B Series Shop Manual 1991 and 1994 Certification Levels Four Cylinder Six Cylinder 4BT3.9 6BT5.9 Copyright® 1994 Bulletin 3666017-01 Cummins Engine Company, Inc. Printed in U.S.A. 11/94 (996) All rights reservedForeword ‘This manual contains complete rebuild specifications and inforrnation for the B Series engines, and all associates components manutactured by Cummins Engine Company, Inc. A listing of accessory and component suppliers’ addresses and telephone numbers 1s located ia Section C. Suppliers can be contacted directly for any information not covered in this. manual Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in this section. The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild procedures require the use of special serwce tools. Make sure the Correct tools are used as described in the procedures, When a specific brand name, number, or special tool 1s referenced in this manual, an equivalent product can be used in place of the recommended item. A series of specific service manuals (Troubleshooting and Repair, Specifications, Alternative Repair, and so on.) are available and can be ordered by filling out and maiting the Literature Order Form located in the Service Literature Section L. Reporting of errors, omissions, and recommendations for improving this publication by the user 1s encouraged, Please use the postage paid, self-addressed Literature Survey Form in the back of this manual for communicating your comments. The specifications and rebuild information in this manuat is based on the information in effect at the time of printing Cummins Engine Company, Inc. reserves the right t6 make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummuns Authorized Repait Location, a Cummins Division Office. or the factory. The latest technology and the highest quality components are used to manufacture Cummins engines. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange pans. These parts can be identified by the following trademarks GE Fieelquart’ 2aczesTable of Contents Introduction... 0.0626 e eee Engine Identification 2.0.02... eee coe Engine Disassembly and Assembly --Group 00 Cylinder Block - Group 01 .......... we ev cece eens weve eee Cylinder Head - Group 02 ........... co ccebteeserseeneeeesenees Rocker Levers - Group 03 Cam Followers - Group 04 ......... Fuel System - Group 08. injectors and Fuel Lines - Group 06 _ beeen eee states Lubricating Ol! System - Group 07.6... 2s. d eee Cooling System - Group 08 Drive Units = Group 09. Air Ihtake System - Group 10 ......... Exhaust System - Group 11-5 ....+ Alr Equipment - Group 12 .:....-.-- Electrical Equipment - Group 13 ....- 6-0... eee eee cece eee cee eee eens Erigine Testing - Group 14 Mounting Adaptations - Group 16 -. . Specifications - Group 18 Service Literature . Component Manufacturer Index ooo ee pee eee eep eee et neces 0-1 1 a4Cummins 22-Group System Exploded Diagram ew900gySection: introduction . How To Use The Manual B Series : Page 1-3 How To Use The Manual All references to engine components in this manual are divided into 22 specitic groups. The organization 1s consistent with the service bulletins, service parts topics, and the parts catalogs for your convenience in updating the shop manual. Table of Contents The Table of Contents in the front of the manual contains a quick page reference for each group number Group Contents Each group contains the following information: + A group index page at the beginning of each group to quickly aid in locating the information desired * General information to aid in rebuilding the component and an explanation of design change differences. = Step-by-step rebuild instructions for disassembly cleaning, inspection, and assembly of the component. * Symbols which represent the action outlined in the instructions. The definitions of the symbols, listed in four languages (English, Spacish, French, and German), appear on pages 1-5 through +8. Index An alphabetical index 1s in the back of the manual to aid in locating specific information. Metric Information Both metric and U.S. customary values are used tn this manual. The metnc value 1s listed first, followed by the U.S, customary in brackets. An example Is 60°C [140°F),Section! Introduction Generic Symbols B Series. Page 1-4 Generic Symbols The following group of symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning detined below. COMEIOHOBRD b> @ } WARNING Serious personal injury or extensive property damage can result if the warning instructions are not followed. CAUTION Minor personal injury can result or a part, an assembly or the engine can be damaged if the caution instructions are not followed Indicates a REMOVAL or DISASSEMBLY step. Indicates an INSTALLATION or ASSEMBLY step. INSPECTION ts required. CLEAN the part or assembly PERFORM a mechanical or time MEASUREMENT LUBRICATE the part or assembly Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque. PERFORM an electrical MEASUREMENT Refer to another location in this manual or another publication fer additional information. The component weighs 23 kg [50 Ib] or more. To avoid personal injury use a hoist or get assistance to lift the component.Hlustrations Page 8 illustrations The illustrations used in the “Repair Sections” of this manual are intended to givo an example of a problem, and to shew what to look for and where the problem can be found. Some of the-illusirations are “generic” and might not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required, and an acceptable or not acceptable condition. The illustrations are intended to show repair or replace- ment procedures. The illustration can differ from your application, but the procedure given will be the same. Section 1 - Introduction B Seres. aaSection Introduction B Series Section i - Introduction . Section Contents About the Manual. General Cleaning instructions .. Glass or Plastic Bead Cleaning. Solvent and Acid Cleaning Steam Cleaning General Repair Instructions General Safety Instructions. Important Safety Notice... Generic Symbols Glossary of Terms How Yo Use The Manual Group Contents Index. Metaic information Table of Contents. Mustrations..... sssneseenue Simbolos Usados En Este Manual SYMBOE -eesrsce ets Symboles Utilises Dans Ce Manuel .. Page +1About the Manual Section: Introduction Page -2 B Senes About the Manual ‘This manual contains information for 1991 and newer engines starting with ESN 44566920. For information on prior built engines refer to the B Series Shop Manual, Bulletin No, 3810206-02 The procedures in this manual were developed for a shop environment with engine disassembly and assembly being performed on a rollover stand. A Group System has been used to subdivide the instructions by major components and systems. Refer to the Table of Contents (page |-1) for the various groups. The information 1s presented in very basic terms to make sure the structions are easily understood. Wrench sizes and shop tooling are identified in the procedure when needed Each group contains the following in sequence: + An Alphabetical Table of Contents (Index). * Exploded view(s) of all the components in the group * General information Section(s) containing the basic service, maintenance, and design information necessary to assist in the rebuild of the engine or a component. * Procedural instructions for the disassembly, inspection, repair, and assembly that can be required to rebuild an engine. Additional repairs that are not essential dunng every rebuild, but can be necessary, are included. These repairs depend on the length of time an engine has been in service and the condition of the parts.Section 1 Introduction General Safety Instructions B Series Page 1-9 General Safety Instructions Important Safety Notice Ay WARNING AY Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodlly injury or death. Read and understand all of the safety precautions and warnings before performing any repaur. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are Included in the procedures when they apply. * Make sure the work ar2a surrounding the product is dry, well lit, ventilated; free from clutter, laose tools, parts, Ignition sources and hazardous substances. Be aware of hazardous conditions that can exist Always wear protective glasses and protective shoes when working Rotating parts can cause cuts, tnutilation or strangulation. Ds not wear loose-fitting or torn clothing, Remove all jewelry when warkiag. Disconnect the battery (negative [-) cable first) and discharge any capacitors before beginning any repatr work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a “Do Not Operate" tag in the operator's compartment or on the controls. * Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan, This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. * Ifan engine has been operating and the caolant is hot, allow the engine to cool before you slowly loosen the filler cap and relieve the pressure from the cooling system. + Do not work on anything that 1s supported ONLY by lifting sacks or a hoist. Always use blocks or proper stands to support the product before performing any service work * Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury. * To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon) lines in a well ventilated area. To protect.the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (tlvorocarbons) into the atmosphere. Federal law requires capture and recycling refrigerant. © To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 Ib] or mare. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded. '* Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. * Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution, Follow the manufacturer's instructions to provide completa safety when using these materials. KEEP OUT OF REACH OF CHILDREN. + Toavoid burns, be alert for hot parts on products that have just been turned OFF and hot fluids mn fines, tubes, and compartments + Always use tools that are in good condition. Make sure you understand how fo use them before performing any service work. Use ONLY genuine Cummins or Cummins Recon® repiacement parts. * Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lessor quality if replacements are necessary. ‘+ Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning. + Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oilGeneral Repair Instructions Section | Introduction Page 1-10 B Series General Repair Instructions This engine incorporates the latest diesel technology at the time it was manufactured; yet, it 1s designed to be repaired using normat repair practices performed to quality standards. * Cummins Engine Company, tnc. does not recommend or authorize any modifics ns or repairs to engines or components except tor those detailed in Cummins Service information. In particular, un- authorized repair to safety-related components can cause personal injury or death. Below 1s a partial listing of components classified as safety-related: ‘Air Compressor Air Controls Alr Shutoff Assemblies Balance Weights Cooling Fan Fan Hub Assembly Fan Mounting Bracket(s) Fan Mounting Capscrews Fan Hub Spindie Flywheel Flywheel Crankshaft Adapter Flywheel Mounting Capscrews Fuel Shutoff Assemblies Fuel Supply Tubes Litting Brackets Throttle Controls Turbocharger Compressor Casing Turbocharger OH Drain Line(s) Turbocharger Ol! Supply Line(s) Turbocharger Turbine Casing Vibration Damper Mounting Capscrews + Follow All Safety Instructions Noted in the Procedures. Follow the manufacturer's recommendations for cleaning sdivents and other substances used dunng the repatt of the engine. Some solvents and used engine oil have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, injestion and contact with such substances. Always use good safety practices with tools and equipment, © Provide A Clean Environment and Foliow the Cleaning Instructions Specified in the Procedures The engine and its components must be kept clean during any repate. Contamination of the engine or components will cause premature wear. + Perform the inspections Specified in the Procedures. * Replace all Components or Assemblies Which are Damaged or Worn Beyond the Specifications * Use Genuine Cummins New or ReCon® Service Parts and Assemblies The assembly instructions have been written to use again as many components and assemblies as possible. When it is necessary to replace a component or assembly, the procedure ts based on the use of new Curmmins or Cummins ReCon® components, All of the repair services described in this: manual are available from all Cummins Distributors and most Dealer locations. + Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components. Somplete rebuild instructions are available the shop manual which can be ordered or purchased from a Cummins, Authorized Repair Location. Refer to Section L, Ulterature, for ordering instructions.Section 1 Introduction General Cleaning Instructions B Series Page i-11 General Cleaning Instructions Solvent and Actd Cleaning Several solvent and acid-type cleaners can be used to clean the engine parts. Cummins Engine Company, Inc. does not recommend any specific cleaners. Always follow tha cleaner manufacturer's instructions. Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95 degrees Celsius [180 to 200 degrees Fahrenheit). A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best'resuits. De Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before putting the parts in a cleaning tank. Be careful not o damage any gasket surfaces. When possible, steam clean the parts before putting them in the cleaning tank. fy Warning: Acid is extremely dangerous, and can damage the machinery. Always provide a tank of strong soda water as a neutralizing agent. Rinse all of the parts in hot water after cleaning. Ory completely with compressed air. Blow the rinse water from all of the capscrew holes and the oil drilings If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The tustproofing compound must be removed from the parts before installation on the engine. Steam Cleaning Steam cleaning can be used to remove all types of dirt that can contamimate the cleaning tank. It is a good way to clean the oil drillings. Warning: Wear protective’clothing to prevent personal injury from the high pressure and extreme heat. Do not steam clean the following parts: 1 Electrical Components 2. Wiring 3. Injectors 4. Fuel Pump 5. Belts and Hoses 6. Bearings Glass or Plastic Bead Cleaning Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process 1s controlled by the size of the glass or plastic beads, the operating pressure, and the cleaning time. A Caution: Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead cleaning on aluminum ring grooves. Small particles of glass or plastic will embed in the alummum and result in premature wear. Valves, turbocharger shafts, etc., can also be damaged. Follow the cleaning \] directions listed in the procedures. NOTE: Plastic bead blasting media, Part No. 3822735, can be used to clean aluminum ring grooves. Do not use any bead blasting media on pin bores or aluminum skirts. Follow the equipment manufacturer's cleaning instructions. The following guidelines can be used to adapt to manufacturer's instructions: 1 Bead size: Use U.S. size No. 16-20 for piston cleaning with plastic bead madia, Part No. 3822735. Use U.S. s1z6 No. 70 for piston domes with glass media. Use U.S. size No, 60 for general purpose cleaning with glass media. 2. Operating Pressure: Glass: Use 620 kPa [90 psi] for general purpose cleaning. Plastic: Use 270 kPa [40 psi] for piston cleaning 3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads after cleaning. Rinse with hot water. Ory with compressed air. 4. Do not contaminate the wash tanks with glass or plastic beads,Glossary of Terms Page 1-12 AG. AFC: TDC: BDC: TDC: Circumferential Direction: Concentricity CPL. Cummins Sealant: DC. Dye Penetrant Method: End Clearance: ESN. Hammer: LD. Loctite 290: Loctite 609: Lubriplate 105: Section: Introduction B Series Glossary of Terms Definition Alternating Current Air Fuel Control; a device in the fuel. pump that limits the fuel delivery until there 1s sufficent intake manifold pressure to allow for complete combustion. After Top Dead Center’ refers to the position of the piston or the crankshaft rod journal. The piston 1s moving downward on the power stroke or intake stroke. Bottom Dead Center: refers to the position of the piston or the crankshaft rod Journal. The piston is at its lowest position in the cylinder. Before Top Dead Center’ refers to the position of the piston or the crankshaft rod journal. The piston is moving upward on the compression stroke or ex- haust stroke. In the direction of a circle in respect to the centerline of a round part or a bore. ‘A measurement of the difference between the centers of elther two or more parts or the bores in one part. ' Control Parts List; this listing entities the specific parts that must be in- stalled on the engine to meet agency certification, This 1s a one part Room Temperature Vulcanizing (RTV) silicone rubber, ad- hesive and sealant material having high heat and oil resistance, and low compression set Some of the equivalent products are Marston Lubricants, Hylosit, Dow Corn- ing, Silastic 722, Loctite Supertiax, General Electric 1473, and General Elec tne'14 Direct Current AA method sad to check for cracks in @ part by using a dye penelrant and @ developer. Use crack detection kit, Part No. 3375432, or its equivalent. The clearance in an assembly determined by pushing the shaft in an axial direction one way and then pushing the shaft the other way Engine Serial Number Ahand tool consisting of a hard steel head on a handle, Ingide Diameter A single component, anaerobic, polyester resin, liquid sealant compound that hardens between closely fitted metal surfaces producing a tough, hard bond, An equivalent product 18 Perma-Lok HL 126, A single component anaerobic, liquid adhesive that meets or exceeds the re- quirements of MIL-R-48082A (MR) TYPE1 Some of the equivalent products are Loctite 601 and Permabond HiL 138. ‘A mineral oil base grease with calcium soap (2 percent to 6 percent), and zinc oxide (2 percent to 4 parcent) additives.Section 1 Introduction B Series Magnetic Particle Inspection: Mallet: MAX, Min No. oD. OS: Protrusion: STD: To: TOC: TLR. Water Pump Grease: Glossary of Terms Page i-13, Definition ‘A method of checking for cracks in elther steel or iron parts. This method requires a Magnafiux or equivalent machine that imparts a magnetic field on - the part being checked A hand tool consisting of a soft head, elther wood, plastic, lead, brass, or rawhide, on a handle. Maximum allowed Minimum allowed Number Outside Diameter Oversize The difference in the height betwoen two parts inthe assembled state Standard Torque Converter: used when referring to the torque converter cooler. ‘Top Dead Center refers to the position of the piston or the crankshaft rod Journal. The piston 1s at its hughest position in the cylinder. The rod journal 1s pointing straight up toward the piston. Total Indicator Runout; used when measuring the concentncity or the runout The TLR. raters to the total movement of the needle on a dial indicator, from the most negative reading to the most positive reading. A premium high temperature grease that will lubricate antifriction bearings continually from minus 40°C [minus 40°F] to plus 150°C [Plus 350°F] Some of the greases meeting this requirement are Aeroshell No. 5, Chevron SRI, Amoco Rykon Premijm No. 2, Texaco Premium AB, and Shell olium R. Aerostell No, 5 Is not compatible with the other greases and must not be mixed. Cummins Engine Company, Inc., uses Aeroshell No. 5 on new en- gines and components,Section E Engine and Component Identification B Series Page E-1 Section E - Engine and Component Identification Section Contents ne Engine Diagram Automotive Engine... a a Engine Identification E2 Automotive Engine Dataplate .. E28 ‘Automotive Engine Nomenclature... £3 Engine Dataplate .. E2 Industrial Engine Nomenciature E38 General Engine Specifications. e6 Batteries (Specific Gravity)... E8 Cooling System. E7 Electrical System Es Fuel System... E7 General Engine Data: E6 Intake Air and Exhaust Sysiam . E? Lubrication System .... . E6 Injection Pump Dataplate......... ese even E4 Lucas CAV BPA dataplate location’... & ron : . vo 4 Robert Bosch VE dataplate location. .Engine Identification Page E-2 Section E Engine and Component Identification B Series Engine Identification Engine Dataplate The engine dataplates show specific information about jour engine. The engine serial number (1) and Control Parts List (CPL) (2) provide information for ordering parts and servicing the engine. NOTE: The engine dataplate must not be changed unless approved by Cummins Engine Company, Ino. Ei a ee Samaras Eh eben [ak F eee ma] & [ee aoa ee fc nd |__Baaee ve Sa cone | | ha mia Don OF ais ea Caloge-PMH. Matwut No. me SSS L, AVERTSSEMENT. Danger de ensue o« Siaxcntaion ane eek ose s EP rat no. Gs perme « cota combust 270M cw aR, dex Sevmk Froe Aen Eon Zee ee See = ae was BAR oe = Sees ars eons 7 “= Sie aims fastener ; Automotive Engine DataplateSection E Engine and Component Identification B Senes Industrial Engine Nomenclature The mode! name for Industrial engines provides the fol- lowing engine data: 4BTA39 Le L. Displacement in Liters Aftercooled Turbocharged Engine Series Number of Cylinders Automotive Engine Nomenclature The model name for Automotive engines provides the following engine data: B59 190 L_ Horsepower Rating Displacement in Liters Engine Series Engine Identification Page E-3Injection Pump Dataplate Section E - Engine and Component Identitication Page E-4 B Senes Injection Pump Dataplate The injection pump dataptate is located on the side of the injection pump. It provides information for fuel pump cal- ibration, Robert Bosch VE dataplate location. ‘e20%00 Lucas CAV DPA datapiate location. Stanadyne DB4 Dataplate Location In-Line Injection Pump Dataplate Location This illustration shows the dataplate location for the Bosch and Nippondenso in-line injection pump.Section E Engine and Component Identification 8 Senes The Cummins part number for the fuel pump-governor combination is focated on the governor dataplate. Injection Pump Dataplate Page E-5General Engine Specifications Section E Engine and Component Identification Page E-6 B Senes General Engine Specifications General Engine Data . 102 mm (4.02 in] BOL cess otnctssessentv Stroke .. a 4120 mm [4.72 in] Displacement 4B... - 3.92 liters [289 in} 6B .... 5.88 liters [359 in*] Compression ratio 4B3.9/6B5.9 Industrial, naturally aspirated + 18.5: 4873.9/6BT5.9 Industrial, turbocharged .. . coe 17.8: 4BTA3.9/68TAS.9 Industrial, turbocharged and‘aftercooled ......- 1 16.5:1 83.9/B5.9" Automotive, charge air cooled . eoseseenuese . 47.631 Firing order 6 cylinder’ . ee 1 VEE 24 oe 1-OAD 4 cylinder ... - Valve Settings Intake Valve Adjustment ... Exhaust Valve Adjustment... soseenseenseennncne oe sescnseee 0.25 mm (0.010 in} . 0.51 mm [0.020 in] Clockwise Engine rotation (viewed from front of engine) a - . Engine weight (with standard accessories) . 325 to 350 kg (715 to 770 Ib] 410 to 440 kg [910 to 970 Ib} 4 cylinder engines . 6 cylinder engines ... - - - Lubrication System Oil pressure At idle (mirumum allowable) At rated speed (minimum allowable) ocsnniseesennnneneerssnsneseens 69 KPA [10 psi] .. 207 kPa [30 psi] . (1991) 449 kPa [65 psi} (1994) 517 kPa [75 psi] Differential pressure to open oil filter bypass Valve... oesttseenecersneee (1991) 138 kPa [20 psi] (1994) 172 kPa [25 psi] Regulating valve opening pressure ...ccsenaee Oil-capacity of standard engine 4 cylinder engines 6 cylinder engines ....... . 8.5 titers (10 U.S. Qts.] ove 14.2 liters (15 U.S. Qts.] Total system capacity 11.0 liters [11.6 U.S. Qts.] ~. 16.4 liters [17.3 U.S. Qts.] 4 cylinder engines 6 cylinder enginesSection E Engine and Component Identification General Engine Specifications B Series Page E-7 Cooling System Thermostat Begins to Open s.ssscsisssse pe - 81°C [181°F] Fully open eesscnennsetee . - - - 95°C (203°F] Pressure cap for 99°C {210°F] system - - - - +. 50 kPa,{7 psi) Pressure cap for 104°C {220°F] system sve 103 kPa [15 psi] Coolant capacity (engine only) 4 cylinder (noniaftercooled, charge atr cooled)” ........ 4 cylinder (jacket water aftercooled) .....2...--+: 6 cylinder (non-aftercooled, charge air cooled)”. 6 cylinder (jacket water aftercooled) ...... 7.0 liters [7 4 U.S. Qts.] - 7.9 liters [8.4 U.S. Qts.] sesseeneen 9.0 liters [9.5 U.S, Qts.] . 9.9 liters [10.5 U.S. Qts.