cause bodily injury.
1. Hand clean gasket surfaces using a gasket scraper or Cleaning Pad (3823258).
2. If residual gasket material can not be felt with a finger, NEW gasket can be installed on
surface.
3. Use steam or solvent to clean housing and dry with compressed air.
4. Remove nicks, burrs, or cracks with a fine crocus cloth.
5. Repair or replace housing if threaded bolt holes are damaged.
Installation

prevent arcing.

1. Remove protective plug from block oil passages. DO NOT allow debris in lubrication system.
2. Carefully wipe oil passage with a clean shop towel and ensure there is no debris in passage.
3. Install cover plate and 2 bolts. Tighten bolts, see TORQUE SPECIFICATIONS.
4. Install 2 guide studs in cylinder block to support and align housing during installation.
5. Place flywheel housing gasket at rear of engine block using guide pins.
6. Install flywheel housing on guide studs.
7. Use clean 15W-40 engine oil to lubricate threads and underneath heads of bolts.
8. Install bolts 1, 2, 3, and 4, and tighten in sequence to 62 In. Lbs (7 N.m).
NOTE: See Fig. 38
Fig. 38: Installing Flywheel Housing Over Guide Studs
9. Flywheel housing can be found on block by 2 ring dowels from factory. If removed, reinstall
flywheel housing with ring dowels in place. Inspect alignment using following alignment
procedure.
10. If alignment is out specification, remove ring dowels and realign housing without ring dowels.
CAUTION: To avoid damage to engine, clutch, or transmission ensure

flywheel housing bore and surface are aligned with
crankshaft.
11. If installing without measuring, go to 13

12. Measure flywheel housing alignment. Go to Flywheel Housing-Measure before continuing
installation.
13. Install remaining bolts and tighten in 2 steps following torque sequence in Fig. 39. See
TORQUE SPECIFICATIONS.
Fig. 39: Flywheel Housing Torque Sequence
14. Install rear engine mounts on flywheel housing.

15. Install starting motor bolts, starter, and spacer.
16. Install rear crankshaft seal. See Rear Crankshaft Seal.
17. Install oil pan. See ENGINE OIL PAN .
18. Fill engine oil.
19. Install flywheel. See Flywheel.
20. Install transmission, clutch, and all related components.
21. Connect batteries and air starter.
Measure
Face Alignment
CAUTION: DO NOT let dial indicator tip enter bolt holes or gauge will be
damaged.
Install a dial indicator.
Extension bar for indicator must be rigid for an accurate reading. Position indicator at 12 o'clock
position and adjust dial until needle points to 0.
Slowly rotate crankshaft. Record readings at 3 o'clock, 6 o'clock, and 9 o'clock positions.
Crankshaft must be pushed toward front of engine to remove crankshaft end clearance whenever a
position is measured.
Rotate crankshaft until indicator is at 12 o'clock position. Ensure that needle points to 0. If it does
not, readings will be incorrect.
Determine total indicator runout.
FLYWHEEL RUNOUT SPECIFICATION

Total Indicator Runout (Example)
Position Runout
12 o'clock 0.000 in. (0.00 mm)
3 o'clock + 0.003 in. (+ 0.08 mm)
6 o'clock -0.002 in. (-0.05 mm)
9 o'clock + 0.003 in. (+ 0.08 mm)
Total Indicator Runout = 0.005 in. (0.13 mm)
Diameter of housing bore determines maximum allowable total indicator reading. Replace housing if
out of specifications.
BORE DIAMETER
Total Indicator Runout
SAE Number Bore Diameter
Maximum
00 30.88-31.00 in. (787.40-787.65 0.012 in. (0.30 mm)
mm)
0 25.50-25.51 in. (647.70-647.95 0.010 in. (0.25 mm)
mm)
1/2 23.000-23.008 in. (584.2-584.4 0.010 in. (0.25 mm)
mm)
1 20.125-20.130 in. (511.18- 0.008 in. (0.20 mm)
511.30 mm)
2 17.652-17.630 in. (447.68- 0.008 in. (0.20 mm)
447.80 mm)
3 16.125-16.130 in. (409.58- 0.008 in. (0.20 mm)
409.70 mm)
FLYWHEEL HOUSING - REPTO
Removal

prevent arcing.

WARNING: DO NOT allow hot oil to touch skin, it can cause injury.
1. Disconnect batteries or air supply to starter to prevent accidental engine starting.

2. Drain engine oil.
4. Remove 3 flywheel bolts equally spaced from flywheel. Install 3 Guide Pins (3164765),
through
5. Use a hoist, 2 T-handles, and a lifting sling. Install T-handles into holes of flywheel. Remove
remaining 10 bolts and remove flywheel. Tap flywheel from crankshaft gear with a mallet, if
necessary.

injuries. Ensure proper ventilation before servicing
batteries. Remove negative (-) battery cable first and
connect it last to prevent arcing.
6. Disconnect battery cables before doing following.

injuries.
7. Remove starting motor bolts, starter, and spacer.

8. Remove 3 bolts from rear of oil pan.

injuries.
9. Remove 10 10-mm bolts from hydraulic housing. Remove hydraulic housing from REPTO
flywheel housing.
10. Remove spray nozzle from oil supply line hole.
11. Remove 12 bolts from seal carrier. Remove seal carrier from REPTO flywheel housing.
12. Remove oil seal and dispose of, see Rear Crankshaft Seal.
13. Remove "O" ring from groove on REPTO flywheel housing.
14. Remove 4 plugs and "O" rings from REPTO flywheel housing.
15. Remove crankshaft gear. Remove idler gear shaft bolt and washer. Remove 3 guide pins.
16. Use a slide hammer similar to Snap-On (CJ114) if idler gear shaft can not be removed with
handle.
17. Place Replacer Idler Plate (3164762), on idler gear shaft. Install and tighten 2 idler gear bolts.
Install Handle (3163089) and tighten to 10 Ft Lbs (14 N.m).
18. Remove idler shaft, idler gear, and bearing from REPTO flywheel housing.
19. Remove 2 bolts from REPTO flywheel housing then install 2 Guide Pins (3164764).
20. Install 2 Eye Bolts (3164767), on top of REPTO flywheel housing. Install lifting slings to
eyehooks. Adjust hoist to remove tension in lifting sling.
21. Remove remaining bolts.

injuries.
22. Tap REPTO flywheel housing off 2 locating dowels with a mallet. Remove and dispose of
gasket.

1. Use steam or solvent to clean REPTO flywheel housing and dry with compressed air.
2. Remove small nicks and burrs with crocus cloth.
3. Repair or replace housing if threaded bolt holes are damaged.
4. Replace idler shaft, bearing, and gear if it shows nicks, burrs, or cracks.
5. Inspect 4 "O" rings from plugs and 1 large "O" ring from REPTO flywheel housing for cuts or
tears. Replace "O" rings if damaged.
Installation
1. Install 2 Guide Pins (3164764) in cylinder block.

2. Use guide pins to place flywheel housing gasket to rear of cylinder block.

injuries.
3. Install 2 eyehooks in top of REPTO flywheel housing. Install lifting slings to eyehooks and
push REPTO flywheel housing onto 2 guides pins.
4. Install 6 short bolts and 4 long bolts in indicated places.
5. Remove 2 guide pins and install 2 other long bolts.
6. Tighten housing to block in following sequence.
7. Tighten 4 equally spaced bolts to initial torque value of 62 In. Lbs (7 N.m).
8. Tighten remaining bolts.
CAUTION: Ensure REPTO flywheel housing bore and face are in

alignment with crankshaft or engine, clutch, or transmission
will become damaged. Measure REPTO flywheel housing
alignment.
9. See Flywheel Housing.

10. Install 3 oil pan bolts.
11. Install large "O" ring seal and small "O" ring seal on idler shaft.
12. Assemble Replacer Idler Shaft Plate and handle together.
13. Install 2 bolts in idler shaft holes and tighten to 10 Ft. Lbs (14 N.m).
14. Lubricate idler shaft with clean 15W-40 oil.
15. 2 cones are loose and can fall out if not contained. Before inserting assemblies through center
or sides of REPTO flywheel housing openings ensure gear, 2 bearing snap rings, and 2 cups
are pressed in place.

16. Lubricate bearing snap rings, cones, cups, idler shaft, and gear with clean 15W-40 oil.
17. Idler shaft plug must face upward during installation in bore.
18. Install gear and bearing assembly through center or sides of REPTO flywheel housing holes.
Position bearing races together and insert idler shaft with tool through first bear bore. Running
clearance must be 0-0.001 in. (0-0.025 mm).
19. Idler shaft must be in proper alignment and must be seated against shoulder of internal bore.
20. Repeat procedure to install second gear (if applicable).
21. Remove 2 bolts, replacer idler plate, and handle from idler shaft. Lubricate threads and under
bolt head with clean 15W-40 oil.
22. Install washer and bolt and tighten bolt to 74 Ft. Lbs (100 N.m).
23. 2nd idler gear can be installed or an insert shaft can be used without idler gear and roller.
24. Install "O" rings on insert shaft and lubricate them with clean 15W-40 oil. Install insert shaft
into flywheel housing hole where cover plate will be installed (opposite pump location). Align
hole with tapped hole in block.
25. Lubricate threads and under bolt head with clean 15W-40 oil. Install washer and bolt and
tighten them to 74 Ft. Lbs (100 N.m).
26. Install 3 guide pins (3164765), equally spaced through crankshaft gear and in crankshaft.
27. If required, rotate idler gears to mesh crankshaft gear with idler gear(s). Then install crankshaft
gear.
28. "O" rings must be properly seated in groove before installation. Lubricate them with clean
15W-40 oil.
29. Install 4 plugs with "O" rings into REPTO flywheel housing holes and torque to 21 Ft Lbs (28
N.m).
30. Install "O" ring in REPTO flywheel housing groove. Install seal carrier (3101789) on 2 dowels
pins on REPTO flywheel housing.
31. Install 12 bolts and tighten seal carrier. Tighten bolts in a star pattern to 21 Ft. Lbs (28 N.m).
32. Install 3 flywheel mounting bolts and spacers. Tighten flywheel mounting bolts to 45 Ft. Lbs
(60 N.m).
33. Remove 3 flywheel mounting bolts and spacers.
CAUTION: Ensure rear crankshaft seal is pressed evenly into bore to

avoid damage to equipment from oil seal.
34. Install rear crankshaft oil seal on rear crankshaft seal replacer (3164780), and on 3 guide pins.
Install 3 flywheel mounting bolts (without washers) through 3 holes in rear crankshaft seal
replacer.
CAUTION: DO NOT install rear crankshaft oil seal using a hammer or

mallet.
35. DO NOT use lubricants during installation process. Apply a 10% soap solution to outer ribbed
surface of rear crankshaft oil seal.
36. Tighten flywheel mounting bolts a 1/2 revolution at a time. Alternate bolts in a clockwise
pattern, until rear crankshaft seal replacer (3164780) seats against REPTO flywheel housing.
Tighten to 15 Ft. Lbs (20 N.m).
NOTE: Flywheel housings use 2 guide pins; REPTO application use 3

guide pins.
37. Remove rear crankshaft seal replacer and 3 flywheel mounting bolts and install flywheel. See
Flywheel.
NOTE: Cover opening along with oil supply line hole and block straight
thread plug hole if one side of REPTO flywheel housing cover
access hole does not get a hydraulic housing.
38. Install 1/8 inch pipe plug in oil supply line hole. Pipe plug must be flush with mounting
surface. See TORQUE SPECIFICATIONS.
39. Install straight thread plug in flywheel housing hole. Pipe plug must be flush with mounting
surface. See TORQUE SPECIFICATIONS.
40. Install diamond seal on REPTO flywheel housing cover access hole.
41. Apply a small amount of RTV on both ends where diamond seal comes together and a small
amount of 15W-40 oil on diamond seal.
42. Install cover plate to REPTO flywheel housing cover access hole. Install 10 bolts and tighten to
48 Ft. Lbs (65 N.m)
43. Idler gear must be locked in position. Inspect backlash using a dial gauge.
IDLER GEAR BACKLASH

Minimum 0.006 (0.15)
Maximum 0.011 (0.28)
44. Replace idler gear and/or REPTO hub gear if backlash is out of specifications.
NOTE: Install spray nozzle, dowel pins, and diamond seal when one side
of REPTO flywheel housing cover access hole receives a
hydraulic housing.
45. Install spray nozzle in oil supply line hole. Tighten spray nozzle to 15 Ft. Lbs (20 N.m).
46. Install diamond seal on REPTO flywheel housing cover access hole.
47. Apply a small amount of RTV on both ends where diamond seal comes together and a small
amount of clean 15W-40 oil on diamond seal.
48. Apply clean 15W-40 oil on gear teeth and bearings. Install hydraulic housing on dowel pins.
Gear inside hydraulic housing must rotate freely to locate position of idler gear while hydraulic
housing is being installed on dowel pins.
49. Install 10 bolts and tighten evenly to 50 Ft. Lbs (65 N.m).
50. Install threaded plug in bottom hole of hydraulic housing. Tighten threaded plug to 25 Ft. Lbs
(32 N.m).
51. Install oil line hose on straight connectors. Tighten hose to 25 Ft. Lbs (32 N.m). Inspect for
leaks.

injuries.
52. Install starting motor bolts, starter, and spacer.

53. Add clean oil to engine.
54. Install transmission, clutch, and all related components.
FLYWHEEL RING GEAR
Removal
CAUTION: Flywheel can get damaged if a cutting torch is used to heat ring
gear.
Use a heating torch to heat outside of ring gear and use a blunt chisel and hammer to remove gear
from flywheel.
Installation
WARNING: Wear protective gloves to handle heated parts.
NOTE: DO NOT overheat ring gear or hardness of metal will be compromised.
1. Heat NEW ring gear in pre heated oven to 600° F (316° C) for at least 1-hour.
2. Remove gear from oven and install it on flywheel before it cools.
NOTE: A heating torch can also be used to heat inside diameter of NEW ring
gear to 600° F (316° C). Inspect gear temperature before installing it on
flywheel.
FRONT CRANKSHAFT GEAR-CRANKSHAFT INSTALLED
On-Engine Repair
Removal
CAUTION: Protect engine internals from debris generated during drilling

operation. Cover engine internals with tape, plugs, and or shields
to prevent debris into engine internals and avoid engine damage.