} intake Air and Exhaust System Maximum alfowable intake restriction at rated speed and load (with dirty air filter element) Naturally Aspirated ...... - 50.8 om H,0 [20 in H,0) Turbocharged ....rsuesseee poner sess »- 63.5 om H,0 [25 in H0] Maximum turbocharger outlet restriction at rated speed and load ....... - 76.2 mm Hg [3 in Hg] Maximum exhaust restriction at rated speed and load Automotive with oxidation catalyst Automotive .. 152.4 mm Hg [6 in Hg} 114.3 mm Hg [4.5 in Hg] 76.2 mm Hg [3 in Hg} Industrial Fuel System Fuel transfer pump maximum inlet restriction .... . . seeseseneens 100 mm Hg [4 in Hg} Fuel transfer pump output pressure al rated speed 70 kPa [10 psi) 172 kPa (25 psi] Distributor fuel injection pumps (maximum) Inline fuel iryection pumps (minimum) . Fuel filter restriction (maximum pressure drop across filters) - seoceeeeteeneeasenness 3S KPa [5 psi} Fuel return restriction (maximum) . scscseeseenenenee 518 mm Hg [20.4 in Hg] * All 1991 and 1994 automotive engines with charge air cooling are designated as B3.9 or B5.9.General Engine Specitications Section E_ Engine and Component Identification B Senes Page E-8 Electrical System Minimum Recommended Battery Capacity Light accessories including alternator, power steering pump, and disengaged clutch 12 Volt System 4 cylinder engine . 625 CCA 6 cylinder engine 800 CCA 24 Volt System* 4 cylinder engine ..... 400 CCA - 400 CCA 6 cylinder éngine .... 7 Heavy accessories including hydraulic pump and torque converter 12 Volt System 4 cylinder engine ...... 6 cylinder engine 24 Volt System* 4 eylinder engine 6 cylinder engine 800 CCA . 950 CCA 400 CCA . 475 CCA * Per battery (two 12 volt batteries in series) CCA Ratings are based on 18°C [°F]. Batteries (Specific Gravity) Specific Gravit State of Charge 1.260 1.280 100% 4.230 1.250 75% 1.200 1.220 50% 1170 1 490 25% 1110 1130 Discharged 'Section E - Engine and Component Identification Engine Diagram Automotive Engine B Series Page E-9 Engine Diagram - Automotive Engine The illustrations which follow show the locations of the major external engine components, the filters, and other service and maintenance points. Some external components will be at different locations for different engine models. Enger. ign Prose Inch AP ~L. a Ino Fi Fl Fer/ ‘sey Separaie ‘x Cartorassor NPT (ny Wa aes yt NTE Reali Stcton Magnede Pickup Location 30 UN A Comoros Fuad Un Pump Engne Data Pate Ofpaick 18 NPTE Gren) Ol Pressure none Inlet Side _ Tuto Exhaust Outlet Flaxpiate Mounting Holes Rear. ViewEngine Diagram Automotive Engine Section E Engine and Component Identiication eres. Page E-10 uot (ypotion Nozzles ‘Turbocharger Side View Texto Air Out Engine Air int _—— Fut Pump Drwe Cover Front ViewSection 0 Engine Disassembly and Assembly Group 00 B Sones Shop Manual Page 0-1 Section 0- Engine Disassembly and Assembly - Group 00 Section Contents Page Accessories Installation - 0-88 Accessories Removal... ve . ec 024 Alternator Installation... om Alternator Removal .. ont Balancer installation... 0-62 . 035 Balancer Removal... Locking the Balancer. Measuring Backlash... Measuring the End Play Removing the Balancer . Belt Tensioner Installation... Belt Tensioner Removal Camshaft _installatio: Camshaft End Play Measuring. sguctnecnsne Camshaft Gear, Backlash - Measuring . 059 O31 Camshaft Removal... sen - a - Measunng Gear Lash... ee ts te cesses : seve 0-31 Crankshatt Installation... Crankshaft Removal. 0-35 0-35 na O85 “0-36 ont 0-10 0-56 . 058 0-42 0-39 Crankshaft End Play Measuring sos 0-66 Cylinder Block Propare for ASSEMBLY .esie-siee ee - en OBI Cylinder Block Removing From the Rollover Stand . a ost Cylinder Head Installation ese 7 0-92 . 0-22 Cylinder Head - Removal . Cylinder Head Tightening .. Dipstick Removal... Drive Belt Installation Drive Belt Removal. Engine Assembly Engine Disassembly eee Engine Disassembly and Assembly . Assembly Disassembiy General Information Engine Disassembly and Assembly Service Toots. Engine Disassemibly Check List Engine Weight ...esc.ccercnn Exhaust Manifold installation ... Exhaust Manifold Removal Fan Hub Installation Fan Hub - Removal Fan Pulley Removal Flywheel InstallaticSection 0 Engine Disassembly and Assembly Group 00 Page 0-2 8 Serres Shop Manual Page Flywheel Removal. a reset 0-23 Flywheel Housing Installation Flywheel Housing Removal. Front Cover Installation... Front Cover Removal... Fuel Filter Removal..... . Fuel Filter Head. Installation ...... Fuel Filter Head Removal... Fuel Lines _installation...... Fuel Drain Manifold Installation. 7 High Pressure Fuel Lines Installation... Injection Pump Supply Line Installation Injection Pump Vent Line Installation Fuel Lines Removal ...... Fuel Orain Manifoid Removal. High Pressure Fuel Line Removal ......0000-0 Low Pressure Fuel Lines Removal. . . Fuel Transfer Pump Installation . . Fuel Transfer Pump Removal «0.0.0 Gear Housing Installation Gear Housing Removal... Injection Pump _ Installation Injection Pumps Unlocking : Locked Timed Injection Pump installation one e Unlocked Bosch VE and P7100 Injection Pump Installation Unlocked CAV Injection Pump. Installation..-m:.-.- Unlocked Stanadyne DB4 Injection Pump installation.... Injection Pump Removal (In-Line). Injgotion Pump Removal (Rotary Type Pumps). Drive Gear Removal Geer Lash Check... Locking the Pump: Injector Nozzles Installation .. Injector Nozzles Removal.......... KSB (Remote Mounted) Instalfation .... KSB (Remote Mounted) Removal Lifting Bracket Removal Rear. Lube Pump Installation... Lube Pump Removal. Measuring Backlash. Manifold Cover Installation ..... ‘Aitercooler installation... Manifold Cover Removal Aftercooler Removal. Oil Draining... Oil Cooler Installation... Oil Cooter Removal Oil Filter Installation... Oil Pan Installation .....Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Oil Pan Sealing’ Surfaces Sealants Oil Pan Removal. Piston and Red Assemblies Installation Piston and Conhecting Rod Assemblies Installation. Piston Grading For 1984 Automotive Applications Only. v Piston and Rod Assemblies Removal Push Rods - Installation .. Push Rods Removal Rear Seal Installation... Rear Seal Housing Removal... Rocker Levers Installation Rocker Levers Removal... Rollover Stand Engine Mounting Rollover Stand Engine Removal Side Oil Fill Installation Side Oj Fill - Removal .. Starter Instalfation......j..denn Starter Removal Steam Cleaning The Engine Suction Tube installation Suction Tube Removal Tappet Cover Installation... Tappet Cover Removat . 0-28 Thermostat Installation eines senses O408 Thermostat Removal... 7 0-12 Timing Pin Installation... . . cones O59 Timing Pin Housing Removal . 034 Turbocharger Installation... eee . 0-108 Turbocharger Removal . . 012 Turbocharger Drain Tube Removal... . 0-41 Valve Clearance Adjustment. 0-97 Valve Covers installation 0-100 Valve Covers Removal sevens 0°20 Valve Tappets Installation 0-42 Valve Tappets Removal... 0-32 Vibration Damper installation os O10” . 0-10 Vibration Damper/Crankshatt Pulley Removal Water Inlet Connection Installation...» z pone pocceneeescnees OTH Water Inlet Connection Removal 0-29 Water Pump installation 0-90 Water Pump Removal 0 - 0-23Engine Disassembly and Assembly Section 0 Engine Disassembly and|Assembly Group 00 Page 0-4 B-Series Shop Manual Engine Disassembly and Assembly General Information ‘These procedures apply to all B Senas engines. The differences between engine models due to the application, the optional equipment on an engine, and the year an engine was built are included in the instructions, Omit the steps that do not apply to the engine being rebuilt. Warning: A Warning statement is included for any component or assembly that weighs more than 23 kg [50 Ib], To avoid personal injury, use a hoist or get assistance when removing or installing these parts. Caution: All fasteners are specified in metric units. All fasteners have right-hand threads unless a Caution states that a fastener has left-hand threads. Disassembly The instructions in this procedure are organized in a logical sequence to disassemble an éngine. This is not the only sequence to disassemble an engine. Certain parts must be removed in the sequence indicated. Use this sequence until you become familiar with the engine. Discard all gaskets, seals, hoses, filters, and o-rings. Keep these parts if they are needed for a failure analysis, Label, tag, or mark the parts for location as the parts are removed. This will help tdertify the parts that can be involved in a failure and will simplify the assembly procedure. i Label, tag, mark, or photograph all special equipment prior to the removal from an engine This engine assembly procedure does not inciude the installation of special optional equipment. Use a mallet when force is required ta remove certain parts. Make sure alt of the fasteners are removed before using force. Avoid as much dirt as possible during disassembly The accumulation of additional dirt will make it more difficult to clean the components. Assembly This procedure assumes that all of the components and assemblies have been cleaned, replaced, or rebut and are ready to be installed on the engine. Torque values are listed in each step. If a torque value ts not specified, use the chart listed in the Specifications, Group 18, to determine the correct torque value. Many of the gasket’ and o-rings are manufactured from a material designed to absorb oil. These gaskets will enlarge and provide.a tight seal after coming in contact with oil. Use ONLY a recommended contact adhesive or a vegetable-based oil to install these parts.Section 0 Engine Disassembly and Assembly Group 00 Engine Disassembly and Assembly Service Tools B Series Shop Manual Page 0-5 Engine Disassembly and Assembly - Service Tools The following special tools are recommended to perform procedures in Group 00. The use of these tools is shown in the appropriate procedure, Thess tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Too! Description Too! illustration Fuel Pump Drive Gear Puller 3824469 Piston Ring Compressor st-755 | Engine Barring Tool 3377371 Injector Bore Srush 3822509 ssz2309 Engine Rebuild Stand SS 3375193 ~ 3375194 sal or0a Engine Rebulld Stand Adapter sxroas aEngine Disassembly and Assembly Service Tools Section 0 Engine Disassembly and Assemb! Group 00 Page 0-6 B Series Shop Manual Too! No. Teo! Description Too! itustration Flexible Injector Puller 3823276 | Dial Indicator & Sleeve Assembly Use with Part No. ST 1325 Dial Gauge Attachment to measure| 3376080 _|{lvwhee! and flywheel housing runout. 2a Ridge Reamer (3823407 Mechanic's Tool Kit SS 3376593 Wear Sleeve Installation Tool Used to install the rear crankshaft lubricating oil seal wear sleeve, 3824078 j 9824498 Oil Seal installation Tool Used to install the froat crankshaft lubricating oil seal in the front cover to a specified depth.SectionO Et Disassembly and Assembly Group 00 Engine Disassembly Check List B Series Shop Manual Ny Crrage OT Engine Disassembly Check List The following 1s a checklist of recommended measurement to be made during disassembly to aid in determining the reuse of certain parts. 1. Injection pump drive gear backlash 0.076 0.330 mm [0.003 0.013 in} 2. Camshaft gear backlash 0.076 0.330 mm {9.003 0.013 in} (refer to page 0-26) 3. Lube pump gear backlash 0.076 0.389 mm [0.003 0.013 in} (refer to page 0-28) 4, Lube pump idler gear backlash (refer to page 0-29) 5. Balancer (Four Cylinder Only) (Refer to page 0-30) * Idler gear to crank gear backlash 0.088 0.420 mm [0.003 0.017 in] * shaft gear to idler gear backlash 0.088 0.420 mm [0.003 0.017 in} 0.076 0.330 mm [0.003 0.013 in} * shaft gear to shaft gear backlash 6. Camshaft End Play 7 Crankshaft End Play 0.153 0.355 mm [0.006 0.014 in} 0.12 0.34 mm [0.005 0.013 in] 0.102 0.432 mm [0.004 0.017 in]Engine Disassembly (0-1) Section 0 Engine Disassembly and!Assembly Group 00 Page 0-8 B Serves Shop Manual = Engine Disassembly (0-1) < Steam Cleaning The Engine (0-2) NY 8, Warning: When using a steam cleaner, wear protective SS Ab clothing and safety glasses or a face shield. Hot steam can cause serious personal injury. oO NOTE: Cover all engine openings and electrical compo- nents. This will prevent water damage. Steam clean the heavy dirt from the exterior of the engine. = ee owsoond Starter - Removal (0-3) 10 mm Remove the starting motor. Te | [| ) Engine Weight (0-4) 3822512 Engine Lifting Fixture 48 Engine (Wet) Weight: 325-350 Kg {715-770 Ib] 68 Engine (Wet) Weight: 410-440 Kg [910-970 tb] Rollover Stand - Engine Mounting (0-5) 18 mm, 3375194 Engine Rebulld Stand, 3376975 Adapter Plate Mount the engine on the rebuild stand. Torque Value: 77Nem [57 tb}. | Mounting Hardware: M12 x 1.75 ‘emsooxeSection 0 Engine Disassembly and Assembly Group 00 Ol Draining (0-8) B Senes Shop Manual Page 0-9 Oil - Draining (0-6) 17mm Rl Remove the drain plug. A drain pan with a capacity of 20 litres [S U.S. gallons] will Ra be adequate. Lifting Bracket Removal! - Rear (0-7) 48 mm Remove the rear lifting brackot from the cylinder head Drive Belt - Removal (0-8) Applying excessive force to the tensioner in the opposite direction of wind-up or after the tensioner has been wound-up to the positive stop can cause the tensioner arm to break, Caution: Keep hands out of the path of the spring-loaded tensioner. 1/2 inch oF 3/3 inch Square Drive Release the tension and remove the drive belt. XQ] Service Tip: Loosen the vibration damperlerankshatl and fan hub pulley capscrews before removing the drive belt <9)Fan Pulley Removal (0-9) Page od ta9pu08 Section 0 Engine Disassembly and Assembly Group 00 'B Series Shop Manual Fan Pulley - Removal (0-9) 13 mm R Remove the fan pulley and capscrews. Vibration Damper/Crankshaft Pulley - Removal (0-10) 2 15 mm Remove the vibration damper or crankshaft pulley and Re capscrews. NOTE: Refer to Component Section 1 for the vibration <= damper inspection procedure. Belt Tensioner - Removal (0-11) 15 mm Remove the belt tensioner from the bracket. <4 NOTE: Refer to Component Section 8 for the belt tensioner inspection procedure. 5mm Allen Remove the tensioner bracket. eBSection 0. Engine Disassembly and Assembly Group 00 B Serres Shop Manual Fan Hub - Removal (0-12) 40 mm ha] Remove the fan hub. NOTE: Refer to Component Section 8 for inspection of the Ro fan hub eS Alternator - Removal (0-13) 13 mm Remove the alternator link. 16 mm Remove the alternator mounting capscrew and alternator. 13 mm. Remove the alternator bracket Fan Hub Removal (0-12) Page 0-11Thermostat Removal (0-14) Page 0-12 tnshems Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Thermostat - Removal (0-14) 10 mm Remove the capscrews from the thermostat housing. Be Remove the thermostat housing, gasket, thermostat and <9 lifting bracket, ZX NOTE: Refer to Component Section 8 for inspection of the thermostat. ‘Screwdriver a If'so equipped, remove the aftercooler supply tube (1) and Rs the coolant return tube (2). 9 Turbocharger - Removal (0-15) 416 mm and 19 mm Remove the turbocharger oil supply line from the turbo- ay) charger and oil filter head.Section 0 - Engine Disassembly and Assembly - Group 00 ‘Turbocharger - Removal (0-15) Page 0-13 B Series Shop Manual 8 mm, Screwdriver Remove the air crossover tube, On Automotive engines, loosen the V-Band clamp and hose clamp and remove the charge air cooler inlet tube. 10 mm Disconnect the drain tube from the bottom of the turbocharger. Screwdriver Remove the turbocharger drain line from the drain tube in the cylinder blockExhaust Manifold Removal (0-16) Page 0-14 Section 0 Engine Disassembly and Assembly Group 00 'B Series Shop Manual ary ‘On engines equiped with wastegated turbochargers, re- move the wastegate intake air hose, eg 15 mm Remove the turbocharger mounting nuts, turbocharger and gasket NOTE: Inspection of the turbocharger 1s described in Com- ponent Section 10, Exhaust Manifold - Removal (0-16) 13 mm . Remove the capscrews, exhaust manitold and gaskets. NOTE: Inspection of the exhaust manifold is described in Component Section 11 Fuel Filter - Removal (0-17) 75-80 mm, 90-95 mm Strap Wrenches Remove the fuel filter(s).Section 0 - Engine Disassembly and Assembly - Group 00 Fuel Filter Head - Removal (0-18) B Series Shop Manual Page 0-15 Fuel Filter Head - Removal (0-18) 24 mm It equipped with a dual filter head, remove the nut, dual filter head and o-ring. &Ra i Screwdriver Remove fuel filter adapter and o-ring, KSB (Remote Mounted) - Removal (0-19) Remove the KSB wiring harness. 10 mm Remove the banjo screw securing the fuel transfer tube to the low pressure fuel supply banjo screw.Fuel Lmes Removal (0-20) Page 0-16 Section 0 - Engine Disassembly and Assembly Group 00 B Series Shop Manual 11 mm and 15 mm QQ) Remove the flex'hose from the KSB assembly. It is not &Ra Necessary to remove the flex hose from the injection pump. XQ] 10mm Remove the KSB assembly from the intake manifold cover. &Re DP a $e Fuel Lines - Removal (0-20) High Pressure Fuel Line - Removat (0-21) 14 mm, 17 mm Crowsfoot Wrench, 19 mm. Crowsfoot Wrench Caution: Hold te fuel pump delivery valves securely when loosening the high pressurejlines on the rotary pumps. Remove the high pressure line fittings from the injection pump. 17 mm, 19 mm Remove the high pressure lines from the mjectors. NOTE: Refer to Component Section 6 for {ual line inspectionSection 0. Engine Disassembly and Assembly Grou B Senes Shop Manual 10mm Remove tie manifold cover capscrews that secure th high pressure ling support brackets. Remove the high pressure lines as an assembly. Cap or cover the injector openings. 12 mm and 13 mm itso equipped, remove the air/fuel control tube and turbo- charger wastegate line. Fuel Drain Manifold - Removal (0-22) 10 mm Remove the fuel drain manifold banjo fittings and sealing washers from the injectors. p00 . a) Ge Fuel Lines - Removal! (0-20) Page 0-17Fuel Lines Removal (0-20) 8 Section 0 Engine Disassembly and Assemb! {on @Pw Group 00 Series Shop Manual 17: mm and 10 mm Rotary Fuel Pump Remove the fuel drain manifold support brackets and banjo fitting, 10 mm, 12 mm In Line Fue! Pump Remove the banjo capscrews and sealing washers at the filter head. : Remove the fue! line support bracket capscrew from the Intake manifold. Low Pressure Fuel Lines - Rémoval (0-23) 17mm Disconnect the two banjo fittings at the filter head. 14 mm and 17 mm Caution: Be sure the fuel transfer pump connection is held securely when loosening the fuel line. Loosen the nut and remove the fuel line from the lift pump.Section 0 Engine Disassembly and Assembly Group B Series Shop Manual 14 mm and 17 mm Caution: Be sure the fuel pump connection is held se- curely when loosening the supply line. Remove the injection pump supply line. Dipstick - Removal (0-24) If equipped with a dipstick tube extension, remove the dipstick and extension. Manifold Cover - Removal (0-25) 10mm H Remove the manifold cover, gasket and grid heater if equipped. Aftercooler - Removal (0-26) 10mm If equipped, remove the aftercooler housing. NOTE: Refer to Component Section 10 for the aftercooler inspection procedure. & SE Dipstick Removal (0-24) Page 0-19 osokma WS iValve Covers Removal (0-27) Page 0-20 Section 0 Engine Disassembly andj Assembly Group 00 R a & B Series Shop Manual Valve Covers - Removal! (0-27) 15 mm Remove the special capscrews, o-ring seals, valve covers and gaskets. Injector Nozzles - Removal (0-28) Rust Penetrating Solvent Caution: When rust has formed on the hold down nut, the injector can turn in the bore when the nut ts loos- ened. This will cause severe damage to the head by the imyector locating ball cutting a groove in the bore. ‘Soak the hold down nut with a rust penetrating solvent for a minimum of 3 minutes. Brass Drift Pin, Hammer Caution: Excessive force will damage the injector. Tap the injector body with the hammer and drift pin to loosen any rust. 24 mm Box Wrench, Adjustable Wrench Hold the injector body with an adjustable wrench while you loosen the hold down nut with a 24mm box wrenchSection 0. Engine Disassembly and Assembly Group 00 B Sertes Shop Manual Injector Puller 3823276 R] Remove ths injectors. if the injector is extremely difficult to remove, remove the injector o-ring and fill the bore around the injector with a penetrating solvent. Attach the Ra injector puller and pull the injector out as far as possible, then use the injactor puller slide hammer to tap against the puller nut and drive the injector into the bore. Re- peating this procedure will allow the solvent to penetrate {o the Injector tip and {oosen the carbon deposits on the tip. Refer to Component Section 6 for the injector test <> procedures. Y Rocker Levers Removal (0-29) Page 0-21 [a 90 Rocker Levers.+ Removal (0-29) 14 mm, Screwdriver Loosen the nuts on the rocker lever adjusting screws and loosen screws until they stop. 13 mm, 18 mm Remove the pedestal/head bolts from the rocker shaft Pedestals and lift off.the pedestal and rocker lever as- semblies, NOTE: Refer to Component Section 3 for disassembly of the rocker lever assemblies. a) Push Rods - Removal (0-30) Remove the push:rods: &R NOTE: Refer to Component Section 4 for the push rod in spection procedure. =Cylinder Head.- Removal (0-31) Section 0 Engine Disassembly and Assembly Group 00. Page 0-22 |B Series Shop Manual Cylinder Head - Removal (0-31) [a] 18mm Remove the remaining cylinder head capscrews in the sequence shown. Ge Remove the cylinder head and gasket from the block, Cylinder Head Weight: 4 Cylinder 36 Kg [80 Ib] 6 Cylinder 52 Kg [114 Ib] NOTE: Disassembly of the heads described in Component Section 2 Front Cover - Removal (0-32) 90-100 mm Strap Wrench Remove the front cover access cap. Service Tip: A strap type filter wrench can-be used to loosen access caps that have been excessively tightened. (ATE Om 10mm Remove the front cover and gasket.Section 0. Engine Disassembly and Assembly Group 00 B Senes Shop Manual Hammer, Punch | ‘Support the seal area in the front cover and drive out the seal. Water Pump.- Removal (0-33) 13. mm Remove the water pump and o-ring, Refer to Component Section 8 for the water pump inspection. Flywheel - Removal (0-34) 18mm Lock the crankshaft and remove the capscrews, washers a and flywheel. NOTE: Refer to Component Section 16 for flywheel inspection. eS ® Flywheel Housing - Removal (0-35) 15 mm. Remove the flywheel housing. NOTE: Refer to Gomponent Section 16 for the flywheel Ga housing inspection procedure. = ‘Water Pump Removal (0-33) Page 0-22Accessories Removal (0-38) Page 0-24 eS 7” edule Section 0 Engine Disassembly and Assembly Group 00 'B Series Shop Manual Accessories - Removal (0-36) 10 mm, 14 mm, 18 mm If equipped, remove all additional gear driven accesso- ZJ_ nes, (air compressor, hydraulic pump, etc). NOTE: Refer to the Manufacturer's Service Information for repair instructions. Injection Pump - Removal (Rotary Type Pumps) (0-37) 2 13mm Caution; A diesel engine cannot tolerate dirt or water in A, the fuel system. tiny piece of dirt or a few drops of water in the injection system can cause damage to the system. SM Ciean all external surfaces of the injection pump, includ- sng all line connections and fittings that are to be discon- nected, Clean the area around the injection pump gear OR cover to prevent dirt from entering the crankcase. Remove the mjection pump support bracket and capscrews. Gear Lash - Check (0-38) @) Position an indicator on the tooth of the injection pump drive gear. Note the total indicator travel as injection pump drive gear backlash, Mark the pump drive gear'and camshaft gear for further analysis if the backlash exceeds the limits. Injeation Pump Drive Ge u Backlash Limit (A) mm. in 0.076 MIN 0.003 0.330 MAX 0.013 NOTE: Prevent movement of adjoining gear when checking backlash or the reading will be the total of both gears.Section 0 Engine Disassembly and Assembly Group Gdjectlon Pump Removal (Rotary Type Pum B Series Shop Manual Locking the Pump (0-33) Locate TDG for Cylinder Number 1 by slowly barring the engine while pushing in on TDC pin. BE SURE TO DISENGAGE THE PIN AFTER LOCATING TDC. 44mm Loosen the CAV injection pump lockserew, position the special washer with the small opening showing, then tighten the lockscrew against the pump drive shaft Torque Value: 7 Nem [5 fttb] 3/8 inch Loosen the lockscrew for the Stanadyne DB4 fuel injec tion pump. Position the special washer behind the lack screen head. Tighten the lockscrew. 