NOTE: Tools used for this repair are contained in Crankshaft Adapter and
Gear Removal Kit (4918530)
1. Disconnect battery.
2. Remove lower gear cover. See Lower Gear Cover.
3. Remove crankshaft adapter. See Crankshaft Adapter.
4. Remove tone wheel. See Crankshaft Tone Wheel.
5. Remove alignment dowel pin.
9. Disconnect and remove engine brake wiring harness.
10. Remove rocker lever shaft. See Rocker Lever Assembly.
12. Remove valve camshaft gear, injector camshaft gear, adjustable idler gear, and lower idler
gear. See Engine Base Timing.
13. Install Plastic Drill Guide (4918547), with "FRONT" facing operator. Align slot with
crankshaft gear tooth root.
14. Install Stop Collar (4918541) or equivalent, onto a 0.250 In (6.35 mm) drill bit at a depth of
4.375 in (111 mm).
15. If drill bit does not break through back of crankshaft gear, tool life will be improved. Use
generous amount of cutting fluid to prolong tool life and for easy drilling operation
16. Drill a 0.250 in (6.35 mm) pilot hole to preset depth.
17. Clean out debris using low pressure air and a shop towel to cover hole as required.
18. Install large Drill Guide Adapter (4918276), onto crankshaft nose with hole labeled "C"
aligned with pilot hole.
19. Align guide with hole using Alignment Pin (4918577). Tighten 5/16 in (7.94 mm) set screw to
hold guide to crankshaft.
20. Install Countersink Cutter (4918578) or equivalent, into a 4 In (102 mm) Extension or
equivalent.
21. Slide 29/64 in (11.5 mm) Drill Bushing (4918534) or equivalent, onto shaft.
22. Install assembly and lock 29/64 in (11.5 mm) drill bushing into hole labeled "C".
23. Countersink pilot hole until outside diameter of countersink is about 1/16-1/8 in (1.6-3.2 mm)
deep.
24. Clean out debris using low pressure air and a shop towel to cover hole as required. Remove
countersink and drill bushing.
25. Insert Drill Bushing (4918539), or equivalent, into hole labeled "C" and lock 1/2 in (12.7 mm)
drill bushing into drill guide.
26. Use generous amount of cutting fluid to increase tool life and for easy drilling operation.
27. Drill a 1/2 in (12.7 mm) hole to depth of previously 1/4 in (6.35 mm) drilled hole.
28. Clean out debris using low pressure air and a shop towel to cover hole as required.
29. Remove tone wheel alignment dowel from crankshaft.
30. Install Locating Gauge (4918314), or other suitable spacer, onto crankshaft gear. Installation of
spacer is necessary to avoid damage of crankshaft during crankshaft gear removal.
31. Insert small Splitting Wedge (4918545), with flatted area facing toward crankshaft and into
drilled hole.
32. Strike small splitting wedge using proper hammer until crankshaft gear splits. Use proper
puller if necessary or remove crankshaft gear by hand.

NOTE: After polishing crankshaft with a crocus cloth if scratches or nicks still
felt with a fingernail, replace crankshaft.
Inspect crankshaft for damage and inspect machined surface for scratches or nicks.
Installation
1. Install Locating Gauge (4918314), onto side of crankshaft gear.
2. Heat crankshaft gear for 3 hours at 350° F (177° C) before installation.
WARNING: Handle heated parts by wearing protective gloves to

prevent personal injury.
NOTE: Install crankshaft gear within 15 seconds when removed from

oven.
3. Install crankshaft gear until locating gauges contacts front crankshaft journal.
4. Hold crankshaft gear in position for nearly 60 seconds. This will allow shrink fit to properly
hold components.
5. Remove locating gauge from crankshaft gear.
6. Use a brass hammer, tap alignment dowel pin in crankshaft hole until it bottoms out.
7. Insert Locating Gauge (4918314), to inspect gap between crankshaft gear and crankshaft first
journal. Replace gear if locating gauge is loose or hard to insert.
8. Install valve camshaft gear, injector camshaft gear, adjustable idler gear, and lower idler gear.
See Engine Base Timing.
10. Install rocker lever shaft. See Rocker Lever Assembly.
11. Connect engine brake wiring harness.
15. Install tone wheel. See Crankshaft Tone Wheel.
16. Install crankshaft adapter. See Crankshaft Adapter.
17. Install lower gear cover. See Lower Gear Cover.
18. Connect battery.

FRONT CRANKSHAFT SEAL
Removal
1. Remove accessory drive belts.

2. Remove fan and water pump belt tensioner.
3. Remove crankshaft pulley and vibration damper(s). See Viscous Vibration Damper.
4. Remove 8 mounting nuts from gear cover studs.
Fig. 40: Front Crankshaft Seal
5. Position replacer plate over crankshaft end and against crankshaft seal. Large notch between
teeth requires to bridge raised gear cover surface.
6. Ensure alignment of 3 welded nuts on crankshaft seal are positioned into counterbore slots of
replacer plate.
7. Install a bolt with a flat washer in upper slot of replacer plate to secure in position.
Fig. 41: Crankshaft Seal Tool
CAUTION: Hand tighten bolts until a slight resistance is felt.

Overtightening can break off seal nuts causing damage to
seal which result in front cover damage.
8. Using small allen wrench, thread removal tool bolts through replacer plate and into seal nuts.
9. Tighten socket head bolts clockwise into 3 seal removal nuts that are welded on crankshaft seal
until a slight resistance is felt.
10. Remove bolt in upper slot of replacer plate.
11. Install replacer screw into replacer plate.
12. Turn screw clockwise until crankshaft seal is removed from crankshaft.
Remove any metal shavings with small magnet. Remove any deposits from crankshaft and seal bore
area with crocus cloth.
Inspect crankshaft for nicks, burrs, and grooves. Damage to sealing surface can result in seal leakage.
Replace crankshaft if nick/burr/groove felt with fingernail.
Installation
NOTE: When NEW crankshaft seal is installed on a gear cover with a seal "O"
ring groove, replace lower gear cover.
1. To determine position of front crankshaft seal on crankshaft, determine position of lower gear
cover.
2. Lower gear cover is mounted to gear cover housing using clearance holes to allow for slight
movement of cover if mounting bolts are loose.
3. Center unitized crankshaft seal on crankshaft for correct operation.
4. Install seal that connects to lower gear cover with lower gear cover bolts loose and cover free
to move.
5. To center seal properly on crankshaft during assembly and maintain its location during
operation, use following installation instructions:
6. Crankshaft seal removal and installation tool correctly centers seal and correctly positions dust
seal portion of seal on crankshaft.
CAUTION: Loosen and remove mounting bolts from gear cover

properly or front crankshaft seal can misaligned and cause
premature seal wear.
7. Align front gear cover as follows:

A. Remove gear cover mounting bolts around crankshaft seal to allow replacer plate to set
against gear cover during seal installation.
B. Loosen remaining mounting bolts on gear cover so it can move freely.
CAUTION: Follow installation and tightening sequence or

crankshaft seal being off center and installed at wrong
depth causing earlier seal wear.
CAUTION: Installing seal using hammer or mallet can damage

crankshaft seal and/or crankshaft.
8. Seal removal and installation tool has provisions for any seal nut orientation, however 1 seal
nut should always be at 11 o'clock position.

9. Prohibit use of lubricants on crankshaft seal and position it onto crankshaft until gear cover
studs are projecting through seal carrier mounting holes.
10. Position replacer against crankshaft seal.
11. Ensure welded nuts on front crankshaft seal are seated in their respective slots on replacer
plate.
12. Large notch between teeth should bridge raised gear cover surface.
13. Install 3 washers and bolts through 3 slots in replacer plate and into crankshaft end.
14. Ensure bolts in replacer plate are equally spaced, which allow proper installation of crankshaft
seal.
15. Hand tighten bolts.
16. Inspect crankshaft seal during installation to ensure it is pressed evenly.
CAUTION: Press crankshaft seal evenly or seal can damage.
17. Tighten Seal Installer bolt(s) 1/2 of a revolution at a time, alternating in a clockwise pattern
until replacer plate bottoms out against face of lower gear cover. See TORQUE
SPECIFICATIONS.
18. To maintain cover position with replacer plate removed, tighten 2 gear cover mounting bolts as
indicated by arrows in graphic.
19. Install crankshaft seal mounting nuts through holes provided in replacer plate.
20. Tighten mounting nuts, see TORQUE SPECIFICATIONS.
NOTE: See Fig. 44.
21. Remove replacer plate.

22. Install all gear cover mounting bolts.
23. Follow torque sequence to prevent gear cover strip seal from squeezing out of groove, see Fig.
44.
25. Install crankshaft pulley and vibration damper(s). See Viscous Vibration Damper.
26. Install fan and water pump belt tensioner. See
27. Install accessory drive belts.
FRONT ENGINE SUPPORT BRACKET

Removal
1. Use a hoist or lifting fixture to support front of engine.

2. Remove fan and water pump drive belt. See
3. Remove fan and water pump belt tensioner if a low mount tensioner is used.
4. Remove vibration damper and crankshaft pulley. See Viscous Vibration Damper.
5. Remove 2 bolts connecting support to equipment frame.
6. Lift weight of engine off front support with hoist.
7. Remove 6 mounting bolts and front engine support.
8. Remove rubber engine mounts.

1. Clean parts with steam or solvent and dry parts with compressed air.
2. Inspect engine mounts for cracks or deterioration.
3. Inspect engine support bracket for cracks or damage.
4. Inspect bolt threads for damage.
Installation
1. Install engine support bracket and 6 mounting bolts.

3. Install rubber engine mounts into crossmember.

injuries.
4. Lower front of engine to rubber engine mounts.

5. Ensure bolt holes in support bracket are aligned with bolt holes in engine mounts.
6. Install 2 bolts in support bracket and engine mount. Tighten bolts.
7. Remove lifting fixture or hoist from engine.
8. Install vibration damper and crankshaft pulley. See Viscous Vibration Damper.
9. Install fan and water pump drive belt tensioner.
FRONT GEAR HOUSING
WARNING: Keep coolant away from children and pets as it is poisonous.

Dispose of as per local environmental regulations when not
reused.
Removal
1. Before removing gears, read Engine Base Timing. See Engine Base Timing.
2. Remove water pump drive belt.
4. Remove fan hub assembly.
5. Remove alternator.
6. Drain coolant.
7. Remove crankcase breather tube. See Crankcase Breather-External.
8. Remove upper and lower gear covers. See Upper Gear Cover and Lower Gear Cover.
9. Remove water pump. See WATER PUMP .
10. Remove valve and injector camshaft scissor gear. See Engine Base Timing.
11. Remove adjustable idler gear. See Engine Base Timing.
12. Remove air compressor. See Air Compressor.
13. Remove lower idler scissor gear. See Engine Base Timing.
14. Remove crankshaft position sensor and bolts from front of oil pan.
15. Remove retaining brace bracket. See Retaining Brace Bracket.
16. Remove accessory bracket. See Accessory Bracket.
17. Remove 2 bolts and install 2 guides.

18. Remove remaining 18 bolts and remove housing and gasket.

19. Dispose of gasket. Remove guide studs.
CAUTION: Insert plug into cylinder block oil passage drilling

immediately after removal of front gear housing. Failure to
do so oil can cause bearing failure, crankshaft failure, or
both.
20. Reusable Plug (4918320), is included in protective Plug Kit (4918319), which prevents debris
to enter lubrication system during repair.
21. Insert plug into front oil passage and push firmly to prevent all debris from entering lubrication
system when cleaning gasket surface.

CAUTION: Crankshaft failure can occur if oil passages are plugged before
cleaning.
Clean gasket surfaces by hand with a gasket scraper or Cleaning Pad (3823258). If gasket material
residue can not be felt with a finger, surface is okay for NEW gasket.
Clean gear housing with steam or solvent and dry with compressed air.
Using compressed air, clear oil galley to air compressor and oil pump of any obstructions.
Inspect gear housing for cracks or other damage.
Inspect seal grooves of housing for debris or damage.
Installation
1. Remove protective plug from cylinder block oil passage.

2. Ensure lubrication system has no debris.
3. Using clean shop towel, clear out oil passage and ensure no debris remains in passages.
4. Install 2 guide studs.
5. Install NEW gear housing mounting gasket.
6. Gear housing has words "Special Bolt" cast into housing at No. 1 mounting location, see Fig.
42. This bolt should be short head to prevent contact between bolt and idler gear.
Fig. 42: "Special Bolt" Mounting Location
7. Install gear housing.

8. Install 18 mounting bolts.

9. Front gear housing uses 4 different length bolts. Following table identifies bolts and their
mounting locations.
BOLT MOUNTING SPECIFICATION

Bolt Mounting Location
Location Size Quantity
14 M10 x 1.5 x 93 1
18, 19, 20 M10 x 1.5 x 70 3
1 M10 x 1.5 x 21.8 (Special Short Head) 1
All remaining M10 x 1.5 x 2.5 15
10. Remove guide studs and install 2 bolts.

11. Tighten bolts in correct sequence. See TORQUE SPECIFICATIONS.
Fig. 43: Front Gear Housing Bolt Torque Sequence
12. Install accessory bracket. See Accessory Bracket.

13. Install retaining brace bracket. See Retaining Brace Bracket.
14. Install crankshaft position sensor. Install bolts at front of oil pan.
15. Install lower idler scissor gear. See Engine Base Timing.
16. Install air compressor. See Air Compressor.
17. Install adjustable idler gear. See Engine Base Timing.
18. Install valve and injector camshaft scissor gear. See Engine Base Timing.
19. Install water pump. See WATER PUMP .
20. Install upper and lower gear covers. See Upper Gear Cover and Lower Gear Cover.
21. Install crankcase breather tube. See Crankcase Breather-External.
22. Fill coolant system.
23. Install alternator.
24. Install fan hub assembly.

26. Install water pump drive belt.
WARNING: To avoid personal injury from hot coolant, remove pressure

cap when coolant temperature is less than 120° F (50° C).
LOWER GEAR COVER
Removal
1. Twist oil filler connector counterclockwise and remove. See Fig. 13.
4. Remove crankshaft pulley and vibration damper(s). See Crankshaft Pulley.
5. Remove front crankshaft seal. See Front Crankshaft Seal.
NOTE: If gear cover has an "O" ring seal groove for crank seal and seal
requires replacement, replace lower gear cover also. NEW crank
seal has "O" ring included into seal.
6. Remove 15 bolts and lower gear cover. Dispose of strip seal.

1. Clean sealing surface on rear face of lower gear cover and seal groove on gear housing.
2. Use steam or solvent to clean lower gear cover and dry with compressed air.
3. Inspect lower gear cover for cracks or damage. Replace if cover is cracked.
4. If gear cover included an "O" ring groove for crank seal and cover is to be replaced, replace
crank seal also.
5. Inspect studs for damage, replace cover if studs are damaged.
6. Position lower gear cover on a flat surface and inspect it for flatness.
7. It is okay to use mallet to straighten a lower gear cover with minor bends.
8. Remove minor bends by laying gear cover on a flat surface and hit upper gear, if required.
Installation
1. Install a NEW strip seal. Adjust overlap joint to upper left of gear housing shown below.
2. Use a small quantity of RTV at overlap joint of strip seal.
3. Position lower gear cover with 15 bolts. Hand-tighten bolts.
NOTE: Installation of NEW crankshaft must be done before tightening

bolts to locate gear cover properly.
NOTE: If gear cover has an "O" ring seal groove for crank seal and seal
requires replacement, replace lower gear cover also.
4. Install a NEW crankshaft seal. See Front Crankshaft Seal.

5. Tighten 15 bolts in following sequence. See TORQUE SPECIFICATIONS.
Fig. 44: Lower Gear Cover Bolts Torque Sequence
6. Install crankshaft pulley and vibration damper(s). See Crankshaft Pulley.