10 mm The special washer on the Bosch injection pump must be removed so the lockscrew can be tightened against the drive shaft, NOTE: Before removing the Bosch pump, the pump must be locked with the No. 1 Cylinder in TDC position. Torque Value: 30.Nem [22 ftb). Wire the special washer to the Bosch pump. '$) (0-37) ge 0-25 Q) ®Injection Pump Removal (In-Line) (0-41) Page 0-26 wotgeme Section 0 Engine Disassembly and Assembly Group 00 B Senes Shop. Manual Drive Gear - Removal! (0-40), 22 mm Caution: Hold the crankshaft to prevent the rotation of the locked injection pump. Remove the mounting nut and lock washer from thepump drive shaft. 75 mm T-Bar Puller or Fuel Pump Drive Gear Puller Part No, 3824469 Pull the pump drive gear loose from the drive shaft. The puller hole threads are MB X 4.25. 13 mm Remove the three mounting nuts. Remove the myection pump. NOTE: Refer to the applicable Manutacturer’s Service In- structions forinjection pump testing/repair. Minor repairs are described in Component Section 5. Injection Pump - Removal (In-Line) (0-41) Caution: A diesel engine cannot tolerate dirt or water in the fuel system. A tiny piece of dirt or a few drops of water in the injection system can cause damage to the system. Clean all external surfaces of the injection pump, includ- ing all line connections and fittings that are to be discon nected. Clean the area around the injection pump gear cover to prevent dirt from entering the crankcase.Section 0. Engine Disassembly and Assembly Group 00 B Series Shop Manual Preparatory Steps: ‘+ Rerhove all fuel lines. * Remove the contro! linkage. ‘+ Remove the fuel shutoff solenoid. * Remove the fuel filter. + Remove the {uel pump support bracket. 14 and 15 mm Ri] Disconnect the lubricating oil supply line from the fuel pump. Disconnect the lubricating oil supply line from the engine 0 block. 9377371 Barring Tool RI Make sure the crankshaft has No, 1 cylinder at Top Dead Center (TDC). Rotate the engine until the timing pin engages. Be sure to disengage the pin after locating TOC. 22mm Q] Remove the nut and washer from the fuel pump shat. Injection Pump Removal (In-Line) (0-41) Page 0-27 spopemsFuel Transter Pump Removal (0-44) Page 0-28 Section 0 Engine Disassembly and Assomb| Group 00 jeries Shop Manual ‘Two MB x 1.25 Capscrews, 75 mm T-Bar, or Fuel Pump Drive Gear Puller 3824468 Ra Pull the pump gear from the drive shaft. 4 7 ts mm QR Fuel Transfer Pump - Removal (0-44) I] 10mm Remove the fuel transfer pump, spacer, and gaskats. 9 NOTE: Refer to Component Section 6 for fuel transfer pump test procedures. 729000 Tappet Cover - Removal (0-45) 10 mm R Remove the tappet cover and gasketSection 0_ Engine Disassembly and Assembly Group 00 B Senes Shop Manual Side Oil Fill - Removal (0-46) 18mm If present, remove the capscrews, side oil fill assembly and rectangular ring seal. Some engines may have an air compressor oil drain connection attached at this location. Remove the connection and rectangular ring seal. Oil Cooler - Removal (0-47) 90-95 mm [3-1/2 to 3 7/8 in] Filter Wrench Remove the oil filter. 10 mm Remove all the capscrews, oil cooler cover, cover gasket, oil cooler and cooler gasket NOTE: Refer to Component Section 7 for inspection procedures. Water Inlet Connection - Removal (0-48) 13. mm Remove the water inlet connection and rectangular ring Seal, 3) &R R) Be Side Olt Fill Removal (0-46) Page 0-28Oil Pan Removal (0-48) Page 0-30 Section 0 Engine Disassembly and Assembly “Group 00 B Senes Shop Manual Oil Pan - Removal (0-49) 40 mm Rotate the engine on the stand and cemove the oil pan and gasket. Suction Tube - Removal (0-50) 10 mm Remove the suction tube and gasket. NOTE: Refer to Component Section 7 for the suction tube inspection procedure. Rear Seal Housing - Removal (0-51) 8mm & Remove the rear seal housing and|gasket. Support the seal area of the rear seal housing and press/ Ro drive out the seal.Section 0_Engine Disassembly and Assembly Group 00 B Senes Shop Manual Camshaft - Removal (0-52) Measuring Gear Lash (0-53) Position an indicator on a tooth of the camshaft gear. NOTE: The cylinder block position shown in the illustration 1s for clarity. The cylinder block must be positioned with the crankshaft on top to keep the tappets in the bores. Note the camshaft gear backlash, Mark the camshatt gear and crankshatt gear for further analysis if backlash exceeds limits. ‘Camshaft Gear Backlash Limit (A) mm in 0.076 MIN 0.003 0.330 MAX 0.013 NOTE: Prevent movement of adjoining gear when checking backlash or the reading will be the tolal of both gears. Rotate the crankshaft to approximately the YDC position for number one cylinder. Failure to do so will result in the camshaft catching on the connecting rads during cam- shaft removal. NOTE: The oylinder block is shown in an upright position in the illustration for clarity. 13mm Remove the thrust plate capscrews. ® Camshaft Removal (0-52) Page 0-31 (oy {cosetValve Tappets Removal (0-54) Section 0 Engine Disassembly and Assembly Group 00 Page 0-32 B Series Shop Manual Visually inspect the tappets fo make sure they are off the block. Take care not to drop the thrust washer. Service Tip: Rotate the camshaft while pulling outward ‘SE with a steady pressure dunng removal. NOTE: Reter to Component Section 1 for disassembly and inspection, R Remove the camshait and thrust plate from the cylinder Valve Tappets - Removal (0-54) Ry Flemove the valve tappets. The engine can be rotated to allow easy access to the tappets. <@E NOTE: Roler to Component Section 4 for inspection proceures. Lube Pump - Removal (0:55) Measuring Backlash (0-56) Position the indicator on a tooth of the lube pump gear. ‘9018Section 0__ Engine Disassembly and Assembly Group 00 B Series Shop Manual Note the lube pump gear backlash. Mark the lube pump gear and idler geas for additional analysis if the limits are exceeded. Lube Pump Gear Backlash Limits (A) mm. m 0.076 MIN 0.003 0.330 MAX 0.013 NOTE: Prevent movernent of the adjoining gear when check: \fig backlash or the reading, will be the total of both gears. Position the indicator on a tooth of the lube pump idler gear. Note the idler gear backlash. Mark the idler gear and crankshaft gear for additional analysis if the limits are exceeded. Lube Pump Idler Gear Backlash Limit (A) mm in. 0.076 MIN 0.003 0.330 MAX 0.013, NOTE: Prevent movement of the adjoining gear when check- Ing backlash or the reading will be the total of both gears. 13 mm Remove the lube pump. NOTE: Refer to Component Section 7 for inspection Lube Pump Removal (0-55) Page 0-33 ‘pepe pagedTiming Pin Housing Removal (0-57) P: 1-34 onscont Sectlon 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Timing Pin Housing - Removal (0-57) T25 Torn Remove the timing pin assembly. Gear Housing - Removal (0-58) 10 mm Remove the capscrews, gear housing and gasket. Plastic Hammer The gear housing is positioned ‘onto the cylinder block with two dowel pins. Tap in the area of the dowel pins with aplastic hammer if difficulty 1s encountered removing the housing.Section.0. Engine Disassembly and Assembly Group 00 Batancer Removal (0-59) B Series Shop Manual Page 0-35 Balancer - Removal (0-59) Measuning Backlash (0-60) Use an indicator to measure the backlash of the idler gear (A) upper shaft gear (8) and lower shaft gear (C) NOTE: Prevent movernent ofthe adjomning gear whencheck- ams, ing backlash or the reading will be the total of both gears. Balancer Gear Backlash m 0.088 MIN 0.003 0.420 MAX 0.017 Upper (B) to (A). «0.153. MIN 0.008 Idler (A) to (0) Shaft 0355 MAX 0.014 Lower (C)10(8)-«0.088_=— MIN 0.003 Shaft 0.420 © MAX — 0.017 Record for use during inspection. Refer to Component Section 1 for disassembly and rebulld instructions. Measuring the End Play (0-61) Use an indicator to measure the end play of the idler gear (D) and shaft (E). Balancer End Play mm © 0.130 MIN 0.005 0.630 MAX 0.024 «) 0.075 MIN 0,003 0.175 MAX 0.007 Record for use during inspection. Refer to Component Section 1 for disassembly and rebuilt instructions Locking the Balancer (0-62) Rotate the balancer gears until the timing marks are aligned.Balancer Removal (0-59) Page 0-36 Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual psf the balancer shaft has a tapped hole, the shaft can be (SS iccked in position by temporarily installing a M8 capscrew through the housing and into the shaft. 4.5 mm Allen, 1 inch Wide Mashing Tape Follow this procedure if the shaft does not have a tapped hole. Wrap the 4.5mm allen wrench with masking'tape until it ‘has a snug fit in the hole in the balancer housing ‘A = Approximately 10mm [0.4 inch] B = 10mm [0.4 Inch) Removing the Balancer (0-63) 8 mm Allen Loosen the socket head capscrews for the balancer idler gear retainer. DO NOT REMOVE THE CAPSCREWS. R Remove the No. 1 and No. 4 main bearing capscrews.Section 0_ Engine Disassembly and Assembly Group 00 B Sertes Shop Manual disengages the slot in the retainer. Remove the balancer Move the idler retainer until the pin in the No. 1 cap Gea assembly. Piston and Rod Assemblies - Removal (0-64) Mark each rod cap according to cylinder. Rotate the engine on the rebuild stand so the cylinder bores ere in a horizontal position. Rotate the crankshaft so the pistons are below the carbon deposits above the ring travel area, Use a scraper or a blunt edged instrument to loosen the carbon deposits. Do not damage the cylinder with the scraper. Piston and Rod Assemblies Removal (0-64) Page 0-37Piston and Rod Assemblies Removal (0-64) Page 0-38 A a 0 on piseoae Section 0 Engine Disassembly and Assembly Group-00 10} B Series Shop Manual Remove the remaining carbon with a Scotch-Brite® clean- ing pad or equivalent. Warning: To prevent serious eye dama; tection during this operation. An alternative method to remove the carbon ridge 1s to use a high quality stee! wire wheel installed in a drill or die grinder, NOTE: An inferior quality ware wheel will lose steel bristles during operation, thus causing additional coritamination. wear eye pro- Do not use the steel wire wheel in the piston travel area. Operate the wheel ina circular motion to remove the deposits. Ridge Reamer If required, cut the ridge trom the top of the cylinders. Make sure ridge reamer does not gouge into the cyl- inder bore or remove more metal than needed. Mark each piston with the cylinder number. During assembly, the piston must be installed into the corresponding cylinder number..Section 0. Engine Disassembly and Assembly Group 00 B Senes Shop Manual 12mm [2] Remove the capscrews, rod cap and rod bearings. Mark the cylinder number on the back side of the rod (Yq bearings. Catch the piston with one hand while pushing the rod and piston assembly out of cylinder bore. Care must be taken xd not to mutilate the connecting rod or bearing. NOTE: Disassembly o the pistonirod assembly sdescrivead in Component Section 1 Crankshaft Removal (0-65) Page 0-39 Crankshaft -. Removal (0-65) 23 mm, Rotate the engine to a horizontal position so the main bearing caps are accessible. Remove the capscrews from &88 the main bearing caps. The main caps should be numbered. ff they are not, markCrankshaft Removal (0-65) Page 0-40- Gee keg00mb Ge B Section 0 Engine Disassembly and Assembt ly Group 00 B Series Shop Manual Remove the main bearing caps. Do not pry on the matin caps to free them from the cylinder block. Use two of the marn cap bolts to “wiggle” the main cap loose, being careful not to damage the bolt threads. Crankshaft Weight: 4 Cylinder 36 Kg {80 Ib} 6 Cylinder 55 Kg [123 (b] Lift the crankshaft and gear from the cylinder block. NOTE: Refer to Gamponent Section 1 for disassembly and inspection. Remove the main bearings from the cylinder block and the main caps. 3/16 Inch Pin Punch Remove the piston cooling nozzles.Section 0 Engine Disassembly and Assembly Group 00 B Senes Shop Manual Install the main caps in their corresponding positions. ly, When correctly installed, the tangs (slots) should both be on the same side, NOTE: #1 1s to the front of the block. Turbocharger Drain Tube - Removal (0-66) 3/4 Inch Drift & Hammer Onve the drain tube out from the inside of the cylinder block & Cylinder Block - Removing From the Rollover Stand (0-67) 18mm Remove the cylinder block from the rollover stand, NOTE: Refer to Component Section 1 for cleaning and in- spection of the cylinder block. 4B Cylinder Block Weight: 6B Cylinder Block Weight: [a] Re Ss ® 91 Kg [201 Ib} 124 Kg [275 Ib] Engine Assembly (0-68) Cylinder Block - Prepare for Assembly (0-69) Install the cylinder block to the rotlover stand. NOTE: Make surethe cylinder block has been cleaned and inspected as described in Component Section 1 Turbocharger Drain Tube Removal (0-66) Page 0-4Valve Tappets Installation (0-70) Section 0 Engine Disassembly and Assembly-- Group 00 Page 0-42 'B Series Shop Manuai A Caution: Be sure the cylinder bores are clean. Valve Tappets - Installation (0-70) Lubricate the tappets with Lubriplate 105® 7 7 Gif Install the valve tappets. peeyl|* | © / Qy, d po LISI NT bool Crankshaft - Installation (0-71) | 23 mm Remove the main bearing-caps. @ smpsaoneB Series Shop Manual Page 0. Section 0 Engine Disassembly and Assembly. Group 00 Crankshaft Installation (0-7) 1/2 Center Punch Install piston cooling nozzles even with or below the bear- ing saddle surface. Cautlon: Be sure spray holes are clean and open. Install the upper main bearings. Make sure the bearing tangs are in the notch in the bear- Ing saddle. Install the combination thrust and main bearing in the second journal from the rear. apCrankshaft Installation (0-71) Section 0 Engine Disassembly and ‘Assembly Group 00 B Series Shop Manual Page 0-44 Lubricate the bearings with Lubriplate 105% Caution: Carefully install ‘the crankshatt to avoid dam- AX. agetotnecrantshattmain bearings, especially the thrust main bearing. ee Install the crankshaft. Crankshaft Weight: 4 Cylinder 36 Kg (80 Ib] 6 Cylinder 55 Kg [123 1b} ' Make sure the ring dowels have been installed into the caps. Install the lower main bearings into the caps. Lubricate the bearings with Lubnplate 105° Make sure the bearing tangs are installed in the notch in the bearing cap.Section 0 - Engine Disassembly and Assembly - Group 00 Crankshatt - installation (0-71) B Serles Shop Manual The main bearing caps are numbered for location. Num- ber 1 starts with the front of the block, and the numbers, face the oil cooler side of the engine. Position the main bearings and caps. Lubricate the main bearing capscrew threads and un- derside of the head with clean engine oil 23 mm Tighten the capscrews evenly following the illustrated sequence. NOTE: When the engine is equipped with a balancer the main bearing caps cannot be torqued until the piston and rod assemblies are installed. Itis also necessary to establish Top Dead Center before the balances can be installed. If a bal- ancer is tobe installed at a later procedure install and tighten No. 2, 3, and § main bearing capscrews until the main bearing caps are seated and proceed to procedure (0-72) Page 0-45 meso0sh 6 900mCrankshaft Installation (0-71) Page 0-46 %\ ) CGA Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Follow these steps to tighten the capscrews. Step Torque Value 1 &O Nem [ 44 fib] 2 119 Nem { 88 ftb] 3 176 Nem [130 ft-io} The crankshaft must rotate freely. ‘Check the bearing installations and the size of the bear- Ings if the crankshaft does not ratate freely. Position a dial indicator to measure crankshaft end play. ‘The dimensions of the thrust bearing and crankshatt journal determine end play. Measure the end play. Crankshaft End Play Limits (A) mm n 0.102 MIN 0.004 0.432 MAX 0.017Section 0, Engine Disassembly and Assembly Group 00 Piston and Rod Assemblies Installation (0-72) B Series Shop Manual Page 0-4; Piston and Rod Assemblies - Installa- tion (0-72) Rotate the engine on the stand until the crankshaft 1s vertical, NOTE: If the engine 1s rotated more than 90 degrees, the tappets will fall out. Piston Grading.For 1994 Automotive Applica- tions Only ‘When rebuilding an engine with the onginal cylinder block, crankshaft, and pistons, make sure the pistons are in- stalled in the onginal cylinder. If replacing the piston(s), make sure the replacement piston(s) are the same grade as the original piston. Ifa new cylinder block or crankshaft 1s used, the piston grading procedure must be performed to determine the proper piston grade for each cylinder. Install the connecting rod/piston assembly into the No.1 jp cylinder without the rings installed. Make sure the word as “Front’’ on the top of the piston 1s toward the front of the cylinder block. NOTE: The connecting rod bearing shells must be installed 1m the original connecting rod and cap. Install the upper bearing shell in the connecting rod with the tang of the bearing in the slot of the connecting rod. Use clean lubricating oil to coat the inside diameter of the connecting rod bearing shell.Piston and Rod Assembli Page 0-48 Installation (0-72) ‘exabonn Section 0 - Engine Rl R) isassembly and Assembly Group 00 B Series Shop Manual Install the bearing shell in the connecting rod cap with the tang of the bearing in the slot to the cap. Use clean lubricating oll to coat the inside diameter of the bearing shell The four digit number stamped on the connecting rod and cap at the parting line must match and be installed on the oil cooler side of the engine. Install the connecting rod cap and capscrews to the con- necting rod. 12 mm, Torque Wrench Tighten the two capscrews. Torque Value: 35 Nen (26 fb] 3823495 Dial Indicator Uso a fine grit stone to remove any burrs from the cylinder block head deck. Zero “0” the dial indicator to the cylinder block head deck.Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Move the dial indicator over the piston directly over the piston pin to eliminate any side-to-side movement. Do not, place the indicator tip on the anodized area. Rotate the crankshaft to top dead center (TDC). Rotate the crankshaft clockwise and counterclockwise to find the highest dial indicator reading. Record the reading. Remove the piston/connecting rod assembly from the No. 1 cylinder and install the assembly into the No. 2 cylinder. &Ra Repeat the procedure for every cylinder using the same piston/connecting rod assembly. Determine the grade of the piston being used by referring to the chart. Four digits on top of the piston are the last four digits of the part number, Piston and Rod Assemblies - Installation (0-72) Page 0-4: Eee 038 [71m 8S ee 028 Leoben PLEne =a pigoogePiston and Rod Assembiles Installation (0-72) Section 0 Engine Disassembly and Assembly Group 00 Page 0-50 B Series Shop Manual PISTON PROTRUSION MEASURING MEASURED USE PART NUMBER PISTON PROTRUSION GRADE 160/175 190/230 A (024-.028 (609mm-71imm) | A 3922571 3922577 A -020-.024 (,508mm-.608mm) 8 3922572 3922578 A 016-.020 (.406rm-.508mm) | Cc 3922573 3922579 B (028-.032 (.711mm-.813mm) A ‘3922571 (3922577 B (024-,028 (.609mm-.71imm) 8 3022572 3022578 8 (020-.024 (.508mm-.609mm) c 3922573 3922579 c (082-.036 (813mm-.914mm) A 3922571 3922577 c (028-.032 (.71imm-.813mm) B 9922572 3922578 c 24-.026 (.609mm-.711mm) c 3922573 3922579 ‘The specification for Piston Protrusion 1s 0.024 to 0.028 inch for emission controlled engines built after 1-1-94. Piston and Connecting Rod Assemblies - Installation Install the bearrng shells into both the rod and the cap. Make sure the tang on the bearing shells 1s in the slot of the cap and rod. Lubricate the rod bearings with a light film of Lubriplate 105°Section 0, Engine Disassembly and Assembly Group 00 Piston and Rod Assemblies Installation (0-72) ge 0-51 B Series Shop Manual Lubnicate the rings and piston skirts with clean engine oil. Position the rings, aN NOTE: Referto componentsection 01 forinstalltionofnings "&js7 on pistons. 75-- 125 mm [3-5 inch] ring compressor RI make 9 @ strap type ring compressor, end of the strap does not hook on a ring gap and break the ring. ‘Compress the rings. Lubricate the cylinder bore with clean engine oil. piariny piotanPiston arid Rod Assembles - Installation (0-72) Page 0-52 exscewo Section 0 Engine Disassembly and Assembly Group 00 'B Series Shop Manual Position the rod journal for the piston to be installed to bottom dead center (BDC). Caution: Take care not to damage the cylinder wall when AX inserting the connecting rod. > _ Position the piston and rod assembly into cylinder bore C&S _ with the word “front’’ on piston towards the front of the

Apply Loctite 205 to the capscrews, eS QP Torque Value: 24.Nem [18 ft-lb] Caution: Make sure the correct pump ts installed. The 4 cylinder pump and 6 cylinder pump are not interchange- able. A = Four cylinder gerotor size 12.947mm [0.516 inch] B = Six cylinder gerotor size 17.947mm [9.715 inch}Section 0 Engine Disassembly and Assembly Group 00 Lube Pump Installation (0-74) B Series Shop Manual Page 0-55 Lube Pump - Installation (0-74) Lubricate the pump with clean engine oll De Caution: Fill the,lube pump before installation to aid with priming during engine start up, tm The idler gear pin fits nto a locating bore in the cyl- inder block. install the lube pump, cylinder block and the capscrews should not draw the The sealing plate on the back of the pump will seat on the flange up to the block. WW tp9owe| 13 mm Torque Value: 24Nem (18 ft-lb]Camshaft Installation (0-75) Page 0-56 Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Caution: Be sure the gear backlash is correct If install- ing 8 new pump. Use a dial indicator to measure gear backlash. Measure gear backlash. ash cits A B 0,08 to 0,33 mm 9.08 to 0.33 mm [.003 to .613 in} (003 to .013 in} NOTE: Prevent movement of adjoining gears when checking backlash or the reading will be the total of both gears. Camshaft - Installation (0-75) Rotate the crankshaft until the number one cylinder is approximately at the TDC position. When properly posi- tioned, the crankshaft gear alignment pin will be post- tioned'in the 12 o'clock position. NOTE: If the crankshatt is not properly positioned, the cam- shaft may contact the connecting rods during installation. Lubricate the camshaft bores with Lubniplate. NOTE: If cam bushing has not been installed, refer to Com- [MooneBalancer Installation (0-78) Page 0-62 Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual 10 mm, 15 mm. Caution: Be sure timing pin s disengaged before rotat- ing the engine. A Remove the crankshaft pulley and wire pointer Re Balancer - installation (0-79) 23 mm Rotate the cylinder block on the relaxed stand until the crankshaft 1s positioned al the top and parallel to the floor. The number 1 and number 4 main bearing capscrews must be removed to install the balancer. Rotate the crankshaft until No. 1 piston is at Top Dead Center. The engine must have a cylinder at TOC for correct gear teeth alignment when the balancer is installed. Rotate the balancer gears until the timing marks are aligned. The balancer must be kept in thts position for cortect installation on the engine.Section 0 - Engine Disassembly and Assembly Group ‘00 Balancer Installation (0-79) B Sertes Shop Manual Page 0-63 locked in position by temporarily installing a M8 capscrew through the housing and into the shaft, MLO 13 mm RB If the balancer shaft has a tapped hole, the shaft can be a] ce Caution: Make sure the idler gear retainer capscrews are 4.5 mm Allen, 1 inch Wide Masking Tape R] loose. A Follow this procedure if the shaft does not have a tapped hole. Wrap the-4.5mm allen wrench with masking tape until it has a snug fit in the hole in the balancer housing A = Approximately 10mm (0.4 inch] B = 10mm [0.4 inch] Position the locked balancer assembly onto the main bearing caps. The assembly must be located squarely with the alignment ears against the side of the caps. Align the slot in the Ider gear retainer with the locating pin in the main bearing cap. Slide the balancer into position.Balancer _ Installation (0-79) Section 0 Engine Disassembly and Assembly Group 00 8 Series Shop Manual Page 0-64 The idler gear can be slightly rotated to help in alignment. Lubricate the main bearing capscrew threads and the underside of the capscrew heads with clean engine oil. it the capscrews do not install freely, check to be sure the engine has a piston at TDC. QI ne Tighten the capscrews evenly and foliow the Iiustrated ® sequence. [88 ft-lb] 176 Nem [130 ft-lb) wnSection 0. Engine Disassembly and Assembly Group 00 B Senes Shop Manual Remove the locking capscrew or allen wrench from the balancer. GRe 8mm Allen Tighten the idler gear retainer capscrews. Torque Value: 57 Nem [42 ft-lb] Measure the idler gear backlash Backlash mm mn 0.088 MIN [0.003] 0.420 MAX {0.017} if the idier gear does not meet the specifications, loosen the idlar gear retainer capscrews. Reposition the idler gear and tighten the capscrews. Torque Value: 57 Nem [42 flo) The Crankshaft Must Rotate Freely If the crankshaft does not rotate freely, make sure the balancer does not have an interferance, Balancer Installation (0-79) Page 0-65Crankshaft End Play Measuring (0-80) Page, 0-66 e900 9000 Section 0 Engine.Disassembly and.Assembly Group 00 B Series Shop Manual Crankshaft End Play - Measuring (0-80) Use a dial indicator to measure the crankshaft end play. Crankshaft End Play Limits mm in 0.102 MIN 0.004 0.432 MAX 0.017 Rear Seal - Installation (0-81) inspect the crankshaft flange and rear cover for dirt and damage. Use a cleaning pad, Part No. 3823258, to re- move ditt or rust deposits. Wipe the crankshatt ‘lange dry. fs Install the reat cover and gasket. Do not tighten the ep capscrews to the correct torque value at t's time. Gas, The replacement rear seal has a pllottoo! installed. Do not Sfp remove the pilot tool at this time.Section 0. Engine Disassembly and Assembly Group 00 8 Series Shop Manual Apply a mild soap to the rubber outside diameter of the oil seal. Use the alignment and installation tool packaged in the ly seal kit. Drive the seal into the housing until the driver (245 bottoms. NOTE: Alternately, drive the seal at the 12, 3, 6 and 8 o'clock positions to mstall the seal square to the crankshaft flange. Make sure the Seal housing'is level with both sides of the ‘cylinder block oil pan rail. Tighten the rear cover capscrews. Torque Value: 7 Nem [80 in-Ib} Remove the seal pilot tool. Trim the gaskets even with the. oil pan mounting surface. Suction Tube - Installation (0-82) Position the suction tube and gasket on the cylinder block. > Suction Tube Installation (0-82) Page 0-67 sess00Cll Pan _ Installation (0-83) Section 0 Engine Disassembly and Assembly Group 00 Page 0-68 B Series Shop Manual 10 mm, 13 mm Tighten the oil suction tube and brace capscrews. 8 Torque Value: 24Nem [18 ft-lb) Oil Pan - Installation (0-83) Oil Pan Sealing Surfaces - Sealants Gifs, Use Three Bond 1207-G® to fill the joints between the pan EB ait gear housing and rear cover. 10. mm Assemble the oil pan and capscrews as illustrated. Gls Torque Value: 24Nem [18 ft-lb} Ky] 17mm 2 Install the drain plug and a new sealing washer. -———-| EB Torque Value: 80 Nem {59 f15) Re Z oopsSection 0 Engine;Disassembly and Assembly Group 00 8 Series Shop Manual Oil Cooler - Installation (0-84) Caution: fa new element.is to be installed, be sure to A remove the shipping plugs. Insert two capscrews through the oil cooler cover. Pack: age the cooler cover gasket, oil cooler, oil cooler gasket and oil cooler cover. 10 mm Install the “package” on the cylinder block. Torque Value: 24Nem [18 fb} Side Oil Fill - Installation (0-85) 15mm If the engine 1s so equipped, install the side oil fill as- sembly and o-ring Torque Value: 43.Nem [32 ft-lo] Fuel Transfer Pump - Installation (0-86) Caution: When installing piston style transfer pumps, alternately tighten the mounting capscrews. As the capscrews are tightened, the transfer pump plunger 1s. A Pushed into the pump. Failure to tighten the capscrews in an even manner can result in the plunger being bent or broken. \nstall the fuel transfer pump, gaskets and spacer if using @ piston style pump. Torque Value: 24 Nem [38 iti} Oil Cooler Installation (0-84) Page 0-62Teppet Cover Installation (0-87) Section 0 Engine Disassembly and Assembly Group 00 Page 0-70 B Series Shop Manual Tappet Cover - Installation (0-87) Gis Install the tappet cover gasket. gna ‘The tappet cover gasket must be installed on the cover as shown in the illustration. ps, Install the tappet cover and batlle with the illustrated ‘mounting capscrews and rubber seals. The remaining capscrews and rubber seals will be installed later with the fuel drain line. R] 10 mm Torque Value: 24Nem [18 ft-lb] 8 1Section 0 Engine Disassembly and Assembly Group 00 Injection Pump Installation (0-88) B Senes Shop Manual Page 0- Injection Pump - Installation (0-88) Install the injection pump gasket. The Nippondenso EPS. and the Bosch P7100 injection pump use a seating o-ring (yp instead of a sealing gasket. Make sure the o-ring 1s po- sitioned properly and not damaged. Lubricate with clean engine oil. jeotion pump shafts. The Nippondenso EP9 and the Bosch Install the key in the keyway of the Bosch and CAV in- ee P7100 pumps do not require a key. ay Service Tip: To prevent the key from falling out of the keyway in the shaft, use a small punch to swell one side of the key. When adequately expanded, it should require a hammer to lightly tap the key into positon in the keyway. Locate top dead center (TDC) for Cylinder Number 1 by barring the engine while pushing in on the engme timing Pin until it engages,Instaltation (0-88) Injection Pump Page 0-72 ap Cp t Sib Srigenss Centavoeanmy Micccomet SRE Reomanchey meena cm 2009s Section 0 Engine Disassembly and Assembly - Group 00 'B Senes Shop Manual The injection pump drive geat has a tapered bore, Orient the wide end of the taper toward the engine {timing marks away). The drive gear for the Nip- pondenso EP9 and the Bosch P7100 pump does not have timing marks and must be positioned using the tapered bore as a reference. This table must be used to make sure of proper fuel injection pump-to-engine timing. The critical parts list (CPL) number from the engine data plate and the Control Parts List Manual (Bulletin No. 3379133-20) must be used to determina whether or not the engine is certified, and if so, what year and regulating agency (EPA or CARB). Given this information, use the table to determine which {etter on the fuel injection pump drive gear ts atigned with the camshaft gear. Align the timing marks and set the gear into the housing. No timing mark alignments required for the Nippondenso EP9, or Bosch Inline fuel pumps. Locked Timed Injection Punip - Installation (0-89) Install the pump. Make sure the key doesn't fall into the gear housing. NOTE: The keyway in the shaft of new and reconditioned pumps will be locked in a position corresponding to the keyway in the drive gear when cylinder number 1 1s at TOC. If the Bosch, Stanadyne or CAV pump was not locked in this position before removal and a timing tool, Part No. 3377259, |s not available for the Bosch pump, refer to installing an unlocked pump, procedures (0-91 and 0-92), Refer to-Section § for the Nippondenso EP9 and Bosch Inline tirinn neneaduceSection 0 - Engine Disassembly and Assembly Group 00 B Sertes Shop Manual Attach the pump by finger tightening the mounting nuts. The pump must be free to move. 22mm Install the drive gear mounting nut and spring washer. The pump can rotate slightly due to gear helix and clear- ance. This is acceptable providing the pump is free to move on the flange slots and the crankshaft does not move. Torque Value: 15. Nem [11 fb} This 1s not the final torque. The drive shaft nut will be torqued to the final specification after the pump 15 unlocked, 13 mm or 15 mm Rotate the pump to align the scribe marks and tighten the mounting nuts. The Nippondenso EP9 and Bosch inline do not have alignment marks. Torque Value Nippondenso EPS “3 Nem [oe fib Bosch P7100 43 Nem [32 ftb} Lucas CAV, Stanadyne, Bosch VE 30 Nem [22 ft-lb] Mfanew or rebuilt Stanadyne, Bosch or CAV pump without scribe marks 1s being installed, take up the gear lash by rotating the pump against the direction of drive rotation. Make sure the engine is at TDC. Tighten the pump retaining nuts. Torque Value: 24.Nem [18 ftib] gs QI] © Injection Pump Installation (5-68) Page 0-7Injection Pump - Installation (0-88) Page 0-74 i) — ed 2 feowano Section 0 Engine Disassembly and Assemb! Group 00 8 Series Shop Manual Injection Pumps - Unlocking (0-90) 14mm Loosen the Stanadyne and CAV pump lockscrew and position the special washer with the large opening show- Ing behind the lockscrew head. 20 Nem [16 ft-b] (CAV) Torque Value: 12Nem { Sftlb] (Stanadyne) 8 mm Allen or 10 mm Hex The special washer for the Bosch pump is wired to the pump and must be installed under the lockscrew. Tighten the pump lockscrew. Torque Value: 13. Nem [10 ft-lb] 34mm ‘The Nippondenso EPS has a plastic timing pin and spring which 1s located under the cap on the outboard side of the pump. This pin locates the pump shaft to correspond with ‘TDG for number one cylinder. To unlock the pump, the spring is placed under the head of the timing pin and the cap installed. Torque Value: 70 Nem [50 ft-lb] Service Tip: If difficulty ts experienced with disengaging the plastic timing pin, use a small flat blade screwdriver to pry the pin free.Section 0 Engine Disassembly and Assembly Group 00 Injection Pump B Serves Shop Manual The Bosch P7100 has a timing pin located under a cap on the outboard side of the governor. To unlock the pump the position of the pin ts reversed under the cap. Disengage the timing pin. 22 mm or 27 mm Tighten the drive gear mounting nut. Torque Value Stanadyne, Bosch and CAV (Rotary) _65 Nem 48 1b] Nippendanso.EP9 423 Nem (91 ft-lb] Bosch P7100 4165 Nem [122 fb] Chisel, Hammer It@ rebuilt pump is being installed, permanently mark the injection pump flange to match the mark on the gear housing. The Nippondenso EP9 and Bosch P7100 do not require timing marks. Installation (0-88) Page 0-75 90m Q)Injection Pump Installation (0-88) Section 0 Engine Disassembly and Assembly Group 00 Page 0-76 |B Seres Shop Manual Unlocked CAV Injection Pump - installation (0-91) Locate Top Dead Center (TDC) for Cylinder Number 1 by barring the engine while pushing in on the timing pin until it engages. Ii the shaft of a Lucas CAV pump was not locked with the engine at TDG, rotate the pump shaft to align the key and the keyway in the gear. Secure the pump by finger tightening the three mounting nuts. Disengage the TDC pin. 22 mm Secure the drive gear with the mounting nut and lock washer. Torque Value: 65 Nem [48 ftb]Section 0_ Engine Disassembly and Assembly Group 00 B Series Shop Manual 13 mm Rotate the pump to align the scribe marks on the pump and gear housing. Torque Value: 30 Nem (22 flo] NOTE: If mo timing marks exist, refer to Bulletin Nos. <> 9810348-01 or 3810486, Unlocked Stanadyne DB4 Injection Pump - Installation (0-92) Locate top dead center (TDC) for cylinder number 1 by rotating the crankshaft while pushing in on the timing pin until it engages, Rotate the fuel injection pump drive shaft in the direction ‘of pump rotation to align the timing line on the weight retamer hub with the line pn the cam ring Position the fuel injection drive shatt locking key plate in the locked position. Turn the locking screw in until contact 1s made with the drive shatt Torque Value: 12Nem [106 in-Ib} Installation (0-88) Injection PumpInjection Pump - Installation (0-88) Section 0 Engine Disassembly and Assembly Group 0 Page 0-78 B Series Shop Manual Verify the timing marks are aligned after lock timed. & Install the fuel injection pump timing cover. Gifs, Secure the pump by finger tightening the mounting nuts. fap [a] 3/8 Inch Loosen the Stanadyne DB4 fuel injection pump look screw and position the special washer behind the lock screw head. 8 Tighten the lock screw. Wnoenea oeSection 0 Engme Disassembly and Assembly Group 00 injection Pump Installation (0-88) 8 Series Shop Manual Page 0-79 22mm ‘Secure the drive gear with the mounting nut and washer. NOTE: This 1s not the final torque value. Torque Value: 15 NNem [11 ftlb] go | Disengage the timing pin. 22mm Tighten the drive gear mounting nut. Torque Value: 65 Nem [48 ft-b] 13mm Rotate the pump to align the scribe marks on the pump and housing. Tighten the mounting nuts. Torque Value: 30 Nem (22 ft-lb] Y soomeInjection Pump Installation (0-88) Page 0-60 Section 0 Engine Disassembly and Assembly Group 00 _ | BSenes Shop Manual Unlocked Bosch VE and P7100 Injection Pump - Installation (0-93) VE Installation The following procedure was written for those without immediate access to a fuel pump timing tool, Part No. 3377259, The procedure for timing an unlocked Bosch VE fuel pump with the pump off of the engine is given in Section 5. If the pump is installed using the following procedure, It should be adjusted to the exact timing Using tool No. 3377258 before being put into service, This procedure is avaliable in Bulletin Nos. 3810348-01 and 3810486. Locate top dead center (TDC) for Cylinder Number 1 by rotating the crankshaft while pushing in on the timing pin until it engages. The Robert Bosch VE pump uses a spning loaded cam mechanism that makes positioning the keyway more dif- ficult To align the Robert Bosch VE keyway, secure the pump in avise and install the lock washer and nut on the drive shaft @ mm Allen or 10 mm Hex Remove the special washer by loasening the lockscrew, ’Section 0. Engine Disassembly and Assembly Group 00 B Sertes Shop Manual 22 mm; 8 mm Allen or 10 mm Hex ‘Tum the shatt so the key 1s aligned with the hash mark on the seal housing. Lock the pump shaft by tightening the lockscrew. Torque Value: 30 Nem (22 ft-lb] Remove the dnve nut and washer from the drive shaft by striking the wrench with a sharp blow in a counterciock- wise direction, Be sure the timing pin ts disengaged. Caution: Make sure the key does not fall into the gear housing Install the pump. Injection Pump Installation (0-88) Page 0-81 & isInjection Pump Page 0-82 Installation (0-88) \n0peon Section 0 Engine Disassembly and Assembly Group 00 Q) Ri B Series Shop Manual ‘Secure the pump by finger tightening the three mounting nuts. The pump must be free to move in the slots. 22 mm Install the drive gear mounting nut and lock washer on the pump drive shaft. Torque Velue: 15 Nem {11 ft-lb] NOTE: This 1s not the final torque vi nut will be torqued to the final sp pump ts unlocked. The drive shaft ation after the 8 mm Allen or 10 mm Hex Loosen the Bosch pump lockscrew and position the spe- cial washer behind the lockscrew head Tighten the lockserew in the unlocked position. Torque Value: 13 Nem [10 ft-lb] 22 mm Tighten the drive geat mounting nut. Torque Value: 65 Nem [48 ft-lb}Section 0 Engine Disassembly and Assembly Group 00 Injection Pump Installation (0-88) B Serres Shop Manual Page 0-83 13mm Rotate the pump to align the scribe marks on the pump g and housing. Tighten the three mounting nuts. Torque Value: 24Nem [18 ft-lb} Disengage the TDC pin. ] L Sisto Be sure the backlash 1s correct for replaced gears. Use a dial indicator to measure backlash. 99012 Pump Gear Backlash Limit A = .076 to 330 mm [0.003 to 0.013 in] A C vninjection Pump Installation (0-88) Section 0 Engine Disassembly and Assembly, Group 00 Page 0-84 B Series Shop Manual Da 19 mm — | a) Attach the injection pump support bracket. Finger tighten =| Zap, all capscrews betore final tightening (24D NOTE: Tighten the capscrews which attach the bracket to the block (1) before tightening the cepscrew which secures the bracket to the pump (2). Torque Value: 24. Nem (18 ft-lb] P7100 Injection Pump Installation Make sure the engine has Cylinder No. 1 at TDC. The mjection pump also has a timing pin (1), located in the governor housing, to position the pump shaft to cor- respond with TDC for Cylinder No. 1 The pin is to be reversed and stored in the housing (2) after the pump 1s installed, Rl 24mm Remove the access plug. BJe 0-85 Section 0 Engine Disassembly and Assembly Group 00 Injection Pump - Installation (0.88 a B Series Shop Manual Remove the timing pin. It the timing tooth 1s not aligned with the timing pin hole, rotate the pump shaft until the timing tooth aligns. Reverse the position of the pin $0 the sfot of the pin will fit over the timing tooth in the pump. Install and secure the pin with the access plug. Jse a 50/50 mixture of clean engine oil and STP® or aquivajent to lubricate the gear cover housing to ensure he injection pump will slide into the housing easily. BInjection Pump - Installation (0-88) Page 0-86 QI) Section 0 Engine Disassembly and Assembly Group 00 |B Series Shop Manual Also lubricate the mounting flange of the injection pump. NOTE: The P7100 mnjection pump driveshaft has a provision for a Woodruff Key, however, it is not required. Timing mark alignment 1s not required for the P7100 drive gear, ‘Make sure the fuel injection pump drive gear inside di- ameter and the shaft outside diameter are clean and dry before the gear ts installed Slide the.pump shaft through the drive gear and position the pump flange onto the mounting studs. Push the pump forward until the mounting flange and ‘o-ring are properly fitted into the gear housing bore. Do not attempt to pull the pump flange into the gear housing with the mounting nuts as damage to housing will oceur. 15 mm Install the mounting nuts. Torque Value: 43 Nem [32 ft-lb]Section 0 Engu B Series Shop 30 mm Install the retaining nut and washer. Torque Value: 15Nem [11 ttb] ‘To prevent damage to the timing pins, do not exceed the torque value given. This 1s not the final torque value for the retaining nut. Disengage the engine timing pin. 24mm Remove the fuel pump timing pin plug, Reverse the po- sition of the pin and install the pin, plug, and sealing washer. Torque Value: 15.Nem [11 ftib] 30 mm Tighten thie fuel pump drive nut Torque Value: 165 Nem [122 ft-lb] Install the gear cover access cap hand tight. isassembly and Assembly Group 00 Rif © Injection Pump installation (°588) Page 0-8:‘Accessories Installation (0-94) Section'0 Engine Disassembly and Assembly Group 00 Page 0-88 B Series Shop Manual 10 mm Install the fuel pump mounting bracket capscrews. Install the fuel jines, contro! linkage and turbocharger wastegate line. ‘Torque Values: High Pressure Fuel Lines 24 Nem [18 ftlb] Low Pressure Fue! Supply Fitting 32 Nem [24 ft-lb] AFC Fittings 9 Nem [80 in-Ib] 9/16 in 2 Install the external oil feed line at the inboard side of the fuel pump and the main oil rifle, & Torque Value: 10 Nem [7 ft-lb] Accessories - Installation (0-94) Install the cover plate or any additional gear driven‘ac. cessones (hydraulic pump, air compressor, etc.) as needed. NOTE: When gear driven accessones are installed, be sure fo install the correct support bracket.Section 0 Engine Disassembly and Assembly Group 00 B Senes Shop Manual Flywheel Housing - Installation (0-95) If removed, install the two ring dowels. Drive the dowels in until they are against the bottom of the bore. ay Install the rectangular seal and lubricate with Lubniplate® py 105... Rp 15 mm Install the flywheel housing. Torque Value: 77 Nem [57 ft-lb] Flywheel - Installation (0-96) Install the flywheel Caution: Install two capscrews in the front of the crank- shaft or otherwise lock the crankshaft to tighten the flywheel capscrews. Do not use the timing pinto lock the engine. Flywheel Housing Installation (0-95) Page 0-8: wagonWeter Pump Installation (0-97) Page 0-90 Section 0 Engine Disassembly and Assembly - Group 00 B Series Shop Manual te0008 wo900me 18mm x Follow the illustrated sequence to tighten the capscrews, Torque Value: 137 Nem {101 ftb] sequence Water Pump - Installation (0-97) Install the o-ring in the groove in the water pump housing Wy RI 13 mm Install the water pump. Gy Torque Value: 24.Nem [18 ft-lb] © Rotate the water pump to make sure it turns freely.Section 0_ Engine Disassembly-and Assembly Group 00 B Series Shop Manus Front Cover - installation (0-98) Lubricate the front gear train with clean engine oil Caution: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. Thoroughly clean and dry the front seal area of the crankshaft. 3824498 Installation Tool Leave the plastic pilot installation (oo! in the lubricating oil seal. Position the seal on the service tool, Part No. 3824499, with the lubricating oil seal dust lip facing outward. NOTE: Properly support the front cover lubricating oil seal flange to prevent damage to the lubricating oil seal and front cover. Press the lubricating oil seal into the front cover from the back side of the cover toward the front side of the cover. Press the lubricating oil seal until the service tool bottoms against the front cover. A Front Cover Installation (0-98) Page 0-91 easoows R)Cylinder Head Installation (0-98) Page 0-92 Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Apply a thin bead of Three Bond™ to the cover side of the front cover gasket only. NOTE: Do not remove the plastic seal pilot tool from the lubricating oil seal at this time, Use the plastic seal pilot tool to guide the seal on the crankshaft. Install the gasket and front cover on the engine. pedtom k] > a 10 mm [a] Remove the alignmentinstallation tool after tightening the capscrews. Qe Torque Value: 24Nem (18 ftlb] @ Install the front cover access cap and seal Cylinder Head - Inetelletypn (0-99) Caution: Make sure the cylinder head and block surface are clean and not nicked or gouged, Mallet {f removed, install the two cylinder head dowels. Drive the dowels to the bottom of the dowel bore. WySection 0_ Engine Disassembly and Assembly Group 00 B Senes Shop Manual Caution: Be sure the gasket 1s correctly aligned with holes im the block. Position the head gasket over the dowels, Carefully put the cylinder head on the block and seat it ‘onto the dowels. Cylinder Head Weight: 4 Cylinder 36.Kg [80 Ib] 6 Cylinder 51.3 Kg [114 Ib] Push Rods - Installation (0-100) Position the push rods into the valve tappets. Lubricate the push rod sockets with engine cil. & @& Push Rods Installation (0-100) Page 0-9:Rocker Levers Installation (0-101) Section 0 Engine Disassembly and Assembly Group 00 Page 0-94 B Series Shop Manual Rocker Levers - Installation (0-101) DL] Lubricate the vaive stems with engine ail 14 mm, Flat Blade Screwdriver Completely. loosen the rocker lever adjusting screws. Ge NOTE: The rocker lever pedestals are aligned with dowels. Install the pedestals. Lubricate the 8mm pedestal capscrew threads and under the capscrew heads with engine oil. Install the capscrews finger tight.Section 0 Engine Disassembiy and Assembly Group 00 Cylinder Head Tighterung (0-102) B Series Shop Manual Page 0- Lubricate the 12mm pedestal/head capscrew bolt threads and under the capsorew heads with engine oll, Install the capserews finger tight. Lubricate the threads and under the heads on the re- maining head capscrews with engine oil Install the capscrews finger tight. Cylinder Head - Tightening (0-102) Use the illustrated sequence to tighten the cylinder head capscrews. ey estes Follow the numbered sequence as shown above and tighten all capscrews to 90 Nm [66 ft-lb], Ty: AOS eyCylinder Head Tightening (0-102) Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Page 0-96 Folfow the numbered sequence and recheck the torque on all capscrews to 90 Nm [66 ft-lb]. Follow the numbered sequence and tighten ONLY THE SIX LONG CAPSCREWS (No. 4, 5, 12, 13, 20 ,21) to 120 Nm [89 ft-lb}. Follow the numbered sequence and turn all capscrews an & additionat 90° of rotation. As an overcheck to make sure all capscrews have'been rotated 90° check the torque on all capscrews to 136 Nm [102 ft-lb]. If any capscrews turn at 186 Nm (402 ft-lb} loosen only that capscrew and retighten using the above mentioned sequence.Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual 13 mm Tighten the &mm pedestal capscrews. Torque Value: 24Nem [18 fttb] Vaive Clearance - Adjustment (0-103) Turn the valve adjustment screws in until they touch the push rod sockets. Loosen them one full turn. Locate TDC for Cylinder Number 1 Disengage the timing pin. @ © Valve Clearance Adjustment (0-103) Page 0-97Valve Clearance Adjustment (0-103) Page 0-88 Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Feeler Gauge Valve Stem to Rocker Lever Clearance Intake Valve Exhaust Valve 0.254 mm 0.508 [0.010 in] {0.020 in} The clearance ts correct when some resistance can be “felt” when the feeler gauge is pulled through the space between the valve stem and rocker lever. Adjust the valves as indicated in the following illustrations. Tighten the locknuts and check the clearance again. Torque-Value: 24Nem [18 ft-lb] Caution: Perform step A of the valve set procedure with Cylinder Number 1 at TDC compression stroke (timing pin will engage). Step A Four Cylinder Vaive linder Ls Intake _E = Exhaust Step A_ Six Cylinder Valve Cylinder Intake Exhaust casera Ny v 8g jot Set) Perform Step B of the valve set procedure with Cyl- Inder Number 1 at TDC plus 360 degrees (timing pin will not engage). Mark the crankshaft and front cover. Rotate the crankshaft one full turnSection 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Step B Four. Cylinder Val Intake Exhaust Set) Do not Set) Step B Six Cylinder Valve Cylinder Is Intake E = Exhaust aason4| Set) Do not Set) Injector Nozzles - Installation (0-104) Apply a coat of anti-seize compound to the threads of the injector hold-down nut and between the top of the nut and Injector body (A). Avoid getting anti-seize compound in the fuel drain hole (B). Assemble a sealing washer on each injector. Use only one sealing washer. NOTE: A light coat of dean 1SW-40 engine oil between the washer and injector can help to keep the washer from falling during installation. Injector Nozzles Installation (0-104) Page 0-98 nea ANTESEIZE LUBRICANTValve Covers Installation (0-105) Section 0 Engine Disassembly and Assembly Group 00 Page 0-100 'B Series Shop Manual 24 mm Deep Well Socket | Q] Install the injectors. J Tighten the injector nozzle nuts. Torque Value: 60 Nem [44 ft-b] NOTE: The protrusion on the side of the nozzle fits into a notch in the cylinder head to orient the injector, sondos Caution: Some sockets can demage the sealing surface of the fuel drain outlet. Valve Covers - Installation (0-105) 16 mm Assemble the gaskets, valve covers, o-rings and special capscrews. Torque Value: 24.Nem (18 ft-lb] Manifold Cover - Installation (0-106) 3375066 Sealant Apply sealant to the capscrews as shown in the illustra- tion. Install the manifold cover, gasket and capscrews. Do not tighten the capscrews until the high pressure line brackets are assembled.Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Aftercooler - Installation (0-107) 3375066, 3823494 Sealant Apply sealant, Part No. 3375066, to the capscrews as shown in the Illustration. Apply a 4 mm bead of sealant, Part No. 3823494, around the sealing surface of the aftercooler as shown in the illustration. Install the aftercooler. Do not tighten the capscrews until the high pressure fuel line brackets are installed Fuel Lines - Installation (0-108) 17mm Install the fuel filter supply line. The banjo fittings at the filter head require sealing wash- ers on each side of the line. The banyo fitting with the vent screw 1s used 10 install the pump supply line {nyection Pump Supply Line - Installation (0-109) 417 and 14 mm. Install the Bosch injection pump supply line. 17 and 14. mm Install the inyoction pump fuel supply line for the CAV or Stanadyne injection pump. a) Fuel Lines Installation (0-108) Page 0-10Fuel Lines Installation (0-108) Page 0-102 Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual scene |