10. Install oil filler connector. See Fig. 13.
MAIN BEARINGS
Removal
injury.


MOUNTED) .
5. Remove block stiffener plate. See Block Stiffener Plate.
6. Replace main bearings one at a time if crankshaft does not remove. Loosen main bearing cap
bolts.
CAUTION: Mark all bearing caps before removing them from cylinder
block. Before removing main bearing bolts pull main bearing
cap, or cap could fall, causing personal injury and parts
damage.
7. Remove cap using Main Bearing Cap Puller (ST-1178). Center tool on cap.
8. Remove main bearing bolts and cap. Mark bearing shells with journal number from which they
were removed. Remove lower main bearing shell from cap.
9. Turn crankshaft with air compressor drive or a barring device to remove main bearing shell.
Mark each main bearing for location if they are to be reinstalled in engine.
Clean components with soft bristle brush and dry with compressed air. Inspect main bearing cap and
bolts for other damage. Inspect bearing shells and thrust bearings for nicks, scratches, or damage.
If main bearings are damaged, inspect crankshaft main bearing journals. If crankshaft is damaged,
remove engine for repair. See Engine-Removal. Thrust bearing replacement is recommended when
main bearings are replaced. See Thrust Bearings.
Use an outside diameter ball-tipped micrometer to measure main bearing shell thickness.
MAIN BEARING SHELL THICKNESS

Minimum 0.126 (3.196)
Maximum 0.127 (3.214)
Replace bearing shell if not within specifications.
Fig. 45: Measuring Main Bearing Shell Thickness
Crankshafts that are ground undersize in connecting rod and main bearing journals are marked on
front counterweight. If crankshaft is marked, inspect bearing shell part number to ensure correct
bearing size is used.
Installation
CAUTION: When bearing shells are installed, ensure cylinder block saddle
and cap mating surfaces are clean and dry. Install used bearings
in their original location to avoid engine damage.
CAUTION: Ensure bearing tang fits into slot in bearing saddle to avoid
engine damage.
CAUTION: Use of bolt or any hard metal object to install bearings can
damage crankshaft and cause an engine failure. Avoid use of
them.
1. Lubricate upper main bearing shell to crankshaft journal mating surface using clean Lubriplate
105 multi-purpose lubricant, or its equivalent.
2. By hand, start bearing into upper saddle. Slide bearing into position. DO NOT damage
crankshaft journal when installing bearing.
3. Lubricate inside diameter of bearing shells and liner side of upper thrust bearings using clean
Lubriplate 105 multi-purpose lubricant, or its equivalent.
4. Align lower main bearing shell and push it into position.
5. Lubricate liner side of lower thrust bearings using Lubriplate 105 multi-purpose lubricant, or
equivalent.
6. Install lower thrust bearings in No. 4 main bearing cap, see Fig. 59.
CAUTION: Position bevel side toward crankshaft journal. Incorrect

thrust bearing installation causes engine damage.
7. Install upper thrust bearings in No. 4 main bearing saddle.
CAUTION: Position bevel side toward crankshaft journal. Incorrect
thrust bearing installation causes engine damage.
8. Push crankshaft toward rear of engine to install front thrust bearing and toward front of engine
to install rear thrust bearing.
9. Lubricate 4 main bearing cap surfaces on each main bearing cap with a bead of Loctite 518
thread sealant.
CAUTION: Only Loctite 518 thread sealant is recommended on main

cap joint mating surface. Other sealants can become hard,
brittle, oil and debris may enter into main bearing/block
joint, causing engine damage.
CAUTION: Ensure bead is 0.12-0.20 in (3-5 mm) wide and does not
allow main bearing shell inside main bearing shell inside
diameter. Sealant in main bearing can cause engine damage.
10. Lubricate bolt threads and flat washers (or underside of bolt heads if washers are not used)
with clean 15W-40 engine oil.
11. Drain excess oil before installing bolts.
12. Align bolt holes in cap with holes in cylinder block. Ensure lower bearing shell is in position.
CAUTION: Main bearing caps are marked with a' V.' Ensure position of
V mark is pointed to front of engine to avoid severe engine
damage.
13. Install bolts through cap and into cylinder block.

14. After applying Loctite 518 thread sealant, tighten main bearing bolts within 15 minutes to
prevent bore size issues, clearance issues, or both.
15. Ensure bearing shell does not move.
16. Tighten bolts in far enough to use a heel bar to pry caps into position.
17. Tighten both of bolts on a main bearing cap to 150 Ft. Lbs (203 N.m). Loosen both bolts
completely. Repeat steps for all main bearings.
NOTE: Thrust bearings are only located at No. 4 Main Bearing journal.
18. Use an air Impact Wrench and Socket, Tool Numbers (3163059) and (3163060), to rotate bolts
an additional 180 degrees.
19. Using torque plus angle method, tighten all main bearing bolts in sequence indicated in Fig.
46.
A. Step 1: 110 Ft Lbs. (149 N.m)
B. Step 2: Turn 180°
Fig. 46: Main Bearing Bolt Torque Sequence
20. Install a dial indicator onto oil pan flange to measure end clearance of crankshaft.
21. Position tip of gauge against crankshaft counterweight and push crankshaft toward rear of
cylinder block.
22. Set dial indicator at 0 and push crankshaft toward front of cylinder block.
23. Loosen all main bearing bolts 1 turn if end clearance is below 0.004 in (0.10 mm).
24. Push crankshaft forward and then toward rear of cylinder block.
25. Tighten main bearing bolts in sequence shown in Fig. 46. See TORQUE SPECIFICATIONS
26. Measure crankshaft end clearance.
CRANKSHAFT END CLEARANCE NEW OR RE-GROUND

Minimum 0.004 (0.10)
Maximum 0.020 (0.50)
27. Crankshafts that are re-ground on thrust bearing surfaces are marked for oversize thrust
bearings on rear crankshaft counterweight. If marked, inspect thrust ring part number to ensure
use of correct thrust ring size.
A. Examples:
a. F0.010 = front 0.010 in. (0.25 mm)
b. R0.020 = rear 0.020 in (0.51 mm)
28. If crankshaft end play is above 0.020 in (0.50 mm), remove engine to allow crankshaft
replacement. See Engine-Removal.
CAUTION: Prime engine oil system before operating engine after any
internal engine repairs to avoid internal component damage.

MOUNTED) .
34. Add engine oil to fill engine.
35. Operate engine until it reaches to 180° F (82° C), and inspect for engine oil leaks.
OVERHEAD INJECTOR CAMSHAFT
Removal

2. Remove rocker lever cover. See Rocker Lever Cover.
4. Remove injector camshaft scissor gear. See Engine Base Timing.
5. Remove integrated fuel system module. See INTEGRATED FUEL SYSTEM MODULE
(IFSM) .
6. Remove camshaft sensor.
7. Remove injector camshaft cover plate bolts.
8. Remove injector cover plate and gasket.
9. Dispose of gasket.
Fig. 47: Rear Cover Plates & Bolts
10. Remove 2 bolts and injector camshaft retainer plate and "O" rings.
NOTE: See Fig. 48.
11. Dispose of "O" rings.
CAUTION: Be careful while removing camshaft to avoid camshaft

bushings damage.
12. Remove injector camshaft.

Use Envirosol 655 solvent, or equivalent and a lint-free cloth to clean injector camshaft and bore of
injector camshaft scissor gear. Inspect injector camshaft and injector camshaft scissor gear for
fretting damage. Replace if found damaged.
Measure 7 injector camshaft bearing journals.
INJECTOR CAMSHAFT BEARING JOURNAL OUTSIDE DIAMETER

Minimum 3.3459 (84.987)
Maximum 3.3469 (85.013)
Replace camshaft if camshaft bearing journals are not within specifications. Ensure camshaft lobes
are free from cracks/scratches/other damage.
Installation
CAUTION: Be careful installing camshaft to prevent camshaft bushings

damage.
1. Use Lubriplate to coat inside of injector camshaft bearings before installing camshaft.
2. Install injector camshaft.
3. Install NEW "O" rings on retainer plate.
4. Install retainer plate and bolts.
NOTE: See Fig. 48.
5. Tighten bolts. See TORQUE SPECIFICATIONS.

6. Install injector camshaft cover plate with NEW gasket.
NOTE: See Fig. 47
7. Install and tighten bolts. See TORQUE SPECIFICATIONS.

8. Install integrated fuel system module. See INTEGRATED FUEL SYSTEM MODULE
(IFSM) .
9. Install camshaft sensor.
10. Install injector camshaft scissor gear. See Engine Base Timing.
12. Install rocker lever cover. See Rocker Lever Cover.
OVERHEAD INJECTOR CAMSHAFT BUSHINGS
Initial Inspection
Remove injector camshaft. See Overhead Camshaft-Injector.
Inspect amount of copper exposure on camshaft bushing. Replace bushing if it extends more than 180
degrees around bushing.
Removal
Remove injector camshaft bushing with Service Tool (3164089).
Hydraulic Camshaft Bushing Tool Kit (3823621), consists of:
1. Air hydraulic pump

2. Center hole ram
3. Hydraulic hose
4. Puller shaft
5. Stop collars
NOTE: l For inner camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6,

7, 8, 9, and 10.
l For rear camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6,
11, 12, and 13.
l For front camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6,
14, 15, and 16.
Step 1
CAUTION: This kit consists of different-size centering guides for journals

both with and without bushings installed. Select correct size
centering guides to avoid journal/guides damage.
Install centering guides in 2 of camshaft bore ends.
NOTE: You can install centering guide in any of holes but keep wider
distance.
Step 2
Install puller shaft through both of installed centering guides.
Step 3
Position receiver spacer on puller shaft with open end facing cylinder head.
NOTE: A receiver spacer has not been included in injector camshaft bushing
Replacer Kit (3164088). Use Receiver Spacer (3824864), or an
appropriate-size spacer from another kit.
Step 4
Slide center hole ram onto puller shaft until it touches receiver spacer.
Step 5
Install stop collar in groove of puller shaft closest to center hole ram.
Step 6
CAUTION: Install proper-size bushing driver to prevent camshaft bushing,

journal cylinder head bore, and tool equipment damage.
1. Position bushing driver on puller shaft next to removed bushing.

2. Slide bushing driver into camshaft bushing until it stops against flange of bushing driver.
Step 7 (For Inner Bushings Only)
Install stop collar into groove on puller shaft closest to end of bushing driver.
WARNING: DO NOT touch journal area while operating air/hydraulic pump

pedal. If hands are caught between journal and bushing area,
fatal injury may result.
Push down on press side of air/hydraulic pump pedal. Hold till cam bushing is out of bore.
Remove camshaft bushing from bushing driver. Remove bushing driver and stop collar from puller
shaft
1. Push down on release side of air/hydraulic pump pedal to release pressure. Push puller shaft
forward until stop collar is touching against center hole ram.
2. Remove service tool from engine.
Step 11 (For Rear Bushing Only)
1. Install bushing driver onto puller shaft behind outer camshaft bushing.
2. Install stop collar into groove on puller shaft closest to end of bushing driver.

Push down on press side of air/hydraulic pump pedal. Hold till rear camshaft bushing and centering
guide are out of bore.
1. Push down on release side of air/hydraulic pump pedal to release pressure.

2. Push puller shaft forward until stop collar is touching against center hole ram.
Step 14 (For Front Bushing Only)
1. Install bushing driver on puller shaft. Larger end of bushing driver should face front camshaft
bushing.

Push down on PRESS side of air/hydraulic pump pedal. Hold till camshaft bushing and centering

Inspect Condition
For reuse clean and inspect camshaft bores in cylinder head. Remove burrs and sharp edges from
bore with an emery cloth.
Installation
l For inner camshaft bushing installation, follow Steps 1, 2, 5, 6, 7, 8, 9, 10, and 11.
l For rear camshaft bushing installation, follow Steps 1, 3, 5, 6, 7, 12, 13, 14, and 15.
l For front camshaft bushing installation, follow Steps 1, 4, 5, 6, 7, 16, 17, 18, and 19.
Step 1

Install centering guides into both camshaft bore ends.
Step 2 (For Inner Bushing Only)
Slide puller shaft through centering guide and into number 2 journal. Place a camshaft bushing, if
needed, over puller shaft end. Move puller shaft through number 3 journal and repeat as above.
Continue through each inner journal until puller shaft is completely through opposite-end centering
guide.
Install puller shaft through 2 installed centering guides.
1. Slide puller shaft through centering guide and into number 1 journal.
2. Place a camshaft bushing over puller shaft end of puller shaft.
3. Continue to slide puller shaft through block and opposite-end centering guide.
Step 5
Position receiver spacer on puller shaft. Open end should face cylinder head.
Step 6
Slide center hole ram onto puller shaft until it touches receiver spacer.
Step 7

1. Position proper bushing driver on puller shaft next to bushing being installed.
2. Slide camshaft bushing over bushing driver.
CAUTION: Install oil ports on camshaft bushings with oil ports in journal.
Engine can be damaged due to misalignment of cam bushing oil
port to journal oil port.
Push bushing driver over until cam bushing just touches cylinder head. Install stop collar into groove
on puller shaft closest to end of bushing driver. Rotate camshaft bushing until oil port is aligned with
bore oil port.

1. Pull cam bushing into cylinder head by pushing down on press side of air/hydraulic pump
pedal. As camshaft bushing oil port comes close to bore oil port, let up on pedal.
2. To stop camshaft bushing in desired position lightly tap press side of air/hydraulic pump pedal.

Remove service tool from engine.
Step 12 (For Rear Bushings Only)

1. Place camshaft bushing over puller shaft end.

2. Position bushing driver on puller shaft and slide camshaft bushing onto bushing driver.
1. Push bushing driver over until camshaft bushing just touches cylinder head.
3. Rotate camshaft bushing until oil port is aligned with bore oil port.

1. To install front and rear bushing, move centering guides to journals 2 and 6.
2. Pull camshaft bushing into cylinder head by pushing down on press side of air/hydraulic pump

Step 16 (For Front Bushings Only)

1. Position proper bushing driver on puller shaft.

2. Slide camshaft bushing over bushing driver.
3. Rotate camshaft bushing until oil port is aligned with oil port of bore.

NOTE: Centering guide will be forced into receiver spacer when bushing and
driver are pulled into bore.


4. Install injector camshaft. See Overhead Camshaft-Injector (002-025).
OVERHEAD INJECTOR CAMSHAFT END CLEARANCE
Measuring

4. Unload injector camshaft scissor gear and remove. See Engine Base Timing.
NOTE: DO NOT remove injector camshaft gear on engines equipped with

a non-scissor injector camshaft gear, to inspect end clearance.
CAUTION: Install rear camshaft cover plate.
5. Inspect gear end clearance with a dial indicator.