injectors securely wy Torque Value: 24.Nem [18 ft-lb]KSB (Remote Mounted) Installation (0-113) Section 0 Engine Disassembly and /gsombly Group 00 Page 0-104 jh B Series Shop Manual 12 mm and 13 mm Install the air fuel control tube. Use new sealing washers when installing the tube. KSB (Remote Mounted) - Installation (0-113) 13 mm and 10 mm Install the remote mounted KSB valve (if equipped) as illustrated. . ® Torque Values . Mounting Capscrew 24 Nem {18 ft-lb] Banjo Screw 8 Nem (6 fo] & | Connect the KSB winng. Fuel Filter Head - Installation (0-114) Gifs, I the optional dual filters to be used, install the adapter (Rip. and square cut seating ring. sSection 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual Lubricate the sealing ring andthe center hole with engine oil. 24mm Install the dual filter head. Tighten the nut. Torque Value: 32'Nem [24 ft-lb] ‘Temporarily install fuel filter(s). NOTE: When the engine 1s ready to be put into service, fill the filter(s) with clean #2 diesel fuel and tighten 1/2 turn after the lubricated gasket contacts the filter head. Exhaust Manifold - Installation (0-113) “Package” the exhaust manifold capscrews and gaskets on the manifold. Apply anti-setze compound to the capsorews, NOTE: The bead on the exhaust manifold gasket can be Installed in either direction. 13mm Install the exhaust manifold and gaskets. Torque Value: 43 Nem [32 ftb] Follow the sequence shown. OG Exhaust Manifold Installation (0-113) Page 0-10:Turbocharger Installation (0-116) Page 0-106 Section 0 Engine Disassembly and Agsembly Group 00 _ B Series Shop Manual Turbocharger - Installation (0-116) €él>_Install the turbocharger gasket and apply antl-seize com- %jy pound to the mounting studs Ql 15mm Install the turbocharger. Cha Torque Value: 45 Nem [33 ft-lb] ® Wf required, loosen the turbine housing capscrews and position the bearing housing to install the turbocharger drain tube. 13 mm Install the hose and clamps on the turbocharger drain ra tube loosely. Install the drain tube and gasket on the 1. turbocharger. Torque Value: 24.Nem (18 ft-lb]Section 0 Engine Disassembly and Assembly Group 00 B Series Shop Manual if the drain tube in the block was removed, apply sealant Part Number 3375068 to the sealing surfaces. 22 mm Open End Wrench, Hammer Install the tube in the block so it is aligned with the turbo- charger drain tube. Screwdriver Position the turbocharger drain hose to connect the drain tubes; tighten the clamps. 13mm If loosened, tighten the turbocharger turbine housing capsorews, Torque Value: 20Nem (15 ft-lb] ‘Turbocharger Installation (0-116) Page 0-107 jane a TL,Turbocharger Installation (0-116) Section 0 Engine Disassembly and Assembly Group 00 Page'0-108 B hoy Series Shop Manual R] 7/16 Inch If required, loosen the compressor housing v-band clamp Gifs, 2nd position the housing to align with the air crossover ee tube. ® 3 7/16 inch Plastle Hammer Tighten the band clamp. Tap around the clamp with a plastic hammer and tighten again. Torque Value: 8.5Nem [75 in-tb} Screwdriver or 5/16 inch Install the air crossover tube and clamps and tighten. Torque Value: 8 Nem [71 1n-Ib] SNem (44 in-lb] Oe Gif Install the boost control capsule actuator hose. apSection 0_ Engine Disassembly and Assembly Group 00 B Senes Shop Manual Caution: The Turbocharger must be prelubricated. Pour 0 to 60cc [2 to 3 oz,] of clean engine oil into the oil inlet fitting on top of the turbocharger while spinning the turbocharger impeller to distribute the oil in the bearing. 16 mm and 19 mm Install the oil supply line. Tighten the fittings seourely. Torque Value: 15 Nem [11 fb] 35Nem [26 ft-lb] (on turbocharger) Connect the aftercooler coolant supply tube (1) and the coolant return tube (2). Thermostat - Installation (0-117) “Package” the lifting bracket and thermostat gasket to the thermostat and thermostat housing. Position the rub- ber seal as shown A QI © LN Gy ap Thermostat Installation or} Page 0-10:Vibration Damper Installation (0-118) Page 0-110 ‘a9pune Section 0 Engine Disassembly and Assembly Group 00 Q) O@e B Series Shop Manual 10 mm Install the "package" Torque Value: 24.Nem [18 ft-lb] Vibration Damper - Installation (0-118) 15mm Install the crankshaft pulley/vibration damper. Torque Value: 125Nem [92 ft-lb] Fan Hub - Installation (0-119) 10 mm Install the fan hub. Torque Value: 24.Nem [18 ft-lb] 10 mm or 13 mm Install the fan hub pulley. Torque Value 8 mm Capscrew 24 Nem (16 ft-lb] 10 mm Capscrew 43 Nem (32 ft-lb]Section 0. Engine Disassembly and Assembly Group 00 B Series Shop Manual Belt Tensioner - Installation (0-120) 5 mm Allen Install the tensioner bracket to the cylinder head. Tighten the socket head screws. Torque Value: 24Nem [18 ft-lb] 13 mm Belt Tensioner Installation (0-120) Page 0-111 Position the belt tensioner on the bracket and secure it with the capscrew. “Torque Value: 43 Nem [32 ftib} NOTE: Some tensioners can be bolted to two different lo- ‘cations on the bracket. Install into the location dictated’ by your requirement, @ & Water Inlet Connection - Installation (0-121) Caution: Do not tighten at this time. To avoid misalign- ment and overstressing the lower support mounting ear on the alternator, leave the capscrews loose until all the alternator parts are installed. Install the water inlet connection and sealing ring. Alternator - Installation (0-122) 10 mm Assemble the alternator bracket to the thermostat hous- Ing. Torque Value: 24Nem [18 ft-lb)Alternator - Installation (0-122) Page 0-112 enscaine Section 0 Engine Disassembly and Assembly Group 00 nh ° o 3 ol eeas) or0Por20ZoroFoed u u 90001 a Section 1 Cylinder Block Group 1_ B Series Shop Manual Clean the combustion deck witha Scotch-Brite® cleaning pad or equivalent and diesel fuel or solvent. Brush, 400 Grit Sandpaper, Diese! Fuel Thoroughly clean all cup plug holes. Caution: Excessive deposits may be cleaned in an acid tank, but the cam bushing must first be removed. Build-up of deposits in the coolant passages can cause engine overheating. Be sure the coolant passages are clean. Warning: Use protective measures to prevent personal injury: The block may be cleaned in a hot tank using a soap and water solution without removing the cam bushing,Section 1_ Cylinder Block Group 1 B Senes Shop Manual After rinsing with clean solvent, use compressed airto dry the block. Cylinder Block - Inspection (1-01) Inspect the cylinder bores for glazing. A surface without glaze will have a crosshatched-appear- ance with the lines at 25 to 30 degree angles with the top of the cylinder block. If de-glazing is required, refer to procedure number (1-05) Inspect the cylinder bores for damage or excessive wear. Measure the cylinder bores. mm in 102.000 MIN [40167] 902.116 MAX (4.0203) Out-of-Roundness: _.038 mm (.0015 in] Taper: 0.076 mm [.003 in} Oversize pistons and rings (0.5 mm and 1.0 mm oversize) are available for re-bored cylinder blocks. Measure the cylinder block overall flatness: End-to-End 0.076 mm [0.003 1n.] Side-to-Side. 0.051 mm [0.002 1n.] Visually inspect for any localized dips or imperfections. If Present, the cylinder head deck must be reground Cylinder Block - Inspection (1-01) Page 1-15 De-Glazed yn 25.4 men CE “tir 144.2 mm exgomeCylinder Block Inspection (1-01) Section 1 Cylinder Blook Group 1 Page 1-16 B Series Shop Manual Inspect the main bearing bores for damage or abnormal wear, Install the main bearings and measure main bearing bore. diameter with main bolts tightened to 176 Nem (130 tt-b), NOTE: Record this measurement for use in determining main bearing clearance as described in procedure (1-12). Diameter mm. in 83.106 MAX 3.2720 Remove the bearing and install the main beanng cap. Torque the main bearing capscrews to 176: Nem [130 ft-lb}. Measure the main bearing bore with the bearing Gi removed 87.983 MIN 3.4639 88.019 MAX 3.4653 Inspect the camshaft bore without the bushing for scoring (P) invpesinecemsn Diameter No. 1 mm in 57.222 MIN 2.2528 57.258 MAX 2.2543 Measure the diameter of camshaft bores No. 2 through No. 5 Diameter No. 2-5 mm mn 34,089 MIN [2.1295] 54.164 MAX (2.2324) Service bushings are available and must be used if wear exceeds above dimensions.Section 1_ Cylinder Block Group 1 8 Series Shop Manual Inspect the tappet bores for scoring or excessive wear. Cylinder Block De-Giazing (1-05) Page 1-17 ® Diameter mm 76.000 MIN 16.055 MAX. NOTE: if the cylinder head or cylinder block ts out of specr- fication, the out of. specification surface must be machined, Refer to the Alternative Repair Menval, Builétin No. 3866109, for re-surfacing information. Cylinder Block - De-Glazing (1-05) New piston rings may not seat in glazed cylinder bores. De-glazing makes the bore ‘‘rough”” to help seat the rings. The size of the bore is not changed by proper de-glazing. Improper de-glazing will change the size of the bore. A correctly de-glazed surface will have a crosshatched appearance with the lines af 15 to 25 degree angles with the top of the cylinder black. | ( LU eand eS De-GlazeaCylinder Block De-Glazing (1-05) Page 1-18 cS \=/"B+O 300 to 400 RPM I~ AR LCG Stroke (f+ })/Per Second —| ISSO ES Section 1 Cylinder Block Group 1 B Series Shop Manual Use a drill, a medium grit Flex-Hone and a mixture of equal parts of diesel fuel and SAE 30W engine ail to de-glaze the bores. The crosshatch angle 1s a function ot drill speed and how fast the hone 1s moved vertically. This illustration shows the result of the drill speed 1s too slow or the vertical stroke 1s too fast. ‘This iilustration shows the sesult of the drill speed Is too fast or the vertical stroke is too slowSection 1_ Cylinder Block Group 1 B Senes Shop Manual NOTE: Vertical strokes must be smooth continuous passes along the full length of the bore. inspect the bore after 10 strokes. Caution: Be extremely careful not to hone the bore out of specification. sizing hone can be used to remove minor grooves or to correct minor out of taper. Taper’ 0.076 mm [0.003 in] Operate the sizing hone similarly to the Flexi-Hone. Inspect the bore after 10 strokes. Immediately clean the cylinder bores with a strong solu- tion of laundry detergent and hot water. After rinsing, use compressed air to dry the block. QP Cylinder Block De-Glazing (1-05 Page 1-1! 1 Stroke @9 Finishing Hone 285 Grit a Minor Grooves or Taper 300 to 400 RPM 1 Stroke eh Per Second kabeahExpansion end Pipe Plug Installation (1-06) Page 1-20 © Section 1 Cylinder Block Group 1 B Series Shop Manual _ Check the bore cleanliness by wiping with a white, lint free, lightly oiled cloth, If grit residue ts still present, re-clean. Wash the block in solvent, Use a brush to clean all oil passages. Expansion and Pipe Plug - Installation (1-06) All expansion plug bores in the block are machined to a standard english dimension (i.¢., 11/16 in, 1-1/4 in, etc.).. To achieve the correct press fit of the expansion plug in the bore, the expansion plug must be larger than the bore. diameter and the expansion plug driver must be smaller than the bore diameter. Therefore, expansion plugs and their drivers are not made to a standard english dimen- sion. The plug drivers are called out by the dimension of the bore they are to be used on (i.¢., a 1 1n driver for 1" bore). The expansion plugs are called out by Cummins part number (a dimension 1s also listed for reference). Apply a bead of Three Bond, Part No. 3823494, around the outside diameter of all expansion plugs before installing.Section 1 Cylinder Block Group 1 B Series Shop Manual Drive all expansion plugs in until the outer edge is flush with the counter sink in the block. Refer to procedure (1-07) for camshaft expansion plug installation. Apply a film of pipe plug sealant, Part No. 3375066, or equivalent, to the threads. Install and tighten the pipe plugs, Refer to the following chart for torque values. Tighten pipe plugs to the appropriate torque values. Driver Part No, 3823524 (Coolant Passages), Part No. 3823520 (OII'Riffe) Expansion plug locations. Front of block. 1 Expansion Plug Part No. 3900965 (58.06 mm) 2. Expansion Plug Part No. 3800956 (17.73 mm) Expansion and Plpe Plug Installation Pipe Plug Torque Values ‘Size Torque Torque ea ie Alum | _in Cat on oF med 0.0. | Componente | Stes Comperect| om Dal] Wee (tba) | Nem lb Br fost | 8 Uesimty| ts 0} woe oa | 98 tae | 208} wr posi | 20s) | 28a) wa oes | 2s oy | 58a zs a) | ps) | ss fap ar te) | est | 585) ss ay | «© us | 85 BO, 2 joy | ssh | os a3 nay | ose} | 0m, tenceCamshaft Expansion Plug Page 1-22 Installation (1-07) ean Rg] Section 1 Cylinder Block Group 1 B Series Shop Manual Driver Part No. 3823524 (Coolant Passages) Pipe plug and cup plug locations. Right side of block. 1 Expansion Plug Part No. 3812090 (58.08 mm) 2. Pipe Plug, 0.50 in (1/2 in) Driver Part No. 3823524 (Coolant Passages), Part No. 3823520 (Oil Rifle) Expansion plug locations. Rear of block. 1 Expansion Plug Part No, 3612090 (58.06 mm) 2. Expansion Plug Part No. 3900956 (17.73 mm) Driver Part No. 3823520 (Oil Rifle), Part No. 3376816 (Crankcase), Part No. 3376817 (Alternate Oil Fill), Part No. 3822372 (Alternate Dipstick Holes) Pipe plug and expansion plug locations, Left side of block. Expansion Plug Part No. 3900956 (17.73 mm) Expansion Plug Part No. 3914035 (25.75 mm) Expansion Plug Part No. 3900955 (9.80 mm) Expansion Plug Part No. 3900958 (32,03 mm) Pipe Plug, 0.125 in (1/8) NPTF Hex Head Peaoene Camshaft Expansion Plug - Installation (1-07) Apply a bead of Three ‘Bond, Part No. 3823494, around the outside diemeter of the camshaft expansion plug.Section 1_ Cylinder Block Group 1 B Senes Shop Manual Fosition the plug with the convex side out. Large Drift, Hemmer Expand the plug with a large drift and a hammer. Expand the plug until the convex side is flush with the block. Camshaft Bushing - Installation (1-08) Mark the camshaft bushing and block to align the oil hole. & Camshaft Bushing Installaion (1-08) 0 1-2: a) LY ae |! a p CN osCamshaft Bushing Installation (1-08) Page 1-24 exsbews 3) @ Section 1 - Cylinder Block Group 1 B Series Shop Manual Apply a bead of Loctite™ 609 to the edge of the bushing that will be installed to the rear of the bore. Apply the Loctite™ to 270 degrees of the diameter of the bushing, see the illustration. Use care to not apply Loctite™ near to or in Tine with the oll hole. Universal Bushing Installation Too! Install the camshaft bushing flush with the block. Be sure the oll hole 1s aligned. A 3.2mm [0.126 in} diameter rod must be able to pass through the hole. Measure the installed camshaft bushing. ‘Camshaft Bushing Bore mm n 54.107 MIN 2.4302 54.146 MAX 21317Section 1. Cylinder Block Group 1 B Senes Shop Manual Dipstick Tube - Replacement (1-09) Pliers If the dipstick tube 1s loose or damaged, remove it from the cylinder block. Apply sealant, Part No. 3375068, to the new dipstick tube, Use a hex head capscrew to drive the tube into the block. Cylinder Block - Storing (1-10) If the block 1s not to be used immediately, lubricate all surfaces to prevent rusting Ra Dipstick Tube Replacement (1-09) Page 1-25Crankshaft Cleaning (1-11) Page 1-26 Section 1 Cylinder Block Group 1 B Series Shop Manual Crankshaft - Cleaning (1-11) Clean the crankshaft oil drillings with a brush. Rinse in clean solvent and use compressed air to dry. Clean the oil seal wear surfaces with diesel fuel and crocus cloth. Crankshaft - Inspection (1-12) Inspect the crankshaft seais wear surfaces for scratches or grooving If shaft 1s grooved, install a wear sleeve. Inspect the rod'and main journal's tor deep scoring, over- heating, etc.Section 1_ Cylinder Block Group 1 B Series Shop Manual Determining Main Bearing Clearance Measure the main journal diameters and determine main bearing clearance. Main Bearing Journal Diameter mm in 82.962 MIN 3.2662 83.013 MAX 3.2682 Out-of-Roundness: 0.050mm [0.002 in] Taper: 0.013mm [0.0005 in] Bearing Clearance = Main Bore Diamater with bearing installed minus (~) Crankshaft Main Journal Diameter. Maximum Bearing Clearance: 0.119mm [0.0047 in] Crankshaft Gear - Replacement (1-13) Remove the crankshaft gear, Use a heavy duty puller. 2 Ib Stee! Hammer, Gear Splitter Part No. 3823585 An optional tool 1s available to split the crankgear off of Pre-1991 crankshatts. Service Tip: Always use a large steel hammer when split- jing the crankshaft gear. Lead hammers absorb the shock required to break the gear. Remove all burrs and make sure the gear surface on the end of the crankshaft is smooth. Ra Ql BS Crankshaft Gear Replacement (1:19) Page 1+ 4 { t so ss00uCrankshaft Gear Replacement (1-13) Page 1-28 i‘ Kishin Section 1 Cylinder Block Group 1 B Series Shop Manual Hammer Rl] If previously removed, install the alignment pin until it & bottoms. Caution: The gear will be permanently distorted if over- AX. heated. The oven tomperature ‘should never exceed 177°C [350°F]. Heat the crankshaft gear in a preheated oven for 45 min- utes at 149° C [300° F}. Apply a thin coating of lubricant to the nose of the crankshatt. Warning: Wear protective gloves to prevent personal in- A iw. Gps, Install the hot gear up to the crankshaft shoulder with the timing mark out.Section 1_ Cylinder Block Group. 1 B Series Shop Manual Camshaft - Cleaning (1-14) Wash the camshaft and gear with solvent and a lint free cloth. Camshaft and Gear - Inspection (1-15) Inspect the lift pump lobe, valve lobes and bearing jour- nals for cracking, pitting or scoring, Inspect the gear teeth for pitting; look for cracks at the root of the teeth: Measure the fuel transfer pump lobe and valve lobes. Diameter at Peak of Lobe mm. in. Intake 47.040 MIN 7.852 47 482 MAX 1.870 Exhaust 46.770 MIN 1.841 47.222 MAX 1.859 Lift Pump 35.500 MIN 4.398 36.260 MAX 1428 Camshaft Cleaning (1-14) Page ‘8Camshaft and Gear Inspection (1-15) Page 1-30 800% 900% qo0cre a Section 1 Cylinder Block Group 1 B Series Shop Manual Measure the bearing journals. Journal Diameter mm in 53.962 MIN 21245 54.013 MAX 2.1265 Camshaft Lobe Pitting Reuse Criteria (1-16) Assingle pit should not be greater than the area of a2 mm [.079 m] diameter circle. Interconnection of pits is not allowable and is treated as one pit. The total pits, when added together, should not exceed a carole of 6 mm [0.236 in].Section 1 - Cylinder Block - Group 1 B Series Shop Manual Only one pit is allowed within + or - 20 degrees of the nose of the cam lobe. Camshaft Lobe Edge Deterioration (Break- down) Criteria (1-17) The area of edge deterioration should not be greater than the equivalent area of a 2 mm [0.079 in] circle within + or - 20 degrees of the nose of the cam lobe. Outside of the + or - 20 degrees of the nose of the cam lobe, the areas of edge deterioration should not be greater than the equivalent area of 6 mm [0.236 in} circle. Camshaft and Gear - Inspection (1-15) Page 1-31 » cosSounCamshaft and Gear inspection (1-15) Section 1 Cylinder Block Group 1 Page 1-32 B Senes Shop Manuel The first of the following illustration shows normal palish and a casting flaw within the nose area. Both of these conditions are acceptable for reuse. The following thrse illustrations show wear patterns that are not acceptable for reuse.Section 1_ Cylinder Block Group 1 Camshaft and Gear Inspection (1-15 B Series Shop Manual Page 1-3:Camshaft Gear Replacement (1-18) Page 1-34 Section 1 Cylinder Block Group 1 'B Series Shop Manush Camshaft Gear - Replacement (1-18) Camshaft Gear - Removal (1-19) Remove the gear. Remove all burrs and smooth any rough surfaces caused by removing the gear. Gyn Camshaft Gear - Installation (Heated Gear GB Method) (1-20) Install the key. Lubricate the camshaft surface with Lubriplate 105.Section 1_ Cylinder Block Group 1 B Senes Shop Manual Caution: The gear will be permanently distorted if over- heated. The oven temperature should never exceed 177°C [350°F]. Heat the camshaft gear in a preheated oven at 149°C [800°F] for 45 minutes. Heat the gear for bolted camshafts (steel gear) to 177°C [350°F]. Wear protective gloves to prevent personal injury. Install the gear with the timing marks away from the cam- shat Be sure the gear 1s seated against the camshaft shoulder. Automotive engines, manufactured before 1994, that use Bosch P7100 fuel pumps require a camshaft capscrew be mstalled. Reter to procedure (1-21) Uf the camshatt is not to be used immediately, lubricate the lobes and journals to prevent rusting. = Camshaft Gear Replacement (1-18) Page 1-36 149°C 1300°F} vre [350°F]| cangentCamshaft Gear Replacement (1-18) Page 1-36 Section 1 Cylinder Block Group 1 Ore Sones ‘Shop Mantial Camshaft Gear - Installation (With Special Tool 3823589) (1-21) ___No. Description Oty, lz | lis 1 ‘Sorew Press 1 2 Yoke 1 3 Rods 3 4 Torque Arm 1 5 Retainer 1 6 Nuts 3 Assemble the screw press, yoke, rods, nuts, and camshaft gear with the chamfered side of the gear facing the camshaft. Clean all oil and lubricant from the camshaft and cam- shaft gear. Position the gear and tool assembly on the camshaft with the yoke placed over the end camshaft bearing journal. Handttighten the screw press and engage the gear to the ‘camshaft and keyway.Section 1_ Cylinder Block Group 1 B Series Shop Manual ‘Once the gear is properly started on the camshaft, insert the torque arm into the screw press and, using a wrench with the screw press, install the camshaft gear. NOTE: Do not exceed 100 ft-lb of torque while installing the gear. Do not use an impact wrench with this or any other ‘Cummins special tool. It can damage the engine parts or the tool, ‘While turning the screw, the effort required should in- crease steadily until the gear seats against the camshaft shoulder. When the gear is properly installed, the gear is in contact with the shoulder on the camshaft. Disassemble the camshaft gear installation tool and re- move the camshaft retainer. Automotive 1991 engines with Bosch P7100 inline injec tion require a camshaft capscrew be installed. Refer to procedure (1-22). Be SS Camshaft Gear Replacement @ ‘ShoulderCamshaft Capscrew Installation (1-22) Page 1-38 eo Ss eee 27 Nem [20 fb] Qs Section 1 Cylinder Block Group 1 B Series Shop Manual Camshaft Capscrew - Installation (1-22) Be sure the gear 1s seated against camshaft shoulder, Using a.001 inch feeler gauge, check to see if the feeler gauge can be inserted between the gear and the shoulder on the camshaft. If the feeler gauge can be inserted, the gear 1s not properly seated. Insert the camshaft capscrew into the gear