6. Push camshaft to rear and set gauge at "0".
7. Pull gear forward and measure end clearance.
INJECTOR CAMSHAFT END CLEARANCE

Maximum 0.0276 (0.70)
8. Replace injector overhead camshaft, if measurement exceeds specifications. See Overhead

Camshaft-Injector.
9. Install and load injector camshaft scissor gear, see Engine Base Timing.
OVERHEAD SET
Measure
NOTE: Set engine base timing properly before measuring/adjusting/setting

overhead. See Engine Base Timing. Before inspecting lash, properly
set engine to correct marks, see Overhead Set-Adjusting
Valve Lash
Measure clearance (lash) amount between crosshead and rocker lever nose using feeler gauges.
Measure and record intake, exhaust, and brake valve lash. Adjust valve if valve lash is not within
specifications listed below. See adjust step in this procedure.
Verify camshaft follower is in contact with camshaft before brake lash measurement by pressing
brake lever down.
ISX SERIES VALVE LASH RE-INSPECTION SPECIFICATION
Maximum 0.019 (0.48)
Maximum 0.032 (0.81)
Brake Minimum 0.271 (6.87)
Maximum 0.281 (7.13)
Brake Running Clearance
Rotate brake lever to detent (neutral) position. Inspect clearance between engine brake actuator piston
and cross head guide pin. Adjust running clearance if brake running clearance is not within
specifications. See OVERHEAD SET-ADJUSTING.
BRAKE RUNNING CLEARANCE

Minimum 0.025 (0.635)
Maximum 0.110 (2.79)
Injector Lash
There is no service procedure to inspect injector free load.
Install rocker lever cover. See Rocker Lever Cover.
Information
NOTE: DO NOT perform this operation without reading entire procedure for
overhead adjustment. See Overhead Set-Adjusting.
Ensure valves injectors, and engine brakes (if equipped) are correctly adjusted for efficient engine
operation. Perform valve, injector, and engine brake adjustment when repairs are complete, see
Overhead Set-Adjusting.
After an engine rebuild or any major repair where injector and valve setting must be disturbed, set all
valves, injectors, and brakes.
Removal

1. Disconnect battery.
3. Ensure engine base timing is properly set before attempting to adjust/set overhead. See Engine
Base Timing.
4. Make all overhead valve, injector, and brake adjustments while engine is cold (any stabilized
coolant temperature at 140° F [60° C] or below).
Installation

negative (-) battery cable first and connect negative (-)
battery cable last to prevent arcing.
2. Connect battery.
3. Inspect aftertreatment system if coolant, oil, excessive fuel, or excessive black smoke, has
entered exhaust system.
OVERHEAD VALVE CAMSHAFT
Removal
1. Remove upper gear cover and see Upper Gear Cover.

3. Disconnect engine brake wiring harness.
5. Remove valve camshaft gear. See Engine Base Timing.
6. Remove retainer bolts, retainer, seal, and "O" ring.
7. Dispose of seal and "O" ring.
Fig. 48: Retainer Bolts & Retainers
CAUTION: Be careful while removing camshaft to avoid camshaft

bushings damage.
8. Remove valve camshaft.

Clean valve camshaft and bore of valve camshaft gear with Envirosol 655 solvent, or equivalent, and
a lint-free cloth. Inspect valve camshaft and valve camshaft gear for fretting damage. Replace If
found damaged.
Outside diameter of 7 valve camshaft bearing journals.
VALVE CAMSHAFT BEARING JOURNAL OUTSIDE DIAMETER

Minimum 2.5585 (64.987)
Maximum 2.5596 (65.013)
Replace camshaft journals if not within specifications.
Inspect camshaft lobes for cracks, scratches, and other damage.
Installation
CAUTION: Be careful while installing camshaft to avoid camshaft damage.
1. Use Lubriplate to coat inside of valve camshaft bushings before installing camshaft.
2. Install valve camshaft.
3. Install NEW "O" rings on retainer plate.
4. Install retainer plate and bolts.
NOTE: See Fig. 48.

6. Install valve camshaft gear. See Engine Base Timing.
8. Connect engine brake wiring harness.
11. Operate engine till it reaches normal operating temperature. Inspect for leaks.
OVERHEAD VALVE CAMSHAFT BUSHINGS
Initial Inspection
Remove valve camshaft. See Overhead Camshaft-Valve.
Inspect amount of copper exposure on camshaft bushing. Replace bushing if it extends more than 180
degrees around bushing.
Removal
Remove valve camshaft bushing with Service Tool, (3164088).
Hydraulic Camshaft Bushing Tool Kit (3823621), consists of:
1. Air hydraulic pump

2. Center hole ram
3. Hydraulic hose
4. Puller shaft
5. Stop collars
NOTE: l For inner camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6,

7, 8, 9, and 10.
l For rear camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6,
11, 12, and 13.
l For front camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6,
14, 15, and 16.
Step 1

Install centering guides in 2 of camshaft bore ends.
NOTE: You can install centering guide in any of holes but keep wider
distance.
Step 2
Install puller shaft through both of installed centering guides.
Step 3
Position receiver spacer on puller shaft and keep open end facing cylinder head.
NOTE: A receiver spacer has not been included in Valve Camshaft Bushing
Replacer Kit, (3164088). Use Receiver Spacer, (3824864), or an
appropriate-size spacer from another kit.
Step 4
Slide center hole ram on puller shaft till it touches receiver spacer.
Step 5
Step 6

Position bushing driver on puller shaft next to removed bushing. Slide bushing driver into camshaft
bushing till it stops against flange of bushing driver.
Install stop collar into groove on puller shaft closer to bushing driver end.

Push down on air/hydraulic pump pedal press side. Hold until cam bushing is removed from bore.
Remove camshaft bushing from bushing driver. Remove bushing driver and stop collar from puller
shaft.

2. Push puller shaft forward till stop collar is touching against center hole ram. Remove service
tool from engine.
1. Install bushing driver on puller shaft behind outer camshaft bushing.

2. Install stop collar into groove on puller shaft closer to end of bushing driver.

Push down on press side of air/hydraulic pump pedal. Hold till rear camshaft bushing and centering

2. Push puller shaft forward till stop collar is touching against center hole ram.
1. Install bushing driver on puller shaft. Larger end of bushing driver should face front camshaft
bushing.

Push down on press side of air/hydraulic pump pedal. Hold it until camshaft bushing and centering

2. Push puller shaft forward until stop collar touches against center hole ram.
Inspect Condition
Clean and inspect camshaft bores in cylinder head. Remove burrs and sharp edges from bore with
emery cloth.
Installation
l For inner camshaft bushing installation, follow Steps 1, 2, 5, 6, 7, 8, 9, 10, and 11.
l For rear camshaft bushing installation, follow Steps 1, 3, 5, 6, 7, 12, 13, 14, and 15.
l For front camshaft bushing installation, follow Steps 1, 4, 5, 6, 7, 16, 17, 18, and 19.
Step 1

Install centering guides into both camshaft bore ends.
Step 2 (For Inner Bushing Only)
1. Slide puller shaft through centering guide and into number 2 journal. Place a camshaft bushing,
if desired, over end of puller shaft.
2. Move puller shaft through number 3 journal and do same as above.
3. Continue through each inner journal till puller shaft is completely through opposite-end
centering guide.
Install puller shaft through 2 installed centering guides.
1. Slide puller shaft through centering guide and into number 1 journal.
2. Place a camshaft bushing over puller shaft end.
3. Continue to slide puller shaft through block and opposite-end centering guide.
Step 5
Position receiver spacer on puller shaft with open end facing cylinder head.
Step 6
Slide center hole ram onto puller shaft till it touches receiver spacer.
Step 7
Install stop collar in groove of puller shaft closer to center hole ram.

Position proper bushing driver on puller shaft next to installed bushing. Slide camshaft bushing over
bushing driver.
1. Push bushing driver over till cam bushing just touches cylinder head.
CAUTION: Install oil ports on camshaft bushings with oil ports in

journal. Engine can be damaged due to misalignment of cam
bushing oil port to journal oil port.
3. Rotate camshaft bushing till oil port is aligned with bore oil port.

1. Pull cam bushing into cylinder head by pushing down on press side of air/hydraulic pump
2. Stop camshaft bushing in desired position by lightly tapping press side of air/hydraulic pump
pedal.


Place camshaft bushing over end of puller shaft. Position bushing driver on puller shaft and slide
camshaft bushing onto bushing driver.
1. Push bushing driver over till camshaft bushing just touches cylinder head.
3. Rotate camshaft bushing until oil port is aligned with oil port of bore.

1. Move centering guides to journals 2 and 6 to install front and rear bushing.
3. To stop camshaft bushing in desired position, lightly tap press side of air/hydraulic pump
pedal.

2. Push puller shaft forward till stop collar is touching against center hole ram.

Position proper bushing driver on puller shaft. Slide camshaft bushing over bushing driver.
3. Rotate camshaft bushing till oil port is aligned with bore oil port.

NOTE: When bushing and driver are pulled into bore, centering guide will be
forced into receiver spacer.
2. To stop camshaft bushing in desired position, lightly tap press side of air/hydraulic pump
pedal.

4. Install valve camshaft. See Overhead Camshaft-Valve.
OVERHEAD VALVE CAMSHAFT GEAR
Removal
Remove valve camshaft gear. See Engine Base Timing.
Installation
Install valve camshaft gear. See Engine Base Timing.
OVERHEAD VALVE CAMSHAFT END CLEARANCE
Measuring

4. Unload injector camshaft scissor gear. See Engine Base Timing.
NOTE: DO NOT remove injector camshaft gear on engines equipped with

a non-scissor injector camshaft gear when inspecting clearance.
5. Remove injector camshaft scissor gear.

6. Inspect end clearance of gear with a dial indicator. Push camshaft to rear and set gauge at "0".
Pull gear forward and measure end clearance.
CAUTION: Ensure rear camshaft cover plate is installed.
VALVE CAMSHAFT END CLEARANCE

Maximum 0.0276 (0.70)
7. Replace overhead valve camshaft if measurement exceeds specifications. See Overhead

Camshaft-Valve.
8. Install and load injector camshaft scissor gear. See Engine Base Timing.
PISTON
General Information
Articulated pistons are equipped in some Signature and ISX engines, which is a 2-piece piston
consisting of forged steel crown and an aluminum skirt.
An open chamber oil gallery on underside of crown of piston provides more oil contact with piston
and better piston cooling. Piston cooling nozzle targeting is critical as oil is captured in shaker trays.
Fig. 49: Articulated Piston-Typical Example
Fig. 50: Single Piece Piston-Typical Example
Some engines are equipped with 1-piece pistons, that does not have a bushing and is forged from a
high-strength, alloy steel.
A non-removable cover plate is located on underside of piston to capture oil and cool piston. DO
NOT remove this plate in any conditions.
CAUTION: Ensure all pistons within a given engine of same design - all are
to be either articulated or single-piece design. DO NOT mix piston
designs in same engine. Single-piece pistons should have drilled
rods and rod bearings. Articulated pistons can use either drilled
or non-drilled rods and bearings.
Removal
1. Remove piston and connecting rod assemblies from engine. See Piston & Connecting Rod
Assembly.
2. Disassemble piston and connecting rod assembly.
Articulated Piston

CAUTION: Ensure cleaning solvent is approved for bushing material to

prevent damage to piston crown. If required, use soft non-metallic
brush to clean piston crowns as metallic brush can damage
piston ring grooves.
Remove carbon buildup only, there is no need to appear crown to be NEW.
CAUTION: When cleaning steel piston crowns with walnut shell blast, use
minimum recommended pressure and avoid to concentrate blast
in any one area for prolonged period. Protect pin bore area from
blast so as not to damage surface finish. It is not recommended
to use walnut shell blast to clean aluminum piston skirts.
DO NOT clean piston crowns with glass or plastic bead media.
Soak piston crowns in an approved solution and/or blast with walnut shell media to clean carbon
deposits.
Soak steel pistons for minimum 30 minutes in an approved cleaning solvent for steel and for brushing
material. Remove carbon deposits using hot soapy solution with a nonmetallic brush.
Soak pistons several hours or overnight to get best results.
CAUTION: DO NOT use metallic brush to clean piston, it can damage surface
finish. Use soft nonmetallic brush if required. Use of glass,
plastic, or walnut media to clean aluminum piston skirts can
damage pin bore surface finish or prevent rings from seating
correctly in ring grooves.
Steam clean pistons and dry with compressed air.
Measure piston pin bore inside diameter on both crown and skirt on articulated pistons.
ARTICULATED PISTON PIN BORE INSIDE DIAMETER - (CROWN)

Minimum 2.502 (63.56)
Maximum 2.503 (63.58)
ARTICULATED PISTON PIN BORE INSIDE DIAMETER - (SKIRT)

Minimum 2.5005 (63.513)
Maximum 2.5010 (63.525)
Piston pin bore inside diameter is not a reuse criteria measurement to be taken on single-piece
pistons.
Inspect piston pin for scratches, grooves, or other damage, visual damage is not acceptable.
Measure piston pin outside diameter. Piston pin outside diameters are same between articulated and
single-piece piston pins.
PISTON PIN OUTSIDE DIAMETER

Minimum 2.4987 (63.4670)
Maximum 2.5000 (63.4999)
Measure piston pin lengths. Single-piece piston pins are shorter than articulated piston pins.
ARTICULATED PISTON PIN LENGTH

Minimum 4.311 (109.5)
Maximum 4.331 (110.0)
Single-Piece Piston
CAUTION: DO NOT remove flat, oil cover plate positioned on underside of

single-piece pistons.

CAUTION: Ensure cleaning solvent is approved for bushing material to

prevent damage to piston. If required, use soft nonmetallic brush
to clean piston crowns as metallic brush can damage piston ring
grooves.
Remove carbon buildup only, there is no need to appear crown to be NEW.
CAUTION: When cleaning steel piston crowns with walnut shell blast, use
minimum recommended pressure and avoid to concentrate blast
in any one area for prolonged period. Protect pin bore area from
blast to avoid damage of surface finish.
DO NOT clean piston crowns with glass or plastic bead media. Soak pistons in an approved solution
and/or blast with walnut shell media to clean carbon deposits.
Soak steel pistons for minimum of 30 minutes in an approved cleaning solvent for steel and for
brushing material. Remove carbon deposits using hot soapy solution with a nonmetallic brush.
Soak pistons several hours or overnight to get best results.
CAUTION: DO NOT use metallic brush to brush piston, it can damage

surface finish. Use nonmetallic brush
Steam clean pistons and dry with compressed air.
Ensure no walnut shell blast media remains between oil cover plate and piston.
CAUTION: DO NOT use pistons with cracks, replace if cracked or serious

engine damage can result.
Inspect piston bowl for cracks or damage.
Inspect piston pin bore for cracks, scratches, galling, dents, or other damage.
Inspect piston skirt pin bore and sides for cracks or damage. Also inspect skirt for scratches. If
scratches can be felt with a fingernail, avoid reuse of skirts.
Inspect ring groove with a NEW ring and a feeler gauge.
Hold a NEW ring in groove even with outside diameter of piston. Install a 0.006 In (0.15 mm) feeler
gauge, if gauge enters groove without resistance, indicates excessive wear. Replace piston.
Piston pin bore inside diameter is not a reuse criteria measurement to be taken on single-piece
pistons.
Inspect piston pin for scratches, grooves, or other damage, visual damage is not acceptable.
Measure piston pin outside diameter. Piston pin outside diameters are same between articulated and
single-piece piston pins.
PISTON PIN OUTSIDE DIAMETER

Minimum 2.4987 (63.4670)
Maximum 2.5000 (63.4999)
Measure piston pin lengths. Single-piece piston pins are shorter than articulated piston pins.
SINGLE-PIECE PISTON PIN LENGTH

Minimum 3.331 (84.6)
Maximum 3.350 (85.1)
Installation
1. Assemble piston and connecting rod.

2. Install piston and connecting rod assembly. See Piston & Connecting Rod Assembly.
3. Inspect aftertreatment system if failure resulted in coolant, oil, excessive fuel or excessive
BLACK smoke entering exhaust system. See
PISTON & CONNECTING ROD ASSEMBLY
Removal
injury.

as per research of some state and federal agencies.


personal injury.


MOUNTED) .
7. Remove connecting rod cap. See Connecting Rod Bearings.
8. Remove cylinder head. See Cylinder Head.
9. Remove carbon using a fine fibrous, abrasive pad such as Scotch - Brite or equivalent, and
solvent.
CAUTION: Emery cloth or sand paper contain aluminum oxide or

silicon particles that may cause serious engine damage.
Avoid use of them to remove carbon from cylinder liners.
DO NOT use any abrasives in ring travel area, cylinder liner
can be damage.
10. Install 2 Connecting Rod Guide Pins (3376038).

11. Using T-handle piston pusher, push connecting rod away from crankshaft until piston rings are
outside of top of cylinder liner.
12. Remove upper connecting rod bearing.
13. Mark cylinder number and letter U (upper) on flat surface of bearing tang.
14. Remove piston and connecting rod assembly by hand. Install both of them in same cylinder
they were removed. This will provide proper fit of worn mating surfaces if parts are reused.
15. Mark cylinder number from which each piston and connecting rod assembly was removed.
CAUTION: To prevent engine damage, ensure all pistons within a given

engine of same design - all are to be either articulated
design or single-piece design. DO NOT mix piston designs
in same engine. Ensure single-piece pistons have drilled
rods and connecting rod bearings. Articulated pistons can

use either drilled or non-drilled rods and bearings.
16. Position connecting rod and piston assemblies in a container to protect them from damage.
17. Connecting rod and matching connecting rod cap has a unique number, not cylinder number,
stamped on them. When connecting rods and connecting rod cap are installed in engine, ensure
numbers on connecting rod and cap matches and installed on same side (exhaust side) of
engine.
Disassembly
Articulated Piston
CAUTION: Piston pins can distort if removed with hammer, causing them to
seize in liner.
CAUTION: Skirt will separate from crown if piston pin is removed from an
articulated piston. Avoid damage to piston.
1. Remove snap rings from both sides of piston using internal snap ring pliers.
2. If difficult to remove piston pins by hand, position piston and connecting rod assembly in a
container of water and heat for 15 minutes.
3. Push piston pin from piston and connecting rod assembly using blunt tool.
4. If they are to be reused, mark number of cylinder that piston, crown, skirt, and pin were
removed from on parts to installed in correct cylinder.
Single-Piece Piston
CAUTION: Piston pins can distort if removed with hammer, causing them to
seize in liner.
1. Remove snap rings from both sides of piston using internal snap ring pliers.
2. If difficult to remove piston pin by hand, position piston and connecting rod assembly in a
container of water and heat for 15 minutes.
3. Push piston pin from piston and connecting rod assembly using a blunt tool.
4. Install piston and connecting rod assemblies in same cylinder they were removed, for proper fit
of worn mating surfaces if parts are reused.
5. Mark cylinder number from which each piston and connecting rod assembly was removed.
Assembly
Articulated Piston
CAUTION: Piston pins can distort if installed with hammer, causing it to

seize in liner.
CAUTION: Align lock tang on connecting rod with cooling nozzle notch in
piston skirt and on side opposite deep valve pocket of piston
crown. Follow this step to prevent extensive engine damage.
CAUTION: Piston pin for articulated piston is longer in length than pin for
single-piece pistons. Never use articulated piston pins in single-
piece pistons and single-piece pins in articulated pistons.
1. Lubricate all pistons (bushed and non-bushed) properly before assembly.

2. For all pistons, use a clean, lint free cloth to apply a heavy film of 85W-140 gear oil with EP
additive to following locations:
A. Piston pin bore inside diameter in piston crown
B. Piston pin bore inside diameter in piston skirt
C. Rod bushing inside diameter
D. Piston pin.
3. Assemble piston crown into piston skirt.
CAUTION: Ensure retainer snap ring seated completely in piston pin

groove to avoid engine damage during engine operation.
A. Articulated pistons do not require to heat before assembly as piston pin is slip fitted.
B. Crown and skirt can only be assembled in one position.
C. Install one NEW snap ring into a pin bore of each piston skirt.
D. If reusing pistons, match crown, skirt, and pin as they were when removed.
E. Position skirt over piston crown.
4. Align pin bore of connecting rod with pin bore of piston skirt and crown, and install piston pin.
5. On articulated pistons, locking tang on connecting rod must be on same side as cooling nozzle
notch in piston skirt and opposite deep valve pocket on crown.
6. Install a NEW snap ring into piston pin bore.
CAUTION: Ensure snap ring seated completely in piston pin groove to

avoid engine damage during engine operation.
7. Install piston rings. See Piston Rings.
Single-Piece Piston
CAUTION: Ensure retainer snap ring seated completely in piston pin groove
to avoid engine damage during engine operation.
CAUTION: Piston pins can distort if installed with hammer, causing it to

seize in liner.
CAUTION: Align lock tang on connecting rod with cooling nozzle notch in
piston skirt and on side opposite deep valve pocket of piston
crown. Follow this step to prevent extensive engine damage.
CAUTION: Apply heavy weight gear oil, such as 85W-140 EP to coat both
single-piece piston pin bores, when assembling single-piece
pistons. Lubricate connecting rod bushing as well. Use Lubriplate
(3163086) if gear oil is not available. Proper lubrication of pin joint
is vital to avoid extensive engine damage, mainly with single-
piece pistons.
1. Install NEW snap ring into one piston pin bore of each single-piece piston.
2. If reusing pistons, match single-piece piston and pin as they were when removed.
3. Coat piston pin using clean 85W-140 oil.
4. A drilled connecting rod and a drilled upper connecting rod bearing are required in single-piece
piston to lubricate pin joint. DO NOT assemble a single-piece piston with a non-drilled
connecting rod nor a non-drilled connecting rod bearing. When assembling a single-piece
piston ensure lubricating hole in connecting rod bearing aligns with lubricating hole in
connecting rod.
5. On single-piece pistons, locking tang on connecting rod is to be on opposite of deep valve
pocket.
CAUTION: Piston pin for single-piece pistons is shorter in length than

pin for articulated pistons. DO NOT use single-piece piston
pins in articulated pistons and articulated pins in single-
piece pistons.
6. Install piston pin.

7. Install a NEW snap ring into piston pin bore.
CAUTION: Ensure snap ring seated completely in piston pin groove to

avoid engine damage during engine operation.
8. Install piston rings. See Piston Rings.
Installation
1. Immerse piston in a container of clean 15W-40 oil.

2. Remove piston from container and drain excess oil from piston.
3. Compress rings using Piston Ring Compressor (3164846). Clean cylinder block and all
components before assembly.
4. Inspect cylinder liners for reuse. See Cylinder Liner.
5. Use a clean, lint-free cloth to clean connecting rods and bearing shells.
6. Backside of bearing shells should not be lubricated, doing so can reduce operating clearance of
bearing and bearing may damage during engine operation.
7. If NEW bearings are not used, install used bearings on same connecting rod from which they
were removed.
8. Install upper bearing shell into connecting rod.
9. Position tang of bearing shell in slot of cap. Level end of bearing shell with cap mounting
surface.
10. Coat entire inside circumference of bearing shell using Lubriplate 105 (3163086), or
equivalent.
11. Lubricate cylinder liner with a film of clean 15W-40 oil.
12. Install Connecting Rod Guide Pins (3163097).
13. Using compressor drive or barring device, rotate crankshaft so connecting rod journal of
connecting rod installed is at bottom dead center.
NOTE: See Fig. 13.
CAUTION: Align deep valve pocket and piston skirt cooling nozzle
notch properly to prevent extensive engine damage.
14. Align piston crown deep valve pocket on exhaust side, and piston skirt cooling nozzle notch to
intake side of engine.
15. If deep valve pocket and piston skirt cooling nozzle notch are not on opposite sides, piston and
connecting rod assembly need to be assembled correctly.
16. Insert connecting rod through cylinder liner until ring compressor contacts top of liner.
17. Arrow on both articulated pistons and single-piece pistons on top of piston crown, points to
front of engine, when installed correctly.
CAUTION: Piston rings or liner can damage if piston pushed into

cylinder liner with metal drift.
18. Hold ring compressor against cylinder liner. Push piston through ring compressor until top ring
is completely in cylinder liner.
19. If piston fails to move freely, remove piston and inspect for broken/damaged rings.
20. While pushing piston and connecting rod assembly into position, align connecting rod with
crankshaft using nylon guide pins.
21. Remove nylon guide pins.
NOTE: Stamp dataplate with letters SP when reconstructing an engine

with single-piece pistons that was originally built with articulated
pistons. This alerts future repair locations that this engine is
rebuilt with single-piece pistons.
22. Install connecting rod cap. See Connecting Rod Bearings.

MOUNTED) .
27. Install cylinder head. See Cylinder Head.
29. Fill cooling system with coolant.
30. Add engine oil to fill engine. See ENGINE OIL SYSTEM .
PISTON RINGS
Removal
Articulated Piston
1. Remove piston rings.

2. Place a tag on rings, and note cylinder number of piston on tag for future reference, if
necessary.
Single-Piece Piston
1. Remove top piston ring.

2. Remove 2nd piston ring using universal ring expander.
CAUTION: DO NOT overexpand 2nd piston ring on single-piece

pistons.
3. Remove oil ring.

4. Place a tag on rings, and note cylinder number of piston on tag for future reference, if
necessary.
Measure
Articulated Piston
To inspect ring gap, install piston rings into cylinder liner in which they were used below ring
reversal area.
Position ring in liner properly using top portion of piston.
Use a feeler gauge to inspect ring end gap.
ARTICULATED PISTON RING GAP

Ring Specification In (mm)
Top Minimum 0.013 (0.33)
Maximum 0.021 (0.53)
Second Minimum 0.074 (1.87)
Maximum 0.084 (2.13)
Oil Minimum 0.008 (0.21)
Maximum 0.020 (0.51)
Single-Piece Piston
To inspect ring gap, install piston rings into cylinder liner in which they were used below ring
reversal area.
Position ring in liner properly using top portion of piston.
Inspect ring end gap using feeler gauge.
SINGLE-PIECE PISTON RING GAP

Piston Ring Specification In (mm)
Maximum 0.021 (0.53)
Maximum 0.048 (1.23)
Maximum 0.020 (0.51)
Installation
Articulated Piston
CAUTION: Install connecting rod in a vise using copper or aluminum vise

protector to avoid damage.
1. Position connecting rod in a vise to hold assembly in a horizontal position.

2. Install piston rings with TOP toward top of piston.
NOTE: Rings have top marked for correct installation.
3. Install 2-piece oil control ring with expander ring gap 180 degrees from gap of oil ring. DO
NOT overlap ends of expander ring. Oil control ring is symmetrical and can be installed in
either orientation.
4. Install intermediate ring. Intermediate ring is a positive twist design with a cutback notch on
topside and a 2-degree taper face.
5. Install top ring. Top piston ring is a keystone ring with no twist or cutback notch.
6. DO NOT align ring gap of each ring with piston pin, or with any other ring gap. Ring will not
seat properly if ring gaps are not aligned correctly.
Single-Piece Piston
CAUTION: Install connecting rod in a vise using copper or aluminum vise

protector to avoid damage.
DO NOT align ring gap of each ring with piston pin or with any other ring. Rings will not seat
properly if gaps are not aligned.
1. Install connecting rod in a vise to hold assembly in a horizontal position while installing rings.
2. Install piston rings with TOP toward top of piston.
NOTE: Rings have top marked for correct installation.
3. Install a 2-piece oil control ring with expander ring gap 180 degrees from gap of oil ring. DO
NOT overlap ends of expander ring. Oil control ring is symmetrical and can be installed in
either orientation.
4. Use a universal piston ring expander to install 2nd ring into piston. 2nd ring has a rectangular
cross-section with an angled cut on upper side of inner diameter to induce a positive twist. This
design improves blowby-resistance of ring pack and prevents excessive oil consumption.
5. Install top ring. DO NOT align ring gap of each ring with piston pin, or with any other ring
gap. Rings will not seal properly if gaps are not properly aligned.
6. If failure resulted in coolant, oil, excessive fuel or excessive black smoke entering exhaust
system, inspect aftertreatment system.
POWER STEERING PUMP (VT)
l Procedure for replacement of power steering pump on VT chassis with Cummins ISX engine is
covered in this information.
l Information may change without notice. Illustrations are meant for reference and hence may
vary from actual vehicle version. However, this article is developed with main components as
accurately as possible.
Removal
Fig. 51: Locating Oil Lines At Power Steering Pump
Fig. 52: Locating Power Steering Pump Mounting Bolt
1. Use approved container to collect power steering fluid.

2. Disconnect power steering pump oil lines.
3. Remove pump from engine after removing two mounting bolts.
4. From old pump, remove oil line fittings and install NEW pump.
Installation
Fig. 53: Locating Power Steering Pump Mounting Bolt
1. Clean engine sealing surface. Install NEW gasket on pump. Then position pump and tighten
two mounting bolts to 55 Ft. Lbs. (75 N.m).
2. Connect and secure power steering pump oil lines.
3. Follow recommended level to fill power steering fluid.
4. With engine ON, turn steering wheel from side-to-side and remove air, switch ignition OFF,
inspect and fill reservoir to correct level.
REAR CRANKSHAFT SEAL
Removal
1. Disconnect driveline and remove transmission.

2. Remove clutch and flywheel. See Flywheel.
3. Secure Rear Crankshaft Seal Tool (3162994), to crankshaft using 3 flywheel mounting bolts.
4. Install a drill/pilot into 1 of holes in rear crankshaft seal tool and drill a hole through seal
casing.
5. Remove drill/pilot, and perform procedure again for minimum 2 more evenly spaced holes of
rear crankshaft seal tool.
6. Install 3 self-tapping screws into rear crankshaft seal tool.
7. Remove flywheel bolts from rear crankshaft seal tool.
8. Install center bolt into center hole of rear crankshaft seal tool. Turn clockwise to remove seal.

1. Clean seal bore surface of flywheel housing.

2. Remove rust or other deposits from crankshaft flange using crocus cloth.
3. Clean crankshaft flange and remove all traces of oil film with clean, lint-free cloth. Seal
leakage can cause if scratches are apparent.
Installation
CAUTION: Installing seal with hammer or mallet can damage seal.
1. Install seal without using lubricants. Apply a 10% soap solution to outer-ribbed surface of seal.
2. Guide rear crankshaft seal and installation tool over crankshaft.
CAUTION: Press rear crankshaft seal evenly into bore or seal can
damage.
3. Finger-tighten 3 installation bolts against Installation Tool (3162994).