retainer and install the capscrew/retamer assembly into the camshaft. Torque the camshaft capscrew to 27 Nem [20 ft-lb]. After torquing the camshaft capscrew to 27 Nem [20 ft-lb], then rotate the capscrew an additional 180° of rotation.Section 1_ Cylinder Block - Group 1 Rubber Element Vibration Damper Cleaning and Inspection (1-23) B Series Shop Manual Rubber Element Vibration Damper - Cleaning and Inspection (1-23) Clean the damper with hot soapy water and a brush. After rinsing with clean water, use compressed air to dry. Check the index lines (A) on the damper hub (B) and inertia member (C). If the lines are more than 1.59 mm [1/16 in] out of alignment, replace the damper. Inspect the rubber member for detenoration and missing pieces. If pieces of rubber are missing or the member 1s more than 3.18 mm [1/8 in] below the metal surface, replace the damper. NOTE: Also look for forward movement of the damper ring on the hub. Replace the damper if any movement has occured. Viscous Vibration Damper Cleaning and Inspection. Check the mounting web for cracks. Check the housing for dents or raised Surfaces. Replace the damper if any of these defects are identified. Refer to replacement pro- cedure in this section, Page 1-3: 290060Hubber Element Vibration Damper Cleaning and Inspection (1-23) Section 1 Cylinder Block Group 1 Page 1-40 ‘tnnc09e ses00t6 aavcoet B Sertes Shop Manual Clean the damper with a solvent cleaner. The viscous damper s filled with a silicone fluid. After many hours or use, the silicone fluid may become thicker and expand. To determine if the damper thickness 1s correct, remove the paint from the damper in four loca- tions on either side of the damper. Measure and record the thickness of the damper in four places. Measure the thickness 3.175 mm [0.125 inch] from the out side of the damper. Replace the damper if its thicknass varies by mare than 0.25 mm [0,010 inch]. Spray the damper with spot check developer, Type SKD-NF or its equivalent. Heat the damper in an oven (tolled lip side down) at 93°C [200°F} for 2 hours. Caution: Wear protective gloves to prevent personal in- Jury when handling parts that have been heated. Remove the damper from the oven and check for fluid leakage. If there 1s leakage, replace the damper.Section 1_ Cylinder Block - Group 1 B Senes Shop Manual Piston and Connecting Rod - Disas- sembly (1-24) Remove the retaining angs. Remove the piston pin. Heating the piston 1s not required. Piston Ring Expander Part No. 3823137 Remove the piston rings. Piston, Pin and Connecting Rod - Cleaning (1-25) Caution: Do nct use the bead blast method to clean the piston. The piston will be damaged by blast material embedded in the aluminum. Soak the pistons in cold parts cleaner. Soaking the pistons overnight will usually loosen the, car- bon deposits. Piston and Connecting Rod ~ Disassembly (1-24) A Page 1-41 exoemePiston Inspection (1-26) Page 1-42 2190000 He Section 1 - Cylinder Block Group 1 B Series Shop Manual Caution: Do not clean the pistons and rods in an acid tank. Wash the pistons and rods in a strong solution of laundry detergent in hot water. Caution: Do not use a ring groove cleaner and be sure fot to scratch the ring sealing surface in the piston groove. Clean the remaining deposits from the ring grooves with the square end of a broken ang. Wash the pistons again in a detergent solution or solvent After rinsing, use compressed air to dry. Piston Inspection (1-26) Inspect the piston for damage and excessive wear. Check the top, ring grooves, skirt and pin bore.Section 1_ Cylinder Block Group 1 B Series Shop Manual Measure the piston skirt diameter as illustrated. Diameter mm in 101.823 MIN (4.0088) 101.887 MAX 4.0113) Use a new piston ring to measure the clearance inthe ring groove. Ring Clearance mm in Tep No Check Needed (Turbocharged) Naturally 0.075 MIN 003] spirated) 0150 = MAX [0.008] Intermediate 0.075 MIN 0.003) 0.150 = MAX —_[0.006] oi 0.040 MIN {0.002 Control 0.130 = MAX —_[0.005] Measure the pin bore. Diameter mm im 40.008 MIN 17.5750] 40.025 MAX [1.5758] Piston Pin - Inspection (1-27) Inspect the piston pin for nicks, gouges and excessive @ wear. Measure the pin diameter. Piston Pin Inspection (1-2 Page 1-4 [ pigoote isooie Diameter mm in 39.980 MIN 115744] 40.003 MAX [1.5749] all> : taConnecting Rod Inspection (1-28) Page 1-44 ad00n A © Section 1 Cylinder Block Group 1 B Series Shop Manual Connecting Rod - Inspection (1-28) Caution: The !-Beam section cannot have dents or other damage. Damage to this part can cause stress risers which will progress to breakage. Inspect the rod for damage and wear. Measure the pin bore (with bushing installed). 1991 Specifications Diameter mm In 40.053 MIN 17.5769) 40.076 MAX [1.5778] 1994 Specifications Diameter mm 0 40.019 MIN 15756 40.042 MAX 1.5765 Rod Bearing Clearance - Checking (1-29) Measure the crankshaft bore with the beanngs installed and the capscrews tightened to 99 Nem {73 ft-lb] Record the smallest diameter. Measure and record the mean diameter of rod journal on the crankshaft, Diameter mm in 68.962 MIN 12.7150) 69.013 MAX (2.7170) Out-of-Roundness: 0.050mm (0.002 in} Taper: 0.013mm [0.0005 in} Bearing clearance = Red Inside Diameter Minus Crank- shaft Journal Diameter. Clearance: 0.114mm [0.0045 In] maximumSection 1. Cylinder Block Group 1 Piston and Connecting Rod Assembly (1-30) B Series Shop Manual Page 1-45 Bearing clearance can also be determmed with plastigage during engine assembly. Piston and Connecting Rod - Assem- bly (1-30) Be sure “front’’ marking on, piston and the numbers on the rod and cap are oriented as illustrated, NOTE: The numbers shown in the illustration are for ex- ample purposes only. Install the retaining ring in the pin groove on the “front” side of the piston Lubricate the pin and pin bores with engine oil. xPiston Ring Gap Checking (1-31) Page 1-46 exseema Na Turbocharged —— — Top Top Intermedt Intermediate 01 Control 011 Control pidrige Section 1 Cylinder Block Group 1 B Series Shop Manual Gps Install the pin. C&D Pistons do not require heating to install the pin, how- ever, the pistons do need to be at room temperature or above. Install the second retaining ning. Piston ig Gap - Checking (1-31) The top ring for a turbocharged engine ts not the same as the top ring for a naturally aspirated engine. Position each ring in the cylinder and use a piston to A = 69mm [3.5 in}Section 1_ Cylinder Block Group 1 B Serres Shop Manual Use a feeler gauge to measure the gap. Top MIN (Turbocharged) MAX Top MIN (N. Aspirated) MAX Intermediate MIN. MAX Oil Controt MIN MAX Piston Rings - Installation (1-32) Caution: Ifa ring expander tool is being used, be careful not to over expand the ring. The top surface of all of the rings are identified: As- semble the word “top” up. Position the oil sing expander in the control ring groove. ‘Install the oil control ring with the end gap 180° from the ‘ends of the expander. [0.010] [0.022] [0.010] (0.022) (0.010) (0.022) A g® \7 Piston Rings Installation (1-32) Page 1-47 © ace q plone plgase piaBalancer Disassembly (1-33) Section 1 Cylinder Block Group 4 Page 1-48 B Series Shop Manual Piston Ring Expander, Part No. 3823137 Install the intermediate ring. | Piston Ring Expander, Part No. 3823137 The top ning fora turbocharged engine is not the same as the top ring for a naturally aspirated engine. Install the top ring. Balancer - Disassembly (1-33) <> Hoefer to the procedures and specifications given in the engine disassembly section, procedure (0-59), (0-60).and (0-61). + The idler gear must be replaced If the backlash end play exceed the specifications. ‘+ The shaft gears must be replaced if the backlash exceeds the specifications. + The thrust bearing must be replaced if the shaft end play exceeds the specifications. 13mm Remove the thrust housing.Section 1_ Cylinder Block Group 1 Balancer Disassembly (1-33) B Series Shop Manual Page. 1-4 8mm Allen Remove the idler gear assembly. 13 mm Remove the balancer weights. Press the shafts from the gears. Remove the shafts from the balancer housing. Ge positsBalancer Disassembly (1-33) Section 1 Cylinder Block Group Page 1-50 B Series Shop Manual _ 3/16 Inch Punch, Hammer Use the punch to drive the roll pins from the shafts, ¢ Ge | ° . sss arg Remove the Woodruff keys from the shafts. I 4 ey) R Press the shatts out of the thrust collars. + C S 5 : | OL time a Oy OL sesbane Ra Press the shafts out of the bearing inner races.Section 1_ Cylinder Block Group 1 B Series Shop Manual Press the bearings out of the balancer housing. Balancer - Assembly (1-34) The oll hole in the center bearings must align with the oil hole in the housing. Mark the housing and bearings so you can align the holes. Caution: Press against the end of the bearing that has the identification mark. Failure to do so will result in , damage to the bearing. Press in the new center bearings until flush with the housing, Install the bearings in the housing so the identification marks are toward the outside of the housing. Balancer - Assembly (1-24) Page 1-57 atta owe. A as CapBalancer ~ Assembly. (1-34) Page 1-52: WH: AD Ny a linder Block Group 4 oe 'Senes Shop Manual Section 1 Caution: Press against the end of the bearing that has the tdentification mark. Fallure to do so will result in damage to the bearing. Press in the new bearings until flush with the inside of the housing. The balancer shafts must be sub-assembled before being installed into the housing. The assembly procedure is the same for both shafts. Use 500 grit sandpaper fo polish the bearing surfaces and to remove burrs and Loctite material. Use cleaning solvent to clean the shafts and bearing surfaces, Hammer or Mallet install a new roll pin into one of the center holes in the shafts. 4 A = 2.5 mm [0.09 (3/32) in] Apply a coat of Loctite 609 to the bearing surface of the shaft. Slide a new inner race into position on the shat.Section 1 Cylinder Block Group 1 B Senes Shop Manual Remove the excessive Loctite from the shaft. Install the three remaining roll pins. A = 2.5 mm [0.08 (3/32) in] Apply a coat of Loctite 609 to the bearing surfaces. Slide two new inner races onto the ends of the shafts. The identification marks.must be toward the end of the shaft. Balancer - Assembly (1-34) Page 1-53Asset Section 1 Cylinder Block Group 4 Page 158 mbly (1-94) B Series Shop Manual Remove the excessive Loctite. Gifs Press on the thrust collars to the step on the shafts. fap Install the Woodruff keys into the shafts. eS Fl Apply a coat of lubriplate to the thrust plate. Position the thrust plate onto the housing. gi >Section 1 Cylinder Block Group 1 B Senes Shop Manual Use clean engine oil to lubricate the bearings. Install the bottom shaft into the housing. The bottom shaft has the hole.for the timing pin. NOTE: Late model shafts have a tapped hole for the timing pin. Earlier shafts have the timing pin hole drilled completely through the shaft. Press the gear that has one timing mark onto the bottom shaft until the gear is flush with the end of the shaft. Use clean engine oil to lubricate the bearings and install the top shat, Caution: The timing marks must be aligned when you Press the gear onto the shaft. Press on the gear that has two timing marks until the gear Is flush with the end of the shaft, A gh &p Balancer Assembly (1-34) Page 1-55Balancer Assembly (1-34) Page 1-56 gis S 13mm Apply a coat of lubriplate to the thrust housing. Install the thrust housing. The mounting holes align in only one position. Torque Value: 24 Nem Section 1 Cylinder Block Group 1 B Series Shop Manual _ [18 feb] Use clean engine oll. Lubricate and install a new bearing into the idler gear assembly. Align the idler gear assembly alignment pin with the hole in the housing. Plastic Mallet Tap the idler assembly gently into position.Section 1_ Cylinder Blook Group 1 Gear Housing and Timing Pin Assembly Inspection (1-35) B Series Shop Manual Page 1-5 Install the two Allen head capscrews into the idler as- Gly sembly. Use your fingers to tighten the capscrews, Sp 8mm Allen Install the balancer weights onto the shafts. The weights must be installed on the counterbore side of the holes. Torque Value: 24Nem [18 ft-lb] Check the balancer assembly for free rotation. If it does not rotate freely, check the thrust housing and bearings for correct installation. Gear Housing and Timing Pin Assem- bly - Inspection (1-35) Visually inspect the gear housing for cracks or damaged @ sealing surfaces.Section 1 Cylinder Block Group 1 Di ibly (1-36) Gear-Housing Disassembly (1-36) linger Block Group 1 Page 1-58 Inspect the timing pin housing and pin for damage. Gear Housing - Disassembly (1-36) Do not remove the timing pin housing unless it is dam- aged or leaking, or the gear housing 1s being replaced, Refer to Page 0-57 for. replacement procedures. Le oO L ! ® ee Use @ new washer and install the spring cap plug. & Torque Value: 2.3Nem [20 in-lb] 21 mm Protective Sleeve Part No. 3376931 (ED Instatt a naw o-nng on the pressure and cap. Use the Sl _ protective sleeve to avoid damaging the o-ring. Ql 24mm Install and tighten the cap. & Torque Value: 24Nem [17.5 ft-lb} ®Section 5 Fuel System Group 05 B Sertes Shop Manual Injection Pump Repairs (5-21) Injection Pump Timing - Stanadyne DB4 (5-22) Remove the timing line cover from the injection pump. Rotate the driveshaft in the direction of rotation and align the timing line on the weight retainer hub with the line on the cam ring Tighten the drivehsatt lacking screw to hold the injection pump in the lock timed position Torque Value: 12Nem [106 1n-Ib] Verify the timing marks are aligned after tightening the locking screw. If the alignment is not correct, loosen the locking screw and readjust Injection Pump Repairs (5-21) Page 6-39 B ©Injection Pump Repairs (5-21) Section 5 Fuel System Group Page 5-40 B Series Shop Manin, Install the timing line cover. ’ ‘Torque Value: 2.Nem [17 in-Ib] Return Connection Replacement, Stanadyne DB4 (5-23) Remove the fuel return connection Inspect the sealing surfaces onthe connection and the @& pump. Inspect the sealing o-ring and check ball p>, Install a new sealing o-ring and tighten the return con- nection ® Torque Value: 11 Nem [97 nb]Section § Fuel System Group 05 B Series Shop Manual Shutoff Solenoid Replacement, Stanadyne DB4 (5-24) The Stanadyne injection pump 1s equipped with one of two types of electrical shutoff devices. Energized to run (ETR) solenoids are the most common. They are ener- ized continuously while the engine is running and when de-energized will cause the engine to shut off. Note the location of the solenoid arm (1) 1n the illustration, ‘The energized to shutoff (ETSO) solenoids are used less frequently. These are designed to be energized only mo- mentarily when engine shutoff 1s desired. Note the loca- tion of the solenoid arm (1) in the illustration. Remove the top cover mounting screws. Remove the four solenoid mounting nuts, grounding strap, washers and terminal. Injection Pump Repairs (5-21) Page 5-41Injection Pump Reps Section 5 Fuel System Group 08 Page 5-42 B Senes Shop Manual f new solenoid. Apply dielectric grease to the terminal studs and to the area the solenoid will come into contact with the top cover. Install new insulating tubes onto the terminal studs of the eB Gps, Install the solenoid to the top cover. eo : CID Torque Value: 14 Nem [12 ft-lb] Use the Stanadyne ETR solenoid erm retaining tool to make sure the arm is in the correct position during the top a cover installation, To Gps Install the top cover and gasket to the injection pump. (EF Tuist the retaining too! to release it from the arm. Silico the tool out from between the top cover and pump. Torque Value: 4.6 Nem [41 into]Section 5 Fuel System Group 05 B Series Shop Manual In the event that the retaining tool 1s not available, install the top cover as follows: Move the shutoff lever to the stop position. NOTE: Extreme care must be taken in assembling the cover to the pump to make sure the shutoff arm is in correct contact with the linkage hook tab. Install the cover to the pump at a downward angle from the drivehsaft end of the pump, then slide the cover horizontally into position. Torque Value: 4.6 Nem [41 intb] Install the top cover, ETSO solenoid and gasket to the injection pump. Make sure the solenoid arm is between the pump housing and linkage tab as shown in the illustration. Torque Value: 4.6 Nem [41 in-tb] Speed Droop Adjustment Off Engine - Stanadyne DB4 (5-25) Loosen the speed droop adjustment locking cap. Turn the droop adjustment screw counterclockwise until itstops. Then, turn the screw five complete revolutions in the clockwise direction. The governor 1s now adjusted to minimum droop. Adjust- ments to increase or decrease governor sensitivity can be made after the injection pump 1s installed to the engine. Injection Pump Repairs (5-21; rection Pump BoP ge 5 wosInjectlon Pump Repairs (S-21) Page 5-44 ww serma Ce snat desea | shauenas we fosprme | @ Section § Fuel System Group 05 B Series Shop Manual Tighten the droop adjustment locking cap. Hold the ad. justment screw with a screwdriver to prevent movement when the locking cap Is tightened. Torque Value: 7.5 Nem (65 in-(b] Injection Pump Timing - Nippondenso EP9 (5-26) The injection pump has a plastic timing pin and spring located under the cap on the outboard side of the pump This pin locates the pump shaft to correspond with TDC. tor cylinder No.1 After the pump is installed, the spring 1s placed under the head of the timing pin and the cap Is installed. 34mm Mount the pump on a suitable bracket Remove the cap from the pump locking device. The cap ts located on the outboard side of the pump. Remove the plastic timing pin and spring.Section 5 Fuel System Group 05 Injection Pump Repairs (5-21) B Series Shop Manual Page 5-45 27mm r | «6 Bar @K VHC Install the nut on the pump shatt. | A (4 . yy fp \ ‘oanvne| Install the timing pin first, then the spring. Service Tip: Use the slot in the end of the timing pin as a reference for properly positioning the timing pin. The slot must be horizontal ta the pump in order for the pin to engage the slot in the pump shatt. se al see Depress the spring and rotate the pump shaft until the tip, ©) of the timing pin goes into the stot in the pump shaft. The & keyway in the shaft will be at approximately the 2 o'clock position. Loe & Valsad 2) fig wy pescud Caution: Although unlikely, it is possible that the timing pin will match the pump notch when the timing pinis first Inserted. If so, the pump will be locked. Do not exert more than 7 Nem [10 ft-lb] torque to turn the pump shaft. if the pump shaft does not turn'with 7 Nem [10 ft-lb] torque, remove the spring and timing pin, then rotate the pump slightly. Repeat the previous step again.Injection Pump Repairs (5-21) Page 5-46 200m R) Qs Q Section 5 Fuel System Group 05 B Series Shop Manua] Install the cap loosely (finger tight). 27mm Remove the nut from the pump drive shaft by striking the wrench with a sharp blow in a counterclockwise direction. Seals Replacement, Nippondenso EPS (5-27) tam Type of Seal Torque A = Sealing washer, 24 Nem [18 ft-lb] B = Sealing washer, 14 Nem [10 ft-lb] C = Sealing washer, 27 Nem [20 ft-lb] D = Copper washer only, 70 Nem [50 ft-lb] E = Copper washer (Bleed screw), 5 Nem [36 in-Ib] Shut Down Lever or Spring Replacement, Nippondenso EP9 (5-28) 10mm Remove the retaining screw.Section 5 ~ Fuel System Group 05 B Series Shop Manual Remove the shut down tever (A) spring housing (B) and return spring (C). & Install the spring as itlustrated Install the spring housing over the spring aligning the jp. spring with the illustrated hole in the housing. Bp Metal awl or pick Load the spring by rotating the spring/housing counter- clockwise approximately 1/4 turn. Injection Pump Repairs (5-21) Page 6-47 vaep2a] epsInjection Pump Repairs (5-21) Page 5-48 Section 5 Fuel System Group 05 B Senes Shop Manu, 10 mm 4 Hold the spring in the loaded position and install the lever, NOTE: If the shutdown shaft slides into the housing, thread the retaining screw into the shaft and slide the shatt to ite original position, Visually inspect the o-ring for distortion or damage. 10 mm Install the retaining screw making sure the spring aligns to the hole in the fever. Pressure Relief Valve and Sealing Washer Replacement, Bosch P7100 (5-28) The pressure relief valve arrangementon the Bosch P7100 Injection pump in the supply side of the fuel circuit creates a self-bleeding system for air introduced during replace- ment of the supply side components. Asticky or malfunctioning relief valve can result in engine muss, low power or hard starting, The Bosch P7100 injection pump has a jump-over tube to route return fual and entrapped air from the pressure relief valve directly to the supply tank.Section § Fuel System Group 05 B Series Shop Manual Mount the pump in a suitable bracket and hold pump with a vise. 19mm Remove the pressure celief valve and sealing washers. Remove the ump-over tube. Thoroughly flush the pressure relief valve with a cleaning solution Use a'small screwdriver to check that the check balls not sticking in the pressure relief valve assembly. A sticky check ball will result in engine low power and hard starting Replace the relief valve assembly if necessary. Injection Pump Repairs (5-21) Page 5-49 fedvavm fapeneeInjection Pump Repatrs (5-21) Page 5-56 fo % Section 5 Fuel System Group 05 B Series Shop Manual 19mm Install the pressure relief valve, jump-over tube, and seat. ing washers in the reverse order of removal. Seal Replacement, Bosch P7100 (5-30) Item Type of Seal A O-Ring Seal B Sealing Washer c Sealing Washers (Rubber Coated) Fuel Inlet Banjo Connector Replacement, Bosch P7100 (5-31) 19 mm. Remove the fuel inlet banjo connector and sealing washers. Thoroughly flush the inlet connector with a cleaning so- lution to ensure it 1s not blocked with foreign debris, Replace the fuel inlet banjo connector if the threads are ruined.Section 5 Fuel System Group 05 B Serles Shop Manual 19mm Install the fuel inlet banjo connector and new sealing washers in the reverse order of removal. Fuel Shut Off Solenoid Replacement, Bosch P7100 (5-32) 10mm Remove and replace the shut off solenoid with the part number facing outward as illustrated. Torque Value: 9Nem [7 ttb] Fuel Shut Off Solenoid Adjustment, Bosch P7100 (5-33) NOTE: The fuel pump solenoid must be adjusted on the vehicle to access the voltage supply. Connect the solenoid wiring harness to the vehicle wiring harness. ‘Turn the key to the “ON” position. This will energize the red (hold) wire and black (common) wire. This 1s the low current holdin coil and must be energized continuously dunng this adjustment. NOTE: Do not turn the key to the ‘'START” position at this, time. This will energize the white (pull-n) wire Injection Pump Repairs (6-21 P RepeatInjection Pump Repairs (5-21) Page 5-52 Section 5 Fuel System Group 05, B Series Shop Manual Move the shut off lever by hand to the full run position, 40 mm, 16 mm Adjust the solenoid linkage to dimension A. Dimension A Is measured from the bottom surface of the solenoid mounting bracket to the top of the pivot pin. When prop- erly adjusted the plunger is magnetically held in with the shut off lever in the absolute full run position, Turn the large hex on the end of the plunger to make adjustments, Solenoid Run Dimension ‘A = 66.9 mra (2.6 in} Fuel Shut Off Solenoid Bracket Replacement, Bosch P7100 (5-34) Praparatory Step: Remove shut off solenoid, 8 mm, 5mm Allen Remove and replace the bracket as illustrated Torque Value: Top Capscrews (2) 7 Nem [5 ft-lb] Side Capserew (1) 10 Nem [74 ft-lb} Fuel Pump Shut Off Lever Replacement, Bosch P7100 (5-35) Preparatory Step: Remove the shut off solenoid.Section 5 Fuel System Group 05 B Series Skop Manual 8mm, 10 mm Remove the capscrews holding the laver bracket to the lever. 