4. Tighten bolts up to 1/2 of a turn at a time, in a clockwise pattern, until installation, tool seats
against flywheel housing.
6. Remove installation tool.
7. Install flywheel and clutch. See Flywheel.
8. Install transmission and driveline.
9. Operate engine to achieve normal operating temperature, and inspect for leaks.
REFRIGERANT COMPRESSOR
Removal
With Water Pump & Refrigerant Compressor Belt Routing
WARNING: Be careful while draining or filling liquid refrigerant as it is

harmful to environment. Use proper equipments to prevent
refrigerant gas leak. Refrigerant should be collected and
recycled as per Federal law.
NOTE: Refrigerant system depressurization is not required while removing

refrigerant compressor to access other components. Keep hoses
connected. Support refrigerant compressor to other vehicle
components.
1. Only when complete removal of refrigerant compressor is required, evacuate refrigerant

system.
2. Remove cooling fan drive belt.
3. Refrigerant compressor belt. See Refrigerant Compressor Drive Belt.
Sanden
Remove 4 refrigerant compressor mounting bolts to remove refrigerant compressor.
Fig. 54: Identifying Refrigerant Compressor & Bolts
Climate Control Incorporated
Remove 4 refrigerant compressor mounting bolts and remove refrigerant compressor and bracket
assembly.
Inspect refrigerant compressor pulley for cracks or broken grooves. Replace if damaged.
Inspect refrigerant compressor bracket for cracks, replace if damaged.
Inspect roll pins for looseness or damage. Replace refrigerant compressor mounting brackets, if
damage is found.
Installation
Sanden
Install 4 mounting bolts through refrigerant compressor and refrigerant compressor bracket. Tighten
bolts to 115 In. Lbs (18 N.m)
Install 4 mounting bolts through refrigerant compressor to alternator/refrigerant compressor

mounting bracket ensuring proper alignment of roll pins. Tighten bolts to 27 Ft. Lbs (36 N.m)
1. Install refrigerant compressor belt. See Refrigerant Compressor Drive Belt.
2. Install fan drive belt.

3. If refrigerant system is depressurized, refill it.
REFRIGERANT COMPRESSOR AUTOMATIC BELT TENSIONER
Inspection
WARNING: DO NOT disassemble tensioner as it is spring loaded and can

cause severe injury.
Install tensioner on engine and pivot it through full range of motion. A resistance must be felt while
tensioner pivots away from belt. If not, replace tensioner.
Inspect belt part number after above inspection. Use correct belt for this refrigerant compressor
option.
If tensioner pulley and body show cracks, replace tensioner.
Tensioner pulley must spin freely, replace tensioner if it does not.
Removal
1. Remove fan drive belt.

2. Remove refrigerant compressor belt. See Refrigerant Compressor Drive Belt.
3. Remove mounting bolt and refrigerant compressor belt tensioner from bracket.
Installation
1. Install refrigerant compressor belt tensioner and tighten bolt. See TORQUE
SPECIFICATIONS.
REFRIGERANT COMPRESSOR DRIVE BELT
Removal
CAUTION: Belt tensioner is spring loaded. Always pivot it away from drive
belt, pivoting in wrong direction can damage belt tensioner or
cause personal injury.
1. Remove cooling fan drive belt. See

2. Pivot automatic tensioner counterclockwise to relieve tension on belt, then remove belt.
Inspect refrigerant compressor pulley for cracks or broken grooves. Replace damaged compressor.
Replace belt if it shows cracks, glazing, tears or cuts, and excessive wear.
Installation
CAUTION: Belt tensioner is spring loaded. Always pivot it away from drive
belt, pivoting in wrong direction can damage belt tensioner or
cause personal injury.
1. Pivot counterclockwise and hold belt tensioner. Install drive belt and relieve tensioner.
2. Install cooling fan drive belt. See
REFRIGERANT COMPRESSOR IDLER PULLEY
Removal

2. Remove refrigerant compressor belt. See Refrigerant Compressor.
3. Remove pulley mounting bolt and remove refrigerant compressor idler pulley.
Inspect Condition
Replace idler pulley if it shows cracks or broken grooves.
Spin refrigerant compressor idler pulley, it must rotate freely when installed.
Installation
1. Install refrigerant compressor idler pulley and mounting bolt.
NOTE: No special alignment procedure is required for refrigerant

compressor idler pulley to alternator/refrigerant compressor
mounting bracket.
2. Tighten mounting bolt, see TORQUE SPECIFICATIONS.

3. Install refrigerant compressor belt. See Refrigerant Compressor.
4. Install cooling fan drive belt.
REFRIGERANT COMPRESSOR MOUNTING BRACKET
Removal
WARNING: Be careful while draining or filling liquid refrigerant as it is

harmful to environment. Use proper equipments to prevent
refrigerant gas leak. Refrigerant should be collected and
recycled as per Federal law.

2. Remove refrigerant compressor belt. See Refrigerant Compressor Drive Belt.
3. Remove refrigerant compressor. See Refrigerant Compressor.
4. Remove 2 bracket mounting bolts and bracket (if required).
5. Remove support links from bracket (if equipped).
Sanden
Remove mounting bolt from each refrigerant compressor bracket and remove brackets.
Remove 4 mounting bolts from refrigerant compressor bracket and remove bracket from compressor.
CM870

Use solvents to clean refrigerant compressor mounting brackets and dry with compressed air.
Replace refrigerant compressor mounting brackets if they are cracked or damaged.
Inspect roll pins for looseness or damage. Replace refrigerant compressor mounting brackets, if
damage pins are damaged.
CM570

Use solvent to clean bracket, links, and mounting bolts and dry with compressed air.
Replace bracket and links if they are cracked or damaged.
Installation
Sanden
1. Install 2 mounting bolts and refrigerant compressor mounting bracket and tighten bolts to 62
In. Lbs (7 N.m)
Fig. 55: Refrigerant Compressor Bracket Bolts - (Sanden)
2. Install refrigerant compressor drive belt.

1. Place refrigerant compressor on top of bracket ledge and install refrigerant compressor
mounting bracket to refrigerant compressor.
2. Install 4 mounting bolts and refrigerant compressor bracket. See TORQUE
SPECIFICATIONS.
CM 570
1. Inspect refrigerant compressor bracket before installation to ensure correct installation of

mounting spacers.
2. Install refrigerant compressor bracket on gear housing with 2 long bolts. See TORQUE
SPECIFICATIONS.
3. Position both links in assembly with part number facing outward.
4. Insert 1 bolt through elongated hole in long link and connect long link to left side of refrigerant
compressor bracket.
5. Insert 1 bolt through small hole in short link and connect short link to right side of refrigerant
compressor bracket.
6. Install refrigerant compressor. See Refrigerant Compressor.
RETAINING BRACE BRACKET
Removal
Remove 2 bolts from retaining brace bracket and gear housing.
Remove 2 remaining bolts, washers, and retaining brace bracket from cylinder head.
Inspect Condition
Inspect retaining brace bracket for cracks.
Installation
NOTE: Bracket to gear housing is connected with two M10 x 1.5 x 25 bolts and
bracket to cylinder head is connected with one M12 x 1.75 x 35 bolt
and washer through engine lifting bracket. Bracket to cylinder head
below engine lifting bracket is connected with one M12 x 1.75 x 30 bolt
and washer. Hand-tighten bolts.
Install retaining brace bracket, 4 bolts, and 2 washers on gear housing and cylinder head hand-tight.
Tighten 2 bolts to gear housing. See TORQUE SPECIFICATIONS.
Tighten 2 bolts to cylinder head. See TORQUE SPECIFICATIONS.
ROCKER LEVER ASSEMBLY
Removal
NOTE: See Fig. 14
1. Remove wire harness of engine brake solenoid valve and rocker lever cover. See Rocker
Lever Cover.
2. Remove wire harness of engine brake.
3. Following are different types of rocker lever shafts:
A. Front - valve and brake rocker lever shaft
B. Rear - valve and brake rocker lever shaft
C. Front - injector rocker lever shaft
D. Rear - injector rocker lever shaft.
CAUTION: It is not possible to loosen some valves. To avoid

engine damage, DO NOT tighten or bottom adjusting
screw against lever. Engine damage can occur.
4. After loosening valve and injector adjusting screw locknuts on each rocker lever, rotate
adjusting screws counterclockwise to loosen rocker levers.
CAUTION: Ensure rocker levers do not fall off shaft during removal.
Handle shaft with care
5. Remove these items: valve and brake, rocker lever shaft bolts, and rocker lever shaft
assemblies.
6. Remove injector, rocker lever shaft bolts, and rocker lever shaft assemblies.
7. Remove valve crossheads.
8. To facilitate installation at correct position, put identification mark on each crosshead and
rocker lever shaft assembly during removal. This is required to prevent increased wear.
Fig. 56: Removing Valve Crossheads
9. Perform following removals:

A. Rocker levers and brake levers from shafts.
B. Rocker lever spacers from shaft.
C. Locknuts and adjusting screws from rocker levers.
NOTE: To facilitate correct installation its original rocker lever, put

identification mark each adjusting screw during removal.
Failure to do so will result in increased wear.

1. Clean rocker lever shaft with steam or solvent and blow dry using compressed air. Ensure oil
passages are blown.
2. Clean following components using steam or solvent and blow dry using compressed air: valve
crossheads, rocker lever adjusting screw, and nuts.
3. Inspect condition of valve and brake rocker lever shaft.
4. Measure valve and brake rocker lever shaft outside diameter in bushing wear area. Replace
valve or brake rocker lever shaft if falls out of specifications. Maximum outside diameter
should be 1.3780 in. (35.000 mm) while minimum outside diameter should be 1.3760 in.
(34.950 mm).
5. Inspect valve and brake rocker lever shaft for wear in brake detent pockets. It is normal
condition to have a raised edge on one side of detent pocket and replacement is not necessary.
6. If an elongated detent pocket is evident typically toward cam follower end of brake rocker
lever, excessive wear is present and replacement is necessary.
7. Measure injector rocker lever shaft outside diameter in bushing wear area. Replace rocker lever
shaft, if falls out of specifications. Maximum outside diameter should be 1.7717 in. (45.000
mm) and minimum should be 1.7697 in. (44.950 mm).
8. Inspect rocker levers for these conditions: cracks, abnormal wear, and thread condition.
9. Measure valve and brake rocker lever bushing bore inside diameter. Replace rocker lever if
valve or brake rocker lever bushing fails to meet specification. Maximum inside diameter
should be 1.3834 in. (35.138 mm) and minimum should be 1.3794 in. (35.037 mm).
10. Measure injector rocker lever bushing bore inside diameter. Replace rocker lever if injector
rocker lever bushing fails to meet specification. Maximum inside diameter should be 1.7771 in.
(45.138 mm) and minimum should be 1.7731 in. (45.037 mm).
11. Inspect condition of valve crossheads and crosshead guide pins.
12. Ensure contact area on crossheads are smooth and have an even seating pattern. Any
distortions or cracks on valve crossheads or adjusting screws requires replacement.
13. Inspect and replace in injector rocker lever adjusting screw socket for excessive wear.
14. Measure intake and exhaust valve adjusting screws for wear. Adjusting screw must be
perpendicular for measurement. Intake and exhaust valve adjusting screw length should be not
less than 1.81 in. (46 mm).
15. Measure rocker lever spacers for wear. Replace rocker lever spacer, if falls out of specification.
Rocker lever spacer width should be not less than 0.453 in. (11.5 mm).
Installation
1. Install adjusting screw and locknut into each rocker lever without tightening locknuts.
WARNING: To prevent possible engine damage, remove oil or debris

from rocker lever assembly mounting bolt holes.
2. Install in order:
A. Injector rocker levers onto shaft.
B. Exhaust and intake rocker levers onto shaft.
C. Engine brake rocker levers onto shaft.
3. Install valve crossheads.
4. Place valve/brake rocker lever assemblies onto cylinder head.
CAUTION: Carefully seat valve rocker shafts on cylinder head

pedestals otherwise inadequate brake rocker lever running
clearance result in accelerated valve rocker shaft damage.
5. Before tightening rocker shaft bolts be sure each valve rocker shaft are seated in cylinder head
pedestals. When engine is turned clockwise front and rear rocker lever shaft assemblies will
seat separately.
as viewed from front of engine). Line up "A" on vibration damper with timing mark on gear
cover.
7. At this point, either front or rear rocker shaft assembly will be fully seated on cylinder head
pedestals.
8. Inspect position of front and rear valve rocker shaft assemblies to determine which one is fully
seated. Apply clean 15W-40 oil to bolts of fully seated rocker shaft
CAUTION: Tighten bolt using recommended procedure and torque.

Failure to do so will result in damaged valve rocker shaft
due to inadequate brake rocker lever running clearance.
Since valve rocker lever shaft has a machined flat on front of
shaft (to provide proper brake rocker lever position), torque
front rocker shaft bolt first to control position of brake
rocker lever position. Inspection of brake lever running
clearance after installation of valve rocker lever shaft is very
important.
9. Inspect brake running clearance. See Overhead Set-Adjustment.

10. To locate shaft, tighten front mounting bolt for fully seated valve rocker lever shaft to initial
torque of 22 Ft. Lbs (30 N.m).
11. Obey torque plus angle method and tighten all bolts to final torque. Tighten bolts from center
out and use following specification:
B. Step 2: Rotate 60 degrees
as viewed from front of engine). 'B' on vibration damper must be line up with timing mark on
gear cover.
13. At this point, other rocker shaft will be fully seated. Apply clean 15W-40 oil to bolts of fully
seated rocker shaft.
CAUTION: Tighten bolt using recommended procedure and torque.

Failure to do so will result in damaged valve rocker shaft
due to inadequate brake rocker lever running clearance.
Since valve rocker lever shaft has a machined flat on front of
shaft (to provide proper brake rocker lever position), torque
front rocker shaft bolt first to control position of brake
rocker lever position. Inspection of brake lever running
clearance after installation of valve rocker lever shaft is very
important.
14. Inspect brake running clearance. See Overhead Set-Adjustment.

15. To locate shaft, tighten front mounting bolt for remaining valve rocker lever shaft to initial
torque of 22 Ft. Lbs (30 N.m).
16. Obey torque plus angle method and tighten all bolts to final torque. Tighten bolts from center
out to following specification.
17. Place injector rocker lever assemblies onto cylinder head and Apply clean 15W-40 oil injector
rocker lever shaft bolts. Install bolts and washers and tighten mounting bolts to 50 Ft. Lbs (68
N.m)
18. Loosen bolts 360° one at a time. Obey torque-plus-angle method and re-tighten. Tighten bolts
from center out to following specification.
19. Adjust valve, injectors, and brake. See Overhead Set-Adjustment.
20. Install wire harness of engine brake.
22. Install wire harness of engine brake solenoid valve.
ROCKER LEVER COVER
Removal
NOTE: Until September 7, 2006 engines were equipped with a separate cover
and separate gasket. Engines built on and after this date, are equipped
with cover gasket that is embedded in rocker lever cover.
1. Remove all bolts and isolator assemblies from rocker lever cover then separately remove cover
and gasket from head. Rocker lever cover gasket can be reused; DO NOT damage during
removal or cleaning process.
Fig. 57: Removing Rocker Lever Cover
2. Loosen all bolts and isolator assemblies fully, then remove following items as an assembly:
A. Rocker lever cover
B. Cover gasket
C. Isolators
3. Cover gasket can be reused; DO NOT damage during removal or cleaning process or when
setting assembly aside during repair.
Remove engine oil from cylinder head cavities properly. Steam clean cover and blow dry using
compressed air.
CAUTION: Cleaning rocker lever cover gasket using solvent is a bad practice
as this may damage gasket material and cause it to swell.
Overexposure of gasket may degrade gasket material.
Use a dry, lint-free cloth and clean old gasket. No oil should remain between sealing beads.
NOTE: A separate rocker lever cover and a separate cover gasket is used on
all engines built before September 7, 2006. Ensure that no engine oil is
remained between sealing beads.
Inspect condition of rocker lever cover and replace as required.
Inspect cover gasket beads for following conditions and make necessary replacement: cuts, missing
beads, kinks, twists, wear, or other damage. A gouged hole is acceptable if bead is not damaged.
Installation
NOTE: From September 7, 2006, engines are built with cover gasket that is
embedded in rocker lever cover.
Installation of cover gasket should be done as soon as possible after
removal. Failure to do so will result in swelling of cover gasket due to
exposure to engine oil. A NEW cover gasket should be lubricated with
P80 lubriplate (3163086), or soapy water.
NOTE: Installation process of a cover gasket (after removal) should be started

at each bolt hole, press cover gasket into groove in rocker level cover
around each bolt hole.
1. When cover gasket is in place around all bolt holes, press cover gasket into grove of rocker
level cover. Start from bolt holes moving to center of each span.
2. Ensure gasket is free from kinks, twists or other damage.
3. Prior to bolts and isolator assemblies installation, line up bolt holes in cylinder head to cover
gasket, and rocker lever cover.
4. Install all bolts and isolator assemblies.
NOTE: A separate cover and a separate gasket is used on all engines

before September 7, 2006. Install 8 bolts and isolator assemblies.
5. Tighten bolts in sequence shown in Fig. 58. See TORQUE SPECIFICATIONS.
Fig. 58: Rocker Lever Cover Torque Sequence
THRUST BEARINGS
Removal
injury.

NOTE: Thrust bearings replacement is recommended when main bearings are

replaced.

3. Remove oil suction tube. See ENGINE OIL SUCTION TUBE-(BLOCK MOUNTED)
5. Remove No. 4 main bearing cap. See Main Bearings
6. Remove thrust bearings from No. 4 main bearing cap.
7. Mark thrust bearings as being lower, and front or rear bearings.
CAUTION: Remove upper thrust bearings with care to prevent damage

to crankshaft.
8. Remove upper thrust bearings with blunt tool.

9. Mark these bearings as being upper, and front or rear bearings.
Inspect Condition
Inspect thrust bearings for scratches, galling, uneven wear, or other damage, replace if so.
If any of thrust bearings are damaged, inspect crankshaft, block, and main bearing cap for damage
also.
Installation
1. Coat upper thrust bearings with Lubriplate 105, or equivalent.

2. Push crankshaft toward rear of engine to install rear thrust bearing, and to front of engine to
install front thrust bearing.
3. Install upper thrust bearings in No. 4 main bearing saddle. Position bevel toward crankshaft.
4. Coat lower thrust bearings with Lubriplate 105, or equivalent.
5. Install lower thrust bearings in No. 4 main bearing cap as indicated. Position bevel toward
crankshaft.
Fig. 59: Installing Lower Thrust Bearings
6. Install main bearing cap. See Main Bearings.

MOUNTED) .
10. Add clean engine oil to fill engine.
11. Engine should have enough oil pressure within 15 seconds after starting. If warning light
indicates low oil pressure or there is no oil pressure indicated on a gauge within 15 seconds,
shut off engine as soon as possible to avoid engine damage. Ensure correct oil level is in oil
pan.
TRANSMISSION OIL COOLER-TO-WATER PUMP PIPE (VT)
possible.
Ensure only experienced personnel perform this procedure. Obtain training if necessary.
Removal
1. Coolant Extractor (DBT2V700) is connected to drain fitting at bottom of radiator, and engine
coolant is drained.
NOTE: Connect Drain Hose (9996049) to drain fitting. Use proper

container to collect coolant.
2. Remove air filter housing and fresh air pipe.

3. Loosen hose clamp. Disconnect transmission cooler coolant hose at metal pipe connecting to
water pump housing.
4. Remove clamp that connects metal coolant pipe over top of transmission, and remove engine
oil filter.
5. Cut nylon ties that connects block heater harness to metal pipe.
6. Remove metal coolant pipe bracket-to-side of cylinder block connecting nut.
7. Disconnect water pump housing fitting and remove metal transmission coolant pipe.
Installation
1. Place metal transmission cooler pipe in between engine and frame on right side. Connect fitting
at water pump housing, DO NOT tighten.
2. On right side of cylinder block, place pipe bracket over stud and install metal pipe bracket-to-
side of cylinder block connecting nut. Now complete tightening of water pump housing fitting.
3. Install and connect block heater harness to metal coolant pipe using nylon ties.
4. Install engine oil filter.
5. Secure metal coolant pipe over top of transmission with clamp.
6. Connect coolant hose to metal pipe of transmission cooler and use single clamp to secure.
7. Install air filter housing and fresh air pipe.
8. Add recommended coolant to specified level with Coolant Extractor (DBT2V700).

9. With engine ON, inspect for coolant leaks.
UPPER GEAR COVER
Removal

personal injury.

3. Remove fan hub assembly.
4. Remove breather tube and hose. See Crankcase Breather-External.
5. Remove 16 bolts and upper gear cover. Dispose of strip seal.
Fig. 60: Identifying Upper & Lower Gear Cover

Use steam or solvent to clean gear cover and dry with compressed air.
Clean sealing surface on rear face of upper gear cover and seal groove on gear housing.
Inspect breather tube elbow and grommet. See Crankcase Breather-External.
Inspect upper gear cover for cracks or damage. Replace if cover is cracked.
Put upper gear cover on a flat surface and inspect it for flatness.
It is okay to use mallet to straighten an upper gear cover with minor bends.
Remove minor bends by laying gear cover on a flat surface and hit upper gear, if required.
Installation
WARNING: Get assistance or lift this component with proper equipment as it

weighs more than 50 lb (23 kg). This will prevent serious
personal injury.
1. Install NEW strip seal. Adjust overlap at top and center of gear housing. Use a small amount of
RTV at overlap joint of strip seal.
2. Install cover with 16 bolts.
Fig. 61: Upper Gear Cover Bolt Torque Sequence

7. Install breather tube and hose. See Crankcase Breather-External.
VISCOUS VIBRATION DAMPER
Removal
CAUTION: Vibration damper(s) can damage if removed with hammer or a

screwdriver. Avoid use of these tools.
1. Remove fan and water pump drive belt.

3. Remove fan and water pump belt tensioner. See
4. Remove 2 of vibration damper(s) and crankshaft pulley retaining bolts and install 2 guide studs
into holes.
5. Remove remaining 10 bolts and remove pulley and vibration damper(s).
NOTE: See Fig. 26

NOTE: Replace vibration damper(s) after a crankshaft nose failure. Mainly

excessive torsional activity causes crankshaft nose to break.
NOTE: Always measure vibration damper after a failure involving broken

gears in front gear train.
1. Clean vibration damper(s) with a solvent cleaner.

2. Inspect mounting web for cracks.
3. Inspect housing for dents or raised surfaces.
NOTE: Replace vibration damper if mounting web is cracked or housing

has dents or raised surfaces.
4. Remove paint on both sides of vibration damper in 4 locations spaced 90 degrees apart.
5. Measure and record thickness at 2 points at each of 4 locations. Difference between 2 of 8
measurements should not be above 0.010 in (0.25 mm).
Fig. 62: Vibration Damper Thickness
6. Spray vibration damper with spot check developer, Type SKD-NF, or equivalent and heat it in
an oven (rolled lip side down) at 200° F (93° C) for 2 hours.
7. Remove vibration damper from oven and inspect for fluid leakage. Replace damper if leak
found.
WARNING: Handle heated parts by wearing protective gloves to prevent

personal injury.
Installation
1. Mounting surfaces of crankshaft nose, vibration damper, and pulley must be clean, dry, and
free from burrs.
2. Install 2 guide studs into crankshaft nose.
3. Align dowel pin in crankshaft with dowel hole in vibration damper. Install vibration damper,
pulley, and clamping plate onto guide plate.
4. Lubricate bolt threads with clean 15W-40 oil. Install 10 bolts.
5. Remove 2 guide studs and install remaining bolts.
6. Tighten bolts in a star pattern to specification.
7. Install fan and water pump belt tensioner.
10. Operate engine and inspect for proper operation.
SPECIFICATIONS
CONNECTING ROD CRANKSHAFT BORE INSIDE DIAMETER SPECIFICATION
Connecting Rod Crankshaft Minimum 3.890 (98.801)
Bore Inside Diameter Maximum 3.891 (98.839)
Connecting Rod Piston Pin Minimum 2.502 (63.55)
Bushing Inside Diameter Maximum 2.503 (63.57)
Connecting Rod Length Minimum 10.293 (261.45)
Maximum 10.297 (261.55)
Maximum Connecting Rod Maximum 0.0008 (0.021)
Bend (Bushing Installed)
Maximum Connecting Rod Maximum 0.002 (0.05)
Twist (Bushing Installed)
CONNECTING ROD BEARINGS THICKNESS SPECIFICATION

Standard Connecting Rod Minimum 0.093 (2.366)
Bearing Thickness Maximum 0.094 (2.378)
CRANKSHAFT SPECIFICATION
Outside Diameter Of Minimum 3.700 (93.98)
Crankshaft Connecting Rod
Journal Maximum 3.702 (94.02)
Crankshaft Main Bearing
Journal Maximum 5.001 (127.02)
Crankshaft Thrust Face Width Minimum 2.163 (54.95)
Maximum 2.167 (55.05)
MAIN BEARING SHELL THICKNESS SPECIFICATION
Standard Main Bearing Shell Minimum 0.126 (3.196)
Thickness Maximum 0.127 (3.214)
Crankshaft End Clearance - Minimum 0.004 (0.10)
New or Re-ground Maximum 0.020 (0.50)
CRANKSHAFT REAR OIL SEAL FLANGE OUTSIDE DIAMETER

Flange Diameter Location (1) Minimum 6.495 (164.964)
Maximum 6.497 (165.035)
Flange Diameter Location (2) Minimum 6.515 (165.475)
Maximum 6.517 (165.525)
CRANKSHAFT FRONT OIL SEAL FLANGE OUTSIDE DIAMETER

Outer Flange Diameter (1) Minimum 5.482 (139.24)
Maximum 5.497 (139.63)
Inner Flange Diameter (1) Minimum 5.507 (139.89)
Maximum 5.513 (140.04)
Crankshaft Pilot Outside Minimum 1.968 (49.985)
Diameter Maximum 1.969 (50.015)
Total Indicator Runout Maximum 0.008 (0.200)
Adjacent Journal Runout Maximum 0.003 (0.075)
Rear Oil Seal Flange Total Maximum 0.0012 (0.03)
Indicator Runout
Front Oil Seal Crankshaft Maximum 0.002 (0.05)
Adapter Diameter Runout
(1) See Fig. 25
CYLINDER LINER SPECIFICATION

Pitting Depth Of Cylinder Maximum 0.060 (1.60)
Liner
Inside Diameter Of Cylinder Maximum 5.40 (137.14)
Liner
Fit Outside Diameter Cylinder Maximum 6.34 (160.98)
Top Press
Cylinder Liner Recession Minimum 0.014 (0.36)
(Groove-Top Cylinder Liners) Maximum 0.019 (0.51)
Cylinder Liner Protrusion Minimum 0.007 (0.18)
(Flat-Top Cylinder Liners) Maximum 0.014 (0.33)
PISTON SPECIFICATIONS
Inside Diameter (Crown) Of Minimum 2.502 (63.56)
Articulated Piston Pin Bore Maximum 2.503 (63.58)
Inside Diameter (Skirt) Of Minimum 2.5005 (63.513)
Articulated Piston Pin Bore Maximum 2.5010 (63.525)
Outside Diameter Of Piston Minimum 2.4987 (63.4670)
Pin Maximum 2.5000 (63.4999)
Articulated Piston Pin Length Minimum 4.311 (109.5)
Maximum 4.331 (110.0)

Single-Piece Piston Pin Length Minimum 3.331 (84.6)
Maximum 3.350 (85.1)
ARTICULATED PISTON RING GAP SPECIFICATION

Maximum 0.021 (0.53)
Maximum 0.084 (2.13)
Maximum 0.020 (0.51)
SINGLE-PIECE PISTON RING GAP SPECIFICATION

Maximum 0.021 (0.53)
Maximum 0.048 (1.23)
Maximum 0.020 (0.51)
VISCOUS VIBRATION DAMPER SPECIFICATION

Vibration Damper Eccentricity Maximum 0.011 (0.28)
Vibration Damper Wobble Maximum 0.011 (0.28)
Measurement
ENGINE BASE TIMING

Outside Diameter Of Lower Minimum 3.4992 (88.88)
Idler Shaft Maximum 3.4997 (88.89)
Adjustable Idler Shaft Maximum 3.4997 (88.89)
Inside Diameter Of Lower Minimum 3.5024 (88.962)
Idler Gear Bore Maximum 3.5035 (88.988)
Inside Diameter Of Adjustable Minimum 3.5024 (88.962)
Idler Gear Bore Maximum 3.5035 (88.988)
Shim Tolerance Minimum 0.009 (0.225)
Maximum 0.011 (0.275)
CYLINDER HEAD VALVE RECESS SPECIFICATION

Maximum 0.190 (4.82)
Maximum 0.036 (0.91)
Valve Guide Bore Inside Minimum 0.649 (16.48)
Diameter Maximum 0.650 (16.50)
Valve to Valve Seat Vacuum Minimum 20 in Hg (508 mm Hg)
Maximum 25 in Hg (685 mm Hg)
CYLINDER HEAD FLATNESS SPECIFICATION

A to A Maximum 0.006 (0.15)
B to B Maximum 0.006 (0.15)
C to C Maximum 0.006 (0.15)
Valve Spring Load at 2.431 in. Minimum 339.5 Ft Lbs (1511 N)
(61.75 mm) Maximum 360.5 Ft Lbs (1604 N)
Valve Stem Outside Diameter Minimum 0.378 (9.593)
Maximum 0.379 (9.627)
Used Valve Guide Inside Minimum 0.380 (9.663)
Diameter (Installed) Maximum 0.382 (9.713)
Valve Guide Height (Installed) Minimum 1.763 (44.77)
Maximum 1.802 (45.77)
INSERT BORE DEPTH SPECIFICATION

Maximum 0.373 (9.48)
Maximum 0.413 (10.48)
INSERT BORE INSIDE DIAMETER

Maximum 1.950 (49.54)
Maximum 1.872 (47.54)
Valve Guide Height Minimum 1.763 (44.77)
(Installed) Maximum 1.802 (45.77)
New Valve Guide Inside Minimum 0.380 (9.66)
Diameter (Installed) Maximum 0.382 (9.71)
OVERHEAD VALVE CAMSHAFT SPECIFICATION

Valve Camshaft Bearing Journal Outside In (mm)
Diameter
Minimum 2.5585 (64.987)
Maximum 2.5596 (65.013)
OVERHEAD INJECTOR CAMSHAFT SPECIFICATION

Outside Diameter Of Injector Minimum 3.3459 (84.987)
Camshaft Bearing Journal Maximum 3.3469 (85.013)
OVERHEAD VALVE CAMSHAFT END CLEARANCE SPECIFICATION

Valve Camshaft End Maximum 0.0276 (0.70)
Clearance
OVERHEAD INJECTOR CAMSHAFT END CLEARANCE SPECIFICATION

Injector Camshaft End Maximum 0.0276 (0.70)
Clearance
ENGINE BRAKE RUNNING CLEARANCE

Brake Running Clearance Minimum 0.025 (0.635)
Maximum 0.110 (2.79)
VALVE LASH SPECIFICATION

Intake Valve Nominal 0.014 (0.36)
Exhaust Valve Nominal 0.027 (0.69)
Engine Brake Lever Running Clearance Minimum 0.025 (0.635)
Engine Brake Lever Running Clearance Maximum 0.110 (2.790)
ROCKER LEVER ASSEMBLY SPECIFICATION

Outside Diameter Of Valve and Brake Rocker Lever Shaft
Minimum 1.3760 (34.950)
Maximum 1.3780 (35.000)
Outside Diameter Of Injector Rocker Lever Shaft
Minimum 1.7697 (44.950)
Maximum 1.7717 (45.000)
Inside Diameter Of Valve and Brake Rocker Lever Bushing Bone
Minimum 1.3794 (35.037)
Maximum 1.3834 (35.138)
Inside Diameter Of Injector Rocker Lever Bushing Bore
Minimum 1.7731 (45.037)
Maximum 1.7771 (45.138)
Intake and Exhaust Valve Adjusting Screw Length
Minimum 1.81 (46)
Rocker Lever Spacer Width
Minimum 0.453 (11.5)
FLYWHEEL BORE RUNOUT

Flywheel Bore Runout Maximum 0.005 (0.127)
REAR PTO IDLER GEAR TO CRANKSHAFT GEAR BACKLASH

Idler Gear to Crankshaft Gear Minimum 0.006 (0.15)
Backlash Maximum 0.011 (0.28)
CM870 GENERAL SPECIFICATIONS

Horsepower On engine dataplate.
Engine Speed:
400-450 hp On engine dataplate.
Displacement 912 C.I.D. (15 liters)
Bore and Stroke 5.40 in. (137 mm) x 6.65 in.
(169 mm)
Dry Engine Weight:
Automotive 2650 lb (1202 kg)

Industrial 3360 lb (1524 kg)
Power Generation 3020 lb (1370 kg)
Wet Engine Weight:
Automotive 2790 lb (1266 kg)
Industrial 3590 lb (1628 kg)
Power Generation 3250 lb (1474 kg)
Firing Order 1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine) Clockwise
Overhead Adjustment:
Intake Valve Adjustment 0.014 in. (0.36 mm)
Exhaust Valve Adjustment 0.027 in. (0.69 mm)
Injector Lash Adjustment Torque 70 In. Lbs (8 N.m)
Engine Brake Adjustment 0.276 in. (7.00 mm)
CM871 GENERAL SPECIFICATIONS

Horsepower On engine dataplate.
Engine Speed:
Displacement 912 C.I.D. (15 liters)
Bore and Stroke 5.40 in. (137 mm) x 6.65 in. (169
mm)
Dry Engine Weight: 3093 lb (1403 kg)
Wet Engine Weight 3246 lb (1472 kg)
Firing Order 1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine) Clockwise
Overhead Adjustment:
Intake Valve Adjustment 0.014 in. (0.36 mm)
Exhaust Valve Adjustment 0.027 in. (0.69 mm)
Injector Lash Adjustment Torque 70 In. Lbs (8 N.m)
Engine Brake Adjustment 0.276 in. (7.00 mm)
CUMMINS 18.7 CFM MODEL AIR COMPRESSOR SPECIFICATION

Cylinders 1
Compressor Swept Volume @ 1250 RPM 14.0 CFM (6.6 L/sec)
Piston Displacement 19.405 C.I.D. (318 cc)
Bore 3.346 in. (85 mm)
Stroke 2.204 in. (56 mm)
Speed Engine Speed
Cooling Engine Coolant
Lubrication Engine Lubricating Oil
Plumbing Line Sizes:
Coolant Inlet and Outlet 3/4 x 16 STOR
Air Inlet 1 in. (25.4 mm) Nominal
Air Outlet M27 x 2 STOR
Unloader Port M10 x 1 STOR
Governor Mounting Direct M8 x 1.25
Height, Overall (Approximate) 8.56 in. (217.4 mm)
Width, Overall (Approximate) 5.59 in. (142 mm)
Length, Overall (Approximate) 8.50 in. (216 mm)
Weight (Approximate) 35.0 lbs (15 Kg)
FUEL INLET & HOSE TEMPERATURE SPECIFICATION

Hose Temperature Minimum 500° F (235° C)
Fuel Inlet Temperature Minimum 45° F (7.2° C)
Maximum 132° F (55.5° C)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Belt Tensioner Mounting Bolt 33 (45)
Power Steering Pump Mounting Bolts 55 (75)
Refrigerant Compressor Idler Pulley Mounting Bolt 27 (36)
Refrigerant Compressor Bracket Wire Harness Bolts 14 (18)
Refrigerant Compressor Mounting Bracket Bolts
Bracket-To-Gear Housing Bolts 41 (56)
All Other Bracket Bolts 27 (36)
Refrigerant Compressor Bracket Bolts (Climate Control Inc.) 30 (41)
Front Gear Housing Mounting Bolts-(All Bolts)
Step 1 15 (20)
Step 2 53 (72)
Front Gear Housing Mounting Bolts-(Bolt No. 1 Only)
Step 1 15 (20)
Step 2 41 (56)
Camshaft Position Sensor 18 (25)
Crankshaft Pulley/Vibration Damper Retaining Bolts 130 (175)
Cylinder Head Bolts
Step 1 148 (200)
Step 2 300 (405)
Step 3 90°
Injector Hold Down Bolt 30 (41)
Injector Lever Adjusting Bolt Locknut 55 (75)
Valve Lever Adjusting Bolt Locknut 33 (45)
Valve Rocker Lever Shaft Mounting Bolts
Front Mounting Bolt Initial Torque 22 (30)
All Bolts 22 (30)
Step 3 60°
Injector Rocker Lever Shaft Mounting Bolts
Initial Torque 50 (68)
Loosen Bolts 360°
Step 3 22 (30)
Step 4 60°
Rocker Lever Cover 18 (25)
Upper Gear Cover Bolts 21( 28)
Lower Gear Cover Bolts 21 (28)
Crankcase Vent Hose P-Clips 21 (28)
Crankcase Breather Element Mounting Bolts
M10 Bolts 35 (47)
M8 Bolts 15 (20)
Main Bearing Cap Bolts

Step 1 110 (149)
Step 2 180°
Used Connecting Rod Bolts
Step 1 48-56 (64-76)
Step 2 60 ± 5°
NEW Connecting Rod Bolts
Step 1 25-33 (34-46)
Step 2 Loosen Bolts
Step 3 48-56 (64-76)
Step 4 60 ± 5°
Block Stiffener Plate Bolts 102 (137)
Accessory Bracket-to-Gear Housing Bolts 33 (45)
Accessory Bracket-to-Cylinder Head Bolts 33 (45)
Adjustable Idler Gear Retaining Bolts
Step 1 22 (30)
Step 2 60°
Lower Idler Scissor Gear Retainer Bolts
Step 1 22 (30)
Step 2 60°
Lower Idler Scissor Gear Loading Screws 21 (28)
Lower Idler Non-Scissor Gear Retainer Bolts
Step 1 22 (30)
Step 2 60°
Valve Camshaft Scissor Gear Retaining Bolt 109 (148)
Valve Camshaft Non-Scissor Gear Retaining Bolt 109 (148)
Valve Camshaft Retainer Plate Bolts 30 (40)
Injector Camshaft Scissor Gear Retaining Bolt
Step 1 160 (216)
Step 2 90°
Injector Camshaft Scissor Gear Loading Screws 21 (28)
Injector Camshaft Non-Scissor Gear Retaining Bolt
Step 1 161 (218)
Step 2 90°
Injector Camshaft Retainer Plate Bolts 30 (40)
Injector Camshaft Cover Plate Bolts 30 (40)
Engine Support Bracket-to-Engine Block
Step 1 72 (97)
Step 2 60°
Retaining Brace Bracket-to-Gear Housing Bolts 33 (45)
Retaining Brace Bracket-to-Cylinder Head Bolt 74 (100)
Retaining Brace Bracket Spacer Bolts 75 (105)
Engine Lifting Bracket Bolts 80 (108)
Flywheel Housing Bolts
Step 1 74 (100)
Step 2 145 (197)
Flywheel Bolts
Step 1 92 (125)
Step 2 184 (250)
Rear PTO Idler Shaft Plate-to-Idler Shaft Bolts 10 (14)
Rear PTO Idler Shaft Retaining Bolt
74 (100)
Rear PTO Flywheel Housing Plugs 21 (28)
Rear PTO Crankshaft Seal Bolts 21 (28)
Rear PTO Crankshaft Seal Replacer Flywheel Mounting 45 (60)
Bolts
Rear PTO Crankshaft Seal Replacer Bolts 15 (20)
Rear PTO 1/8 inch Pipe Plug 15 (20)
Rear PTO Straight Thread Plug 26 (35)
Rear PTO Flywheel Housing Cover Plate 48 (65)
Rear PTO Oil Spray Nozzle 15 (20)
Rear PTO Hydraulic Housing Mounting Bolts 50 (65)
Rear PTO Hydraulic Housing Bottom Threaded Plug 25 (32)
Rear PTO Hydraulic Housing Oil Line Hose 25 (32)
Air Compressor Mounting Bolts
Step 1 33 (45)
Step 2 33 (45)
Air Compressor Mounting Brace Bolts 33 (45)
Air Compressor Coolant Elbow Mounting Bolts 33 (45)
Air Compressor Discharge Line 44 (60)
Air Compressor Cylinder Head Bolts-(Single Cylinder) Used Assembly
Step 1 18 (25)
Step 2 90°
INCH Lbs. (N.m)
Injector Lever Adjusting Bolt 71 (8)
Crankcase Breather Element Cover Bolts 46 (5.2)
Crankcase Breather Element Sensor Clamp 20 (2)
Refrigerant Compressor Bracket Bolts (Sanden) 62 (7)
Crankshaft Adapter 120 (13.6)
Front Crankshaft Seal Tool Mounting Bolts 177 (20)
Front Crankshaft Seal Retainer Plate Bolts 71 (8)
Valve Adjusting Screw 5 (0.6)
Engine Brake Lever Adjusting Locknut 177 (20)
Rear Crankshaft Seal Retainer Bolts 141 (16)
Air Compressor Cylinder Head Bolts-(Single Cylinder) NEW Assembly
Step 1 53 (6)
Step 2 90°
Air Compressor Inlet Hose Clamp 71 (8)
Flywheel Housing Bolts Initial Torque 62 (7)
Rear PTO Flywheel Housing Bolts Initial Torque 62 (7)
Flywheel Housing Cover Plate 97 (11)
The above content is not endorsed by, sponsored by, or affiliated with Cummins Inc.
PIPE PLUG TORQUE VALUES
Torque Table
TORQUE CHART
Size Torque Torque
Actual In Cast Iron or Steel
Thread Thread O.D. In Aluminum Components Components
in in N.m Ft. Lbs N.m Ft. Lbs

1/16 0.32 5 45 In. Lbs 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100

Mechanical

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CUMMINS - ISX - CM870/871 - MECHANICAL -2013 Volvo VNL - Series - VNL-64 Стр.

Cummins ISX CM 870/871 - Engine Mechanical

Fig. 1: Identifying Engine Dataplate

l P/N = Part Number

Fig. 2: Locating ECM Dataplate (CM870 & CM871)

Fig. 3: CM870 - Left Side View

Fig. 4: CM870 - Right Side View

Fig. 5: CM870 - Front View

Fig. 6: CM871 - Left Side View

Fig. 7: CM871 - Right Side View

ST 1166-1 Magnetic Crack Detector

3164846 Piston Ring Compressor

DESCRIPTION & OPERATION

Important Safety Notice

WARNING: Use of proper practices, precaution, or aware of warnings is vital.

negative (-) cable first.

liquefied petroleum gas lines are disconnected in a well ventilated area.

GENERAL REPAIR INSTRUCTIONS

Safety-related components are given:

For inspections, follow recommended procedure. Damaged or excessively worn components or

Use of specified disassembly/assembly procedures is recommended for long service life of

Welding on a Vehicle with an Electronic Controlled Fuel System

CAUTION: Avoid connecting welder ground cable to ECM cooling plate or

GENERAL CLEANING INSTRUCTIONS

Abrasive Pads & Abrasive Paper

NOTE: Blowing debris out of oil drilling using compressed air on an

NOTE: Use hand to clean around oil hole/opening to prevent contamination of

NOTE: Blowing debris out of oil drilling using compressed air on an

CAUTION: If these scrapers are used on soft materials based components,

DO NOT scrape or brush across gasket surface if possible.

Solvent & Acid Cleaning

NOTE: Obey manufacturer's instructions ONLY while cleaning.

WARNING: Obey manufacturers instructions to use solvents, acids, or

NOTE: As much as pH value of a chemical, increases from neutral 7.0,

A listing of components that should be avoided from steam cleaning are:

l Bearings (ball or taper roller)

Plastic Bead Cleaning

Read and digest following information regarding cleaning:

CAUTION: Ensure bead blasting operation does not disturb metal

NOTE: Disturbance of machining marks by blasting process

NOTE: Spray does not just hit dirt or carbon. Disturbance of

ENGINE BASE TIMING

Front Gear Assembly Configuration

Fig. 8: Front Gear Assembly (Non-Scissor Gears)

WARNING: Read scissor gear definitions before removing gears. Adhere to

1. Unloaded: When removing, installing, and setting gear backlash.

ADJUSTABLE IDLER GEAR

NOTE: Before installation or removal of any gears, inspect engine base

LOWER IDLER GEAR

Before installation or removal of any gears, inspect engine base timing.

PERMISSIBLE MAGNETISM LEVELS

5 or less gauss units 15 or less gauss units

NOTE: NEVER demagnetize sensors, engine control modules, or actuators.

DO NOT attempt to demagnetize a whole engine assembly.

Following are sources of electrical damage:

l Electrically actuated components e.g., clutch.

Contaminated Intake Air

Whenever making any replacement, remember:

l Not all replacement procedures are applied to all types of equipment.

Fig. 9: Engine Lifting Brackets

Fig. 10: Identifying Groove-Top Liners & Flat-Top Liners

CYLINDER HEAD VALVE GUIDE SEAL

NOTE: Seals mating with grooved valve guides had 2 iterations.

1. Engines built from 15 May 2000 to February end 2002 had

For information about adjustment values, see Overhead Set-Adjustment.

COMPRESSED AIR SYSTEM

Common components of a compressed air system are:

l Air compressor (Gear-driven)

Fig. 11: Air Compressor

Common components of a single cylinder air system are:

NOTE: Early oil consumption or high-blowby are symptoms for running

Engine Dynamometer Run-In

Chassis Dynamometer, Portable Dynamometer, or Load Bank Run-In

WARNING: Allow air discharge lines to cool before handling to prevent

Remove air inlet and outlet connections from air compressor.

Measure total carbon deposit thickness inside air discharge line.