8mm Remove the capscrew holding the shut off lever to the shut off shaft. NOTE: The shut off lever is indexed fo the shaft with a Woodruff key. 8mm, 10 mm Install in the reverse order of removal. Adjust the shut off solenoid. Refer to Procedure (5-29). Throttle Lever Replacement, Bosch P7100 (5-36) 8mm Remove and replace the throttle lever as illustrated, NOTE: The throttle is indexed on the throttle shaft with a Woodrutt kay. al a Q) Injection Pump-Repaurs (5-21) - Page 5-53 > Bh abeInjection Pump Repairs (5-21) Page 5-54 sox 006% B Series Shop"Manuat : Shutdown Solenoid Inspection, Bosch P7100 (5-37) Engines using the Bosch P7100 fuel injection pump with the RQVK governor are equipped with the synchro-start fuel shut off solenoid to actuate the shut off fever. Both 12 volt and 24 volt external fuel shut off solenoids’ are avallable, The synchro-start has @ weatherpack connector with 3 wares in it Color Deseri Weetherpack Port Black Ground White Pull In. ‘Be Red Hold tn " Wiring Guidelines Refer to the chart below to find the correct gauge size and length of continuous wire for the white (pullin) wire, which connects to the solenoid wiring Black to Red - Hold In Black to White ~ Pull In Length of Wire 0-4.5 ft 0-7.0 ft Gauge 4 1 NOTE: 14 gauge wire 's required for the red (hold-in) wire, which connects to the “Fun” terminal on the ignition switch NOTE: The black (ground) wire must be the same size as the white (pullin) wire. Onn ft 10 Solenoid Resistance Check The synchro-start solenoid can be checked using a volt- ohmmeter. Check the solenoid resistance, Resistance Solenoid Min Ohms Voltage Pull-tn Hold-in 12 0.22 Ti 24 0.82 a3Section § Fuel System Group 05 Injection Pump Repairs (5-21) B Series Shop Manual Page 6-55 Solenoid Voltage Check If the Synchro-Start solenoid checks good, the problem is with the wiring circuit to the solenoid. ‘To pertorm the solenoid voltage check, connect the wiring harness and apply voltage to the solenoid with the ignition key as follows: 1 With the key in the run position, check the voltage holdun. 2. With the shut down lever held in the shut down posi- tion, move the key to the start’position and check the pullin voltage. Battery Min Voltage Voltage Putl-In Hold-In 12, 65 4.0 24 13.0 8.0Section 6 - Injectors Group 06 Page 6-1 Section 6 - Injectors - Group 06 Section Contents Fuel Lines Clean and Inspect... Fuel Drain Manifold... High Pressure Fue! Lines Low Pressure Fuel Lines... Fuel Transfer Pump Cleaning and Inspecting Fuel Transfer Pump General information... Fuel Transfer Pump Identification..... jon Style Rebulld Fuel Transfer Pump ‘Assembly Cleaning... General Information injectors Injector Assembly Injector Clean and inspect... Injector Disassembly Injector Service Tools Injector Testing Chatter Test, Injector Group Exploded VIeW «cen 6-12 6-13Injector Service Tools Section 6 Injectors Group 06 Page 6-2 B Series Shop Manua| Injector - Service Tools The following special tools are recommended to perform procedures in Group 06. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location Too! No. Tool Description Too! Illustration Injector Tester 3376946 Nozzle Cleaning Kit 3376947 Flexible Injector Puller 3823276Section 6 Injectors Group 06 Injector Group Exploded View B Series Shop Manual Page 6-2 Injector Group - Exploded View ft900gr¥ General Information Injectors Section 6 Injectors Group 9 Page os ue 'B Series Shop Manus, General Information - Injectors ‘The injector needle valve and the nozzietip are machined toa very precise tolerance. Never replace only the needa valve. Never mix the needle valves and nozzle tips, they are matched sets. This group provides instructions for disassembly cleaning, assembly and test of the injectors. Also included are cleaning and inspection procedures for the fuel lines, fuel transfer pump, and fuel filter head.Section 6 Injectors Group 06 B Series Shop Manual Fuel Transfer Pump General information Page 6-5 Fuel Transfer Pump - General Information Fuel Transfer Pump - Identification The B senes engine uses three different piston style, and one diaphragm style, transfer pumps. The diaphragm style transfer pump cannot be rebullt. Piston style transfer pump, Part No, 3918076, 1s offered as an option on B series engines equipped with distrib- utor type fuel injection pumps. NOTE: Part No. 3918076 and 3918000 are identical im ap- pearance. The pumping spring free length can be measured to identity the pump. Fuel transfer pump 3918076 spring free length 53.5 mm [2 7/64 in). Piston style transfer pump, Part No. 3918000, 1s used on the 300 HP marine B series engine. NOTE: Part No. 3918076 and 3918000 are identical in ap- pearance. The pumping spring tree length can be measured to identity the pump. Fuel transfer pump 3918000 spring free length 58 mm [2 9/32 in] Piston style transfer pump, Part No. 3917334 and 3921550, 6 used on the 91 B series engine equipped with the Bosch P7100 in-line injection pumps. feosona fs85000" Fuel Transfer Pump Identification Section 6 Injectors Group 9 Paseo 'B Series Shop Manag, Diaphragm style transfer pump. fes0%60Section 6 Injectors Group 06 _ B Senes Shop Manual Injector - Disassembly Clean the carbon residue from the nozzle, Use a brass wire brush and a piece of hardwood dipped in test oll. Remove the copper sealing washer and discard. 15mm Clamp the nozzle holder in a soft jawed vise and remove the nozzle nut Remove the nozzle needle valve and intermediate plate. NOTE: To avoid damage place injector nozzle and needle valve in a suitable bath of clean test oll, Be Ry & Injector Disassembly Page 6-7Injector - Clean and Inspect Page 6-8 nn tia00%4 ts WN geome) <3 | coe svete Section.6 injectors Group 0g B Series Shop Manual Caution: Hold the needle vaive by the stem only. Skin | olls will corrode the finely lapped surfaces, Caution: The needle valve and nozzle tip are matched AX tortie They must not be intermned Remove the nozzle holder from the vise; then remove the <9 pressure spindle, pressure spring and stums. injector - Clean and Inspect Edge-type filters may be cleaned by applying compressed air to the fue! passage from the nozzle side of the nozzle holder. Edge-type filters ace not removable for service. Rinse new nozzle bodies and needle valves in solvent to thoroughly flush and completely remove all protective coating material.Section 6 Injectors Group 06 Injector Clean and Inspect B Senes Shop Manual Page 6-9 Nozzle Cleaning Kit 3376947 Caution: Never use emery paper or any other metal scraper to clean the nozzle. Clean the nozzle seat with scraper as shown dipped in test oll, Polish the needle seat with the piece of hardwood dipped in test oil. E> Clean the interior nng groove of the nozzle with the scraper as shown, Rinse in solvent to remove all dirt and carbon residue and dip in clean test oil. 7 a san Clean the spray holes of hole type nozzles as shown with the appropriate size cleaning needle. Remove burned-on combustion deposits on all nozzles with a commercially available cleaner. Rinse all parts in clean test oil Clean the needle valve tip with a brass brush. Then, Inspect for rough surfaces or erosion. The pressure shoul- der will normally have a rough machined appearance, NOTE: Deteriorated needle valves must be replaced as a matched unit with their compatible nozzle body.Injector - Assembly Page 6-10 A A a Section 6 Injectors Group 0g B Senes Shop Manus] Dip the needle vaive in clean test oil and insert the needie valve all the way into the nozzle body. Caution: Any needle valve and nozzle body assembly which cannot pass this test must be replaced. Pull the needle vaive one-third of the way out of the nozzle body. The needle valve must slide all the way back into the nozzie bedy under its own weight. Ifthe nozzle fails the slide test, clean the nozzle again and retest it. Injector - Assembly NOTE: Make sure all mating surfaces and pressure faces are absolutely clean and lubricated with fuel oll before assembled. Caution: Install the same thickness of shims that were removedindisassembly. Use the pressure spring to make sure the shims are installed flat. gps Install the shims,Section 6 Injectors Group 06 Injector Assembly B Series Shop Manual Page 6-11 Clamp the nozzle holder in a soft jawad vise and install jx. the spindle. Sp Install the intermediate plate. Cg install the needle valve and nozzle assembly. El ap 15 mm Install the nozzle nut. Torque Value: 30 Nem [22 ft-lb] OSek ahs. _ me |Injector Page 6-12 90022 10 Seconds >> Section 6 Injectors Group 09 B Series Shop Manuel seca injector - Testing Warning: Keep your body clear of test spray. Flutd can be injected into the bloodstream causing blood poison- ing and possible death. All nozzles must be tested for opening pressure, chatter and spray pattern, Check the opening pressure. a. Open valve b. Operate lever at one stroke per second. ©. Read pressure indicated when spray begins. Ifthe opening pressure is out of specification, then change the shim pack. Adding shims will crease pressure. Leakage Test: a, Open valve. b. Operate lever to hold pressure 20 bar [290 psi} below opening pressure. . No drops should fall from the tip within 10 seconds.Section 6 Injectors Group 06 Fuel Transfer Pump Cleaning and Inspectin B Series Shop Manual Page e183 Chatter Test ‘The chatter test indicates the ability of the needle valve to move freely and correctly atomize the fuel. You should hear the valve open and should see a well atomized spray pattern. Used nozzles should not be evaluated for chatter at lower speeds. A used nozzle can generally be used if it passes the leakage test, chatters audibly at high lever speeds and uniformly atomizes the fuel. Fuel Transfer Pump - Cleaning and Inspecting Visually inspect the fuel transfer pump for obvious cracks or damage that would prohibit reuse. Inspect the weep hole area for signs of {uel leakage. Clean the pump in mineral spirits. Blow dry with com- pressed air. Inspect the camshaft lever and the return spring for ex-Fuel Transfer Pump Piston Style Rebuild Page 6-14 Outlet Fitting Infet Fitting Hand Prime| Fitting (a9ne0 @) Qo . Section 6 Injectors Group og B Series Shop Manu; To inspect the transfer pump, pour clean diesel fuel or engine oll into the inlet connection and perform the fol, lowing test: Inspect the diaphragm by blocking the fuel inlet line with your finger and operating the priming lever. A good pump will have suction that will not bleed down Until the finger Is removed from the inlet. ‘On diaphragm style fuel transfer pumps, parts replace- ment is not practical; the pump is serviced as an assem~ bly. An optional piston style pump 1s available which can be cleaned and repaired with a minor repair kit. Fuel Transfer Pump - Piston Style Rebuild Preparatory Step: * Clean debris from the fuel line fittings and the fuel transfer pump. 20 mm, 26 mm Wrench Caution: The hand-prime fitting and inlet fitting are spring loaded. Sudden removal of these two fittings can cause personal injury. ‘Secure the pump ina vise, taking care not to damage the pump housing. Remove the rubber boot from the hand-prime fitting. Remove the three illustrated fittings. a i iSection 6 Injectors Group 06 B Senes Shop Manual Remove alt internal components of the pump. NOTE: Make sure the check valve gaskets are removed from the inlet fitting (A) Outlet Fitting (B) Inlet Fitting (C) Hand Primer Fitting Cleaning Thoroughly flush the pump with a cleaning solution to remove any debris. Assembly 20 mm, 26 mm Wrench Assemble the pump with the new components supplied In the rebuild kit Check valves Check valve gaskets O-ring seal Outlet fitting/check vaive “O-ring seal (25 mm) “O-ring seal (30 mm) or (25 mm) = O-ring required 1s determined by the size of the inlet fitting. Discard unused o-ring. Papens NOTE: Extreme caution must be used to make sure the check valves are installed to open in the direction of the fuel flow. Improper installation of the check valves will result in low power from the engine, Fuel Transfer Pump Piston Style Rebulld Page 6-15 ns0000Fuel Lines Clean and Inspect Section 6 Injectors Group 0g Page 6-16 B Series Shop Manual_ Place the pump in’a vise and torque the fittings te the © wet (A) Outlet Fitting 30Nem [22 ft-lb] { (8) Hand-Prime Fitting 30.Nem [22 ft-lb] 4 (©) Inlet Fitting 30Nem [22 ft-lb} Fuel Lines - Clean and Inspect High Pressure Fuel Lines Visually inspect the high pressure fuel lines for obvious damage such as lines that have bent to facilitate injector removal. High pressure pulses expand and contract the injector lines which result in internal flaking at the bent areas. Bent lines should be replaced. Wash the fue! lines in clean solvent and blow dry with compressed ait. Make sure all paint chips are removed. Visually inspect for cracks at both ends of the fuel lines.Section 6 Injectors - Group 06 Fuel Lines Clean and Inspect B Series Shop Manual Page 6-17 Caution: The high pressure lines must be clamped se- curely and routed so they do not contact each other or A any other component. Inspect for areas of contact that have worn the material thin. Inspect the vibration isolators (clamps). Make sure all the vibration isolators are positioned and tightened properly. Missing or improperly installed isolators will almost cer- tainly result in fuel line failure. Caution: Do not weld or substitute lines; use only the specified part number for the engine. A The length, internal size and rigidity of the lines 1s critical to smooth engine operation. An attached metal tag is used to identify each line with a part number. Fuel Drain Manifold Inspect the fuel drain manifold for cracks and obviousFuel Lines Clean and Inspect Sectlon 6 Injectors Group 0g Pageéie " B Series Shop Manual Inspect the sealing surfaces for leak paths, 13 mm. Inspect the rubber seals, Replace any damaged seals or seals that are hard or brittle. Service Tip: Lubricating the seals with clean engine oil will facilitate the installation, \ 2 (@ poe a S *| OK 90040 Low Pressure Fuel Lines Wash the low pressure fuel lines in clean solvent. Blow dry with compressed ait. SS @ Visually inspect the lines for obvious damage such as cracks or worn araas,Section 6 Injectors Group 06 Fuel Lines Clean and Inspect B Series Shop Manual Page 6-19 17 mm, 16 mm Ql Inspect the rubber seals, Replace any damaged, hard, or brittle seals. Service Tip: Lubricating the seals with clean engine oil will facilitate the installation. alSection 7 Lubrication Oil System Group 7 B Series Page 7-1 Section 7 - Lubrication Oil System - Group 7 Section Contents Page 78 78 76 76 Filter Bypass Valve Replace General Information Lubrication System Oil Cooler Core ....eresense 7 Oil Filter Head/Pressure Regulator Plunger. Lubricating Oil Cooler Exploded View. 75 Lubricating Oi! Pump Exploded View 710 Lubrication Oil Pump General Information...... 7A Oil Cooler Cleaning... . 78 Oil Cooler Inspection ....ensnseisneneninnntnnenennnenne 79 Oil Pan and Suction Tube Cleaning and Inspection seseeeene een 14 Oil Pan and Suction Tube Exploded View......... eovecententnenese 72 Oil Pan and Suction Tube General Information ... . wo TB Oil Pump Inspection... . TAD Pressure Regulator Valve Assembly 78 Pressure Regulator Valve Disassembly. eeseenennee . cad Pressure Regulator Valve - inspection... v7Oi! Pan and Suction Tube Exploded View Page 7-2 Oil Pan and Suction Tube - Exploded View Section 7 Lubrication Oil System Group 7 B Series. op900gr Ref. No. Part Name Qty. Remarks, 7 Pan, Oil 1 2 Plug, Threaded 1 Mi8 1.5.x 12mm 3 ‘Washer, Sealing 1 4.5mm thick, 18.40 1.D. 4 Screw, Hexagon Head Cap 3 M8 1.25 x 16mm 5 Connection, Oil Suction 1 6 Screw, Hexagon Head Cap 36 M8 1.25 x 20mm 7 Washer, Spring 36 8 Washer, Sealing 1 22.2 1.D. x 1.5mim thick 9 Plug, Threaded 1 M22 x 1.5 mm 10 Gasket, Oil Pan 1 "1 Gasket, Flange 1 :Section 7 Lubrication Oil System Group 7 Oil Pan and Suction Tube General Information B Series Page 7-3 Oil Pan and Suction Tube - General Information The 8 Series engine is available with various oil pan/suction tube configurations based on the customer's needs; 1.@., oil capacity angularity limits, drain plug location, etc. However ail the oil pans fall into two basic types, center sump and front or rear sump. Both types of oil pans can be rotated front to back to meet vanous installation requirements such as moving a drain plug to @ specific side or front and rear sump requirements.ll Pan and Suction Tube Cleaning and Inspection (7-01) Section 7 Lubrication Oll System Group 7 Page 7-4 B Seri Oil Pan and Suction Tube - Cleaning and Inspection (7-01) Steam clean the pan and suction tube. Inspect the pan for cracks and damaged threads. ZS) _ Inspect the oil suation tube and brace for cracks. Do not | reuse a cracked oil suction tube or brace. Also check the block mounting surface for damage.Section 7 Lubrication Oll System Group 7 Lubricating Oil Cooler Exploded View B Series Page 7-8 Lubricating Oi) Cooler - Exploded View le900gs Hef. No. Part Name Qty. Remarks. T ‘Screw, Hex Flange Head Cap 14, MB x 1.25 x 35 2 Valve, Bypass 3 Spning, Compression 4 Plug, Pipe 5 Head, Lub Oil Filter 6 7 8 9 1/8 NPT 1 1 1 1 Adapter, Filter Head (Not Replaceable) 1 Core, Cooler 1 Gasket, Filter Head 1 1 1 1 1 1 Plug, Threaded M22 x 1.50 10 Seal, O Ring 1 Plunger, Prs Regulator 12 Gasket, Oil Cooler Core 13 Cartridge, Lub Oit FitterGenerat Information Lubrication System Section 7 Lubncation Oil System Group 7, Page 7-6 B Series. General Information - Lubrication System Oil Cooler Core The B Series engine uses a full flow plate type oil cooler The oil flows through the element where it 1s cooled by engine coolant flowing past the plates of the element. The four cylinder engine uses five plates. The six cylinder engine uses seven plates. NOTE: Some engines use a jumper plate in place af an oll coolerSection 7 Lubrication Ol! System Group 7 Prassure Regulator Valve Disassembly (7-02) B Series. Page 7-7 Pressure: Regulator Valve - Disassem- bly (7-02) 19 mm Remove the plug and sealing washer. Remove the spring and plunger. Pressure Regulator Valve - Inspection (7-03) Inspect the plunger bore tor nicks or scratches. The plunger must move freely in the bore.Pressure Regulator Valve Assembly (7-04) Page 7-8 Section 7 Lubrication OW System Grounig Series, Check the pressure regulator spring at the following two heights. Free Length 60.6 mm [2.38 in] Limit F 1991 é © 44.5 mm [1752 in] Min. Load 105 N [23.6 (ib) (regulator valve opens) © 41.25 mm [1.624 in] Min. Load 142 N [32 Ib] (regu. lator valve seated) Free Length 66 mm [2.59 in] (1994) © 44.5 mm [1.752 in] Mi (regulator valve opens) + 41.25 mm [1.624 in] Min. load 137 N [30.8 Ibf] (regulator valve seated). Load 116 N [26.1 Ibfj Pressure Regulator Valve - Assembly (7-04) RQ] som Install the valve. V7 Torque Value: 80 Nem [59 ft-lb] Filter Bypass Valve - Replace (7-05) Ro Remove the valve from the cooler cover.Section 7 Lubrication Oll System Group 7 O11 Cooler Cleaning (7-06) B Series 7- Page Drive the new valve in until it bottoms against the step in the bore. Oil Cooler - Cleaning (7-06) Plug the cooler and soak it in a cleaning solution to [C remove the coolant deposits. Remove the plugs and soak the cooler in solvent. The cooler can be cleaned in a hot tank Back flush the oil passages with clean solvent and use compressed air to dry. Oil Cooler - Inspection (7-07) Inspect the soldered joints for carrasion or cracks. @ll Coaler Inspection (7-07) Section 7 Lubrication Oil System Gro Page 7-10 8 ‘Sores Pressurize the cooler to 483 kPa [70 psi} and check forSection 7 Lubrication Oil System Group 7 Lubricating Oil Pump Exploded View B Series Page 7-11 Lubricating Oil Pump - Exploded View Ret. No. Part Name ay. Remarks 1 Pump, Lube 1 (Note 1) 2 Body, Lube Pump 1 3 Bearing, Sleeve 1 4 Shaft, Lube Pump iaier 1 5 Plug, Oil Rifle 1 6 Screws 2 7 Shaft, Lube Pump 1 8 Gear, Lube Pump Drive 2 9 Gear, Lube Pump tdier 1 10 Key, Woodruff 1 1" Gerotor, Driver 1 12 Gerotor, Planetary 1 43 Plate, Lube Pump Back i 14 Screw, Hex Hd Cap 4 M8-1.25x30 Note 1 Item 4 1s available as an assembly only. Exploded view is shown for information purposes.Lubrication Ol! Pump General Information Section 7 Lubrication Oll System Page 7-12 Lubrication Oil Pump - General Information It is not practical to rebuild the gerotor pump. It can be reused if it meets the inspection criteria. There are two basic B Series lubrication pumps one for the four cylinder and one for the six cylinder. ‘The gerotor width on the four cylinder pumps 1s narrower than in the six cylinder pumps. Group 7 B SertegSection 7 - Lubrication Oll System Group 7 ll Pump Inspection (7-08) B Series Pago 7-13 Oil Pump - Inspection (7-08) Visually inspect the lube pump gears for chips, cracks, or excessive Wear. Remove the sealing plate. Maik “‘top”’ on the gerotor planetary. Remove the gerotor planetary. Inspect for excessive wear or scoring. X 900mSection 7 Lubrication Oll System Group 7 B Sones Clean all parts in solvent and use compressed air to dry, Inspect the pump housing and gerotor drive for damage and excessive wear. Be sure the gerotor planetary is installed in the onigi- nal position. Gl Install the gerotor planetary. fap Measure the tip clearance. Tip Clearance om in 0.1778 MAX 10.007}Section 7 Lubrication Oll System Group-7 B Series Measure the clearance of the gerotor drive/gerotor plan- etary to port plate. Port Plate Clearance mm in 0.127 MAX [0.005] Measure the clearance of the gerotor planetary to the body bore, Body Bore Clearance mm mn 0.381 MAX [0.015} Measure the gears backlash Limits for a “Used Pump" 0.076 0.33 mm [0.003 0.013 in} NOTE: Prevent movement of the adjoining gear when check- ing backlash or the reading will be the tolal of both gears. Install the lube pump back plate. Ol! Pump Inspection (7-08) Page 7-15 @® (poepnsSection 8 Cooling System Group 8 B Series Shop Manual Page 8-1 Section 8 - Cooling System - Group 8 Section Contents Belt Tensioner Inspection... Belt Tensioner and Fan Hub Exploded View... Belt Tensioner and Fan Hub General information Belt Tensioner ... Fan Hub Disassembly Fan Hub Inspection .. Fan Hub Assembly General Information About Fans .. Thermostat Inspection ..... ate B43 Thermostat Housing Assembly Exploded View . a sos BF Thermostat Housing Assembly General information. 12 Water Pump Exploded View... one a 82 Water Pump General Information... os . 83 a 7 84 Water Pump Inspection - seenSection 8 Cooling System Group 9 Water Pump Exploded View Page8-2 B Series Shop Manual Water Pump - Exploded View jet Ref. No. I Part Name ary. Remarks 1 Pump, Water 1 2 Seal, Rectangplar Ring 4 5.16 min Thick a Screw, Hex Hd Cap 2 M8-1.25x22 |Section 8 Cooling System Group 8 Water Pump General Information B Series Shop Manual Page 8-3 Water Pump - General Information The water pump 1s a belt driven, centrifugal type pump with the inlet and bypass line as an integral part of the cylinder block, Its not practical o replace the parts in the pump, the water pump 1s serviced as an assembly ReCon® wates pumps are available from Cummins Distributors and Dealers.Water Pump Inspection (8-01) Page 8-4 od Cooling §) B Serres Shop Water Pump - Inspection (8-01) @ Inspect the impeller blades for wear or corrosion. 4, Inspect for tree rotation of the pump. © Check the weep hole for evidence that the seal has been Teaking. Parts replacement is not practical: the water pump Is, serviced as an assembly.Cooling System Belt Tensioner and Fan Hub Exploded View B Series Shop Manual Page 8-5 Belt Tensioner and Fan Hub - Exploded View #a900gx Ref. No. Part Name [ Qty. Remarks, 1 ‘Support, Fan q ‘Mounts to block. 2 Bearing, Ball 1 3 Hub, Fan 1 27.0 mm Thick, 25.4 mm Dia. Shaft 4 Retainer, Fan 1 5 Screw, Hex Hd Cap 1 M12-1.75x70 mm 6 Screw Hex Hd Cap i MB-1.25x75 mm 7 Screw, Hex Hd Cap 3 M8-1.25x30 mm 8 Pulley, Fan 1 9 Piate, Clamping 1 10 Screw, Cap 4 MB-#.25x20 mm n Screw, Cap 4 M8-1.25x16 mm 12 Bracket, Belt Tens. i 13 Screw, Flat Head Cap 2 M8-1.25x25 14 Tensioner, Belt 1 15 Screw, Hex Hd Cap 1 M10-1.5x61.86 mm 16 Belt, V-ribbed t 1524 mm LongBelt Tensioner and Fan Hub General Information Cooling System Page 8-6 B Series Shop Manual Belt Tensioner and Fan Hub - General Information Belt Tensioner The only practical repair for tensioners 1s pulley replacement. Slight vanations exist in the pulley removal and installation for each pulley version. Itthe pulley exhibits excessive wear _a special service tensioner is available which features a hardened pulley with Increased resistance to wearCooling System B Series Shop Manual Fan Hub - Inspection (8-02) Inspect for free rotation of the fan hub shaft. Check the end of the bearing for evidence that the lubri- cant has leaked. Rebuild or replace as required. Inspect the fan hub bearing for wear. The bearing should have a minimal amount of side to side or end play move- ment. Replace the bearings if more than a minimal amount can be felt. Fan Hub - Disassembly (8-03) 16 mm Secure fan hub and remove the center bolt and retainer. Snap Ring Pliers If the assembly 1s equipped with snap rings, remove the snap ring as illustrated. Fan Hub Inspection (e-02 Page 8- sipeeeFan Hub Assembly’ (8-04) Page 8-8 Q) Q) cy B &R Be Cooling S) B Series Shop. 1 inch Drift ‘Support the fan hub bracket housing and press out the shaft/hub. Approximately 6 tons of pressure is required. ‘Snap Ring Pliers ‘Turn the bracket housing over and remove the snap ring It so equipped. 2 inch Pipe Press on the ©.D. of the bearing to remove from the housing. Fan Hub Assembly (8-04) Snap Ring Pliers If the bracket housing 1s equipped for snap rings, install the front snap ning,Cooling System B Series Shop Manual 2 Inch Pipe Press the bearing flush with the front of the housing or to the snap ring. Snap Ring Pliers Install the second snap ring if so equipped. ‘Supporting the bearing inner race with a 1.25 inch pipe coupling, press the hub/shaft in until it bottoms on the bearing. 16 mm Secure the assembly and install the retainer and center bolt. Tighten to 77 Nem [87 ft-lb}. Fan Hub Assembly (8-04)Belt Tensioner Inspection (8-05) Page 8-10 ection (8-05) Cooling System B Series Shop Manual Belt Tenstoner - Inspection (8-05) Inspect the pivot tube area of the tensioner for excessive wear evidenced by an elongated hole. If the tensioner exhibits excessive Wear, it must be replaced. Roll the bearing and check that it rotates freely with no rough spots.Cooling System Thermostat Housing Assembly Exploded View B Series Shop Manual Page 8-11 Thermostat Housing Assembly - Exploded View th900gm Ref. No. Part Namo Qty. Remarks 7 Housing, Thermostat 1 2 Gasket, Thermostat Housing 1 3 Sorew, Hex Hd Cap 1 MB-1.25x95 4 Screw, Hex Hd Cap 2 MB-1.25x70 5 Bracket, Lifting 1 6 Thermostat Coolant 1Cooling System Thermostat Housing Assembly General Information B Series Shop Mantisl Page 8-12 Thermostat Housing Assembly - General Information I A pressure balanced thermostat is used on the B Series. No special orientation 1s required with the new thermostat. The thermostat is compatible with thermostat housings which have a groove cut for the old thermostat tang.Cooling System Thermostat Inspection (8-06) B Series Shop Manual Page.8-13 Thermostat - Inspection (8-06) Visually inspect the thermostat for obvious damage such as obstructions caused by debris, broken springs, or stuck or missing vent pins. New old The thermostat can be checked for correct operation. Requirements Start to open at 83°C [181°F] Fully open at 95°C [203°F].: General Information About Fans Cooling System Page 8-14 B Series Shop Manual General Information About Fans Warning: Never attempt to rotate the engine by pullling or prying on the fan. This practice can result in serious personal injury and damage to the fan. Use only the proper engine barring techniques to manually rotate the engine. Check the fan for missing balance weights at each regular maintenance interval. Do not attempt to reparr broken or bent fans, or fans with missing balance weights. Most equipment that has a Cummins engine uses a radiator and a fan. The radiator and fan transfer heat from the cooling water to the atmosphere. The fan selection process must conclude that the fan,’the fan mounting arrangement, and the fan dnve system are designed and matched for compatibility Upon request, Cummins Application Engineering Department will assist in determining the proper selection. Refer any fan changes other than the direct replacement of a fan with precisely the same Cummins part number to the Cummins Application Engineering Department for prior approval. Examples that require approval are, Using an approved fan from one engine model on a different engine model. Using an approved fan on an engine with a different fan mounting arrangement Using an approved fan on an engine with a different fan drive arrangement. Rona Converting an engine from one market model to another An example is the converston of a G-drive engine to @ power unit application’ 5. Converting an engine model to a different’ model. An example 1s converting a 6875.9 to a 6BTAS.9. This list is not inclusive. Always contact Application Engineering for assistance. At times an existing fan can yreld ONLY marginal cooling capability when being considered for a new application. Ly Caution: Never repitch (bend) the blades to obtain additional air delivery. Bending the blades or spider creates stress in the material used for the construction of the fan. Repitching (bending) will cause fan failure. The proper diameter fan must be selected. Never modify an existing fari. Application Engineering will provide assistance in the selection of a fan with the correct pitch and diameter for proper coolingSection 9 Drive Units - Group 9 8 Senes Shop Manual Page 9-1 Section 9 - Drive Units - Group 9 Section Contents Page Accessory Drive Cleaning... Accessory Drive Inspection ... . Accessory Drive Adapter Exploded View... Accessory Drive Adaptor Assembly Accessory Drive Adaptor Disassembly. Drive Units General Information... Agcessory Drive AdapterAccessory Drive Adapter Exploded View Section 9 Drve Units Group 9 Page 9-2 8 Series Shop Manual Accessory Drive Adapter - Exploded View ci900g¢ Ref. No. Part Name Remarks ‘Adapter, Accessory Drive Bearing Shatt, Accessory Drive Gear, Accessory Drive Gasket, PTO Drive Cover Screw, Hex Hd Gap Gasket, PTO Drive Cover Plate, PTO Drive Cover Screw, Hex Hd Cap ©orvanson4|Seetion 9. Drive Units Group 9 Drive Units General information B Sertes Shop Manual Page 9-3 Drive Units - General Information Accessory Drive Adapter ‘A gear driven adapter provides accessory drive capability of up to 142 Nem [108 ft. Ib.] of torque. The accessory drive 1s equipped with either SAE A or B flange adapters,Accessory Drive Cleaning (9-01) Section 9 - Drive Units Group 9 B Series Shop Manual Accessory Drive - Cleaning (9-01) Clean the Accessory Drive with clean solvent and blow dry with compressed air Accessory Drive - Inspection (9-02) Visually inspect for obvious damage such as cracks, bro- ken teeth and damaged threads. Rotate the gear and inspect for rough spotsin the bearing Accessory Drive Adaptor - Disassem- bly (9-03) 1.25 inch Pipe Coupling Support the housing. Press the bearing, shaft, and gear 9 assembly tram the housing. Approximately 4 tans of force 1s required.Section 9 Drive Units Group 9 Accessory Drive Adaptor Assembly (9-04) B Series Shop Manual Page 8. 1 inch Dritt Press the shaft and bearing assembly out of the gear. 1 inch Drift ‘Support the bearing assembly and press the shatt from the bearing. Accessory Drive Adaptor - Assembly (9-04) : 1.25 inch Pipe Coupling Q ‘Support the inner race of the new bearing and press the > shaft into the bearing until the shaft bottoms on the inner race, Z. ote 2 inch Pipe Caution: Press on the outer race of the bearing assem- bly. Pressing on the Inner race will damage the bearing. ‘Support the housing and press the bearing and shaft assembly 1n until it bottoms. aceAccessory Drive Adaptor Assembly (9-04) Section 9 Pee unis, Group 8 Page 9-6 1.25 inch Pipe Coupling Support the bottom of the shaft with a 1.25 inch pipe Zs, coupling and press the gear on untilit bottoms against the Se inner-bearing race. TemSection 10 Air Intake System Group 10 B Series Shop Manual Page 10-1 Section 10 - Air Intake System - Group 10 Section Contents Page 10-6 10-6 10-7 10-8 10-8 10-8 10-2 10-4 10-7 10-7 Attercooler Assembly Cleaning and inspection for Reuse. Inspection. Attercooler Assembly Rebuild... Aur Crossover Tube Cleaning and Inspection for Reuse... Cleaning. Inspection. Air Intake System Exploded View . Air Intake System General Information pe Cleaning and Inspection for REUSE worn nn Air Transter Cleaning, . Inspection coe . . 108 Charge Air Cooler (cAc) Cleaning and Inspection f for REUSE oo esesornnen . . ceeees 108 Cleaning... ceceep 108 Inspection . voce 10-9 Charge Air Cooler (CAC) Pressure TeStING ven 10-9 Turbacharger Cleaning and Inspection for Reuse nnn . 10-5 femme ceteecenes 105 InspectionAir Intake System Exploded View Section 10 Air Intake System Group 19 Page 10-2 B Series Shop Manual Air Intake System - Exploded View S77 cauTion GE code ounma rus| 20 img00ga |Section 10 Alr Intake System Group 10 Air Intake System Exploded View B Sores Shop Manual Page 10-3 Ref. No. Part Name Req. Remarks 1 Turbocherger 1 2 | Gasket, Turbocharger 1 3 | stud 4 4 Nut, Hexagon Flange 4 5 Manifold, Exhaust 1 6 Gasket, Exhaust Manifold 6 7 Screw, Hexagon Head Cap 12 | M10 1.5x 70mm 8 Aftercoole: 1 9 Gasket, Int Manifold Cover 1 10 Screw, Hexagon Head Cap 14 | MB 1.25 x 26mm 1" Connection, Air Crossover 1 12 Gasket, Connection 1 13 Screw, Hexagon Head Cap 4 | MB 1.25 x 25mm 14 Hose, Plain 2 15 Clamp, Hose 4 16 Tube, Air 1 18 Plug. Pipe 1 19 Draincock 1 20 Decal 1 at Hose, Flexible 1 22 Connector Female 1 23 Connection, Tur Oil Drain 1 24 Gasket, Oil Drain 1 25 Screw, Hexagon Head Cap 2 | MB 1.25 x 20mm 26 Hose, Plain 1 20. Clamp, Hose 2 28 Tube, Tur Gil Drain 1 29 Hose, Elbow 1 30 Tube, Aftercooler 1 31 Coupling, Plain Hose 1 32 Hose, Molded 1 33 Hose, Plain 1 34 Clamp, Hose 6Aur Intake System General Information Section 10 Air Intake System Group 10 Page 10-4 B Series Shop Manual Air Intake System - General Information The air intake system for the B Series turbocharged and aftercooled engines, Models 48TA3.9 and 6BTAS.9, consists of the aftercooler and connections, air crossover hardware, turbocharger, and associated hardware. The turbocharged engines, Models 4873.9 and 6BTS.9 use a manifold cover in place of the aftercooler, The air intake system for the naturally aspirated engines, Models 483.9 and 6B5.9 consists of the manifold cover mounted to the Intake manifold in the cylinder head. The air intake system for the 8 Series automotive engines, Models 83.9 and 85.9, consists of the turbocharger, the charge air cooler, turbocharger-to-charge air cooler hardware, charge air cooler-to-intake manifold cover hardware, intake manitold cover, and associated hardware. On the higher horsepower ratings of the B5.9 engine, the turbocharger 1s equipped with a wastegate which limits the amount of boost pressure. The turbocharger Is cooled and lubricated with engine The instructions for rebuilding the turbocharger are printed in Turbocharger Shop Manual Bulletin No. 3610321 from the engine lubricating system. Caution: If the engine experlences a turbocharger fallure or any other occasion where ol or debris can enter the charge air cooler (CAC), the CAC must be cleaned (refer to Procedure 10-08).Section 10 Air Intake System Group 10 Turbocharger Cleaning and Inspection for Reuse (1 B Series Shop Manual Turbocharger - Cleaning and Inspec- tion for Reuse (10-01) Remove all carbon deposits and gasket material from surfaces (1), (2), and (3). Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Caution: Tape or plug all openings to prevent solvent or steam from damaging the oil cavities in the turbocharger. Use solvent or steam to clean the exterior of the turbo charger. Dry with compressed ar Inspection Visually inspect the housings for damage. Visually inspect the turbine wheel and compressor im- peller (1) for fretting, cracked or broken vanes. Turn the impeller in the direction shown with arrow (2), to inspect the turbine shaft for freedom of rotation. The shaft must rotate freely. Replace damaged parts. Measure the turbocharger shaft end clearance with the Part No, ST-537 Dial Depth Gauge. Push the rotor assembly away from the gauge. Set the gauge on zero. Push the rotor assembly toward the gauge and record the data. End Play mm m 0.03 MIN 0.001) 0.08 MAX {0.003} 01) Page 10-5Aftercooler Assembly Cleaning.and Inspection for Reuse (10-02) Page 10-6 SE A 3 Section 10 Air Intake System Grou B Sertes Shop Manual Push the compressor impeller by hand toward the com- Pressor housing. Install a wire feeler gauge, at the minimum clearance point, between the impeller and the housing to measure the clearance. Record this clearance. With the feeler gauge in the same location, push the turbine wheel by hand away from the compressor hous- ing. Install a wire feeler gauge, at the same point. Record this clearance. Subtract the smaller from the larger clearance. Radial Clearance mm i) 0.30 MIN (0.012) 0.46 MAX 0.018) If the radial clearance does not meet the above specifi- cations, the turbocharger must be rebuilt. Refer to Turbo- charger Components Shop Manual, Bulletin No. 3810321 for rebuild instructions. Aftercooler Assembly - Cleaning and Inspection for Reuse (10-02) Remove all gasket material from the mounting surfaces. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use solvent or steam to clean the aftercooler assembly. Bry with compressed arr. Inspection Visually inspect the aftercooler assembly for cracks or damage. Replace if damaged.Section 10.- Air Intake System Group 10 B Senes Shop Manual Pressure Test the Aftercooler Core Install the hose, hose clamps, and solid pipe plug (1) onto the inlet tube, Install the hose and hose clamps (2), and air pressure gauge (3) onto the outlet tube, Connect the air pressure gauge to a regulated air supply. Aw Pressure: 552 kPa [50 psi] Submérge the aftercooler in a tank of water. it air bubbles appear, the core is damaged and the af- tercooler must be replaced, Remove the aftercooler from the water tank. Remove the test equipment. Use compressed air and dry the aftercooler. Aftercooler Assembly - Rebuild (10-03) Caution: The aftercooler is a unitized assembly anid can- not be rebuilt. Any attempt to repair the aftercooler core will reduce the coolant flow and cause future engine damage. Refer to Aftorcooler Assembly ‘Cleaning and Inspection for Reuse (10-02), Air Transfer Pipe - Cleaning and Inspection for Reuse (10-04) Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use solvent or steam to clean the air transfer pipe. Dry. with compressed air. Rebuild (10-03) Page 10-7 Aftercooler AssemblyAtt Crossover Tube Gleantng and inspection for Reuse (10-05) Section 10 Air Intake System Group 19 Page 10-8 Brox antes B Series Shop Manual inspection Visually inspect the turbocharger compressor V-bandout. let and the arr transfer pipe connection for dents or fret. ting. Replace the turbocharger compressor housing or air transfer pipe, if damaged. Air Crossover Tube - Cleaning and Inspection for Reuse (10-05) Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause Serious personal injury. Use solvent or steam to clean the air crossover tube. Dry with compressed a's Inspection Visually inspect the air crossover tube for cracks or dam- age. Visually snspect the hose sealing surfaces for pitting or damage. Replace damaged parts. Charge Air Cooler (CAC) - Cleaning and Inspection for Reuse. (10-06) ; Cleaning Caution: If the engine experiences a turbocharger fal ure or any other occasion where oil or debris ts put into the CAC, the CAC must be cleaned. Remove the CAC from the vehicle. Reter te the vehicle manufacturer for instructions.Section 10 Air Intake System Group 10 B Series Shop Manual Caution: Do not use caustic cleaners to clean the CAC. Damage to the CAC witl result. NOTE: Make sure that the tubes are in the vertical direction when flushing. Flush the CAC internally with solvent in the opposite Girection of normal air flow. Shake the CAC and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. Continue flushing until ali debris or oil is removed NOTE: If internal debris cannot be removed, scrap the CAC. Use a flashlight and mirror to visually inspect the CAC for internal.debris. After the CAC has been thoroughly cleaned of all oi! and debris with solvent, wash the CAC internally with hot soapy water to remove the remaining solvent. Rinse thor- oughly with clean water. Blow compressed air into the CAC in the opposite direc tion of normat ate flow until the GAC 1s dry internally. Cauilon: The CAC must be rinsed, ded, and free of solvent, oll, and debris or engine damage will result. Inspection Visually inspect the CAC for cracks, holes or damage. Inspect the tubes, fins and welds for tears, breaks or other damage. If any damage causes the CAC to ail the arr leak check mentioned in Procedure (10-07), the CAC must be replaced, Install the CAC on the vehicle. Refer to the vehicle manu- facturer for instructions. Charge Air Cooler {CAC) - Pressure Testing (10-07) To check the charge air cooler for gracked tubes or header, remove the inlet and outlet hoses from the CAC, Remove the charge air cooler. Refer to the vehicle manu- facturer for instructions. Charge Asr Coater (CAC) Pressure Testing (10-0:Charge Air Cooler (CAC) Pressure Testing (10-07) Page 10-10 gp ce) Section 10 Air Intake System Group 4 B Series Shop Manu 3824556 Test Kit Install a cap over the outlet side of the CAC. Install ¢ pressure gauge, air supply, and air pressure regulator to the inlet side of the cooler. Warning: To prevent possible injury if elther plug blows off during the test, secure safety chains on the test plugs to any convenient capscrew on the radiator assembly, This test must be performed with securely fastened satety chains. Apply 207 kPa [30 psi] of air pressure to the cooler. Close the air pressure regulator. ] Monitor the pressure gauge and determine the rate of pressure decay with a stop watch If the pressure decay 1s 49 kPa [7 psi] or less in 15 seconds, the cooler is okay. If the pressure drop 1s greater than 49 kPa [7 psi] in 15 seconds, check alf connections, again. Determine if pressure decay 1s caused by a leak in the CAC or from a leaky connection. Use a spray bottle filled with soapy water applied to all hose cennections, and. watch for bubbles to appear at the location of thé leak. Il the pressure decay 1s caused by a leaky connection, repair the connection and repeat the test. If the leak 1s, within the CAC, repeat the test to verify the-accuracy of the pressure decay measurement. Similar pressure de- cay readings must be obtained at least three consecutive tests before the reading can be considered accurate, If the pressure drop 1s greater than 49 kPa [7 psi] in 15 seconds, the CAC must be replaced. Refer to the manufacturer's repair manual for repalce- ment instructions. . NOTE: Charge air coolers are not designed to be 100% leak free. If the pressure decay 1s less than 49 kPa [7 psi in 15 seconds, then the CAC does not need to be replaced.Section tt Exhaust System Group 11 B Senes Shop Manual Page 11-1 Section 11 - Exhaust System - Group 11 Section Contents Page Exhaust Manifold Exploded View . 1-2 Exhaust Manifold Inspection 1-4 Generai information . 13 Exhaust Manifold... 13 Turbocharger Mounting Stud Replacement......c.00. 1-4Exhaust Manifold Exploded View Page 11-2 g Section 11 Exhaust System Group 11 B Series Shop Manual Exhaust Manifold - Exploded View xmg00gn Ref. No. Part Name. 1g Remarks tdcovonsen4| Brace, Exh. Out Conn. Screw, Hex Hd Cap Connection, Exh. Out Clamp, V Band Pipe, plug Gasket, turbocharger Stud Nut Manifold, exhaust Screw, Hex Hd Cap Gasket, manifold oRsaess4n04 90 degree turbo exhaust elbowSection 11 Exhaust System - Group 11 General Information B Series Shop Manual Page 11-3 General Information Exhaust Manifold The 8 sentes engine uses a pulse-type manifold with a divided turbocharger entry passage (exhaust manitold outlet). Multiple turbocharger locations are available to suit space constraints of various installations. Center front, rear and high, low turbo mounting focations are offered Warping can be corrected by machining or grinding the sealing surfaces to the flatness specification.Exhaust Manifold Inspection (11-01) Section 11 Exhaust System Group 11 jertes Shop Manual Page 11-4 Exhaust Manifold Inspection (11-01) Inspect the Exhaust Manifold for cracks, burn-out, or dam. aged threads. Place straight edge across the exhaust ports. The maxi- mum allowable clearance between the manifold and straight edge is 0.10 mm [0.004 inch] Turbocharger Mounting Stud Replace- ment (11-02) Inspect the turbocharger studs for damaged threads. To repiace the studs, use tWo nuts Jam locked on to the stud Before installing the studs, coat the threads with anti- sieze compound.Section 12 Air Equipment Group 12 B Sertes Shop Manual Page 12-1 Section 12 - Air Equipment - Group 12 Section Contents Page ‘Aw Compressor Cleaning and inspection for Reuse. 123 Inspection. 123 Aur Equipment General Information ..... 122 ‘Air Compressor 122pment Group 12 Air Equipment General Information Section 12. Air ries Shop Manual Page 12-2 Air Equipment - General Information Air Compressor The air equipment group consists of Cummins single and two cylinder air compressors, compressor check valves and air and coolant piping. Two cylinder air compressors used on B & C engines are normally manufactured by Bendix & Midland The air compressor ts lubricated by engine lubricating oil which enters the compressor through a drilling in the support. The oil lubricates the connecting rod bearings and the crankshaft, The oil then flows to the air compressor crankcase and returns to the engine through a drain passage located in the air compressor support. The air compressor 1s cooled by the engine coolant. Only the cylinder head ts cooled on most single cylinder air compressors. Both the cylinder head and cylinders are normally cooled on the two cylinder air compressor ns, and repair of Cummins air compressors are contained in the following Service information, specific publications: Holset SS191 Single Cylinder 8.5 CFM Air Compressor Rebuild Manual Bulletin # 3810433 Holset SS296 Single Cylinder 13.2 C.F.M. Air Compressor Bulletin # 3810242 Holset SS338 Single Cylinder 15.0 CFM Air Compressor Bulletin # 3810457 Instructions for testing and repairing air cranking motors and air compressors not manufactured by Cummins, can be obtained from the original equipment manufacturers. The following list contains the addresses of suppliers of air equipment for use on Cummins engines: U.S.A. Canada Bendix H.V.S.G. Bendix H.V.S.G. 901 Cleveland St. P.O. Box 5712 Elyria, OH 44036 1005 Wilton Grove Rd. Attention: Technical Services Dept. London Ontario, Canada N6A4S8 Engine Starting Systems Attention: Technical Services Dept. Allen and Martinsville Rd. P.O. Box 1776 International Liberty Gomer‘ Nd 97888: Bendix H.V.S.G. Europe Ltd. Midland Brake, Inc. 66 Grosvenor St. 490 South Chestnut St. London, England W1X90B Owosso, MI 48867 Attention: Technical Services Dept.Section 12 A Equipment Group 12 B Series Shop Manual Air Compressor - Cleaning and Inspection for Reuse (12-01) Remove all gasket material from the sealing surtaces. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Caution: Seal all openings with tape to prevent damage from solvent or steam entering the oll passages inthe air compressor. Use solvent or steam to clean the air compressor. Dry with compressed air, Inspection Visually inspect the compressor housing for cracks of damage. Visually inspect the compressor gear drive for cracks or broken teeth. Visually inspect the fuel pump drive hub or spider cou- piing for wear or damage. Power Steering Coupling (if Applicable} Inspect the coupling for wear or cracks. Replace the coupling if damaged. A A | Aw Compressor - Cleaning and Inspection for Reuse (12-01) Page 12-3Air Compressor Cleaning and Inspection for Reuse (12-01) Section 12 Air Equipment Group 12 Page 12-4 B Series Shop Manual Power Steering Adapter Inspect and replace the adapter if any damage 1s found. Measure the single cylinder air compressor crankshaft end clearance. Crankshaft End Clearance mm in. 0.05 MIN 0,002 0.15 MAX 0.008 ratingSection 13. Electrical Equipment - Group 13 B Series Shop Manual Page 13-1 Section 13 - Electrical Equipment - Group 13 Section Contents Page 133 132 . 133 Alternator inspection... . Electrical Equipment General Information... Starter Inspection ..Electrical Equipment General Information Page 13-2 Section 13 Electrical Equipment Group 13 B Sentes Shop Manual Electrical Equipment - General Information ‘The electrical equspment used on the B series engine 1s not manufactured by Cummins Engine Company Ino, Complete instructions for adjusting, testing, and repairing the electrical equipment can be obtained from the equipment manufacturer The following list contains the suppliers of the electrical equipment used on Cumming engines. Alternators Robert Bosch Lid. P.O. Box 166 Rhodes Way Watford Wo2 418 England Telephone: 0923-44233 Butec Electrics Cleveland Road Leyland PRS 1XB England Telephone: 0744-21663 C.AV Electrical Equipment P.O. Box 36 Warple Way London W3 7SS England Telephone: 01-743-3111 A.C. Delco Components Group Civic Offices Central Milton Keynes MK SEL England Telephone: 0908-66001 Delco-Remy P.O. Box 2439 Anderson, IN 46018 U.S.A. Telephone: (317) 648-7898 Leece-Neville Corp. 1374 E. 51st St Cleveland, OH 44013 USA. Telephone: (216) 431-0740 * Non Electrical Equipment Suppliers Electric Starting Motors Butec Electrics Cleveland Road Leyland PRS 1X8 England A Telephone: 0744-21663 C.AV Electrical Equipment P.O, Box 36 Warple Way London W3 7SS England Telephone: 01-743-3111 AC. Delco Components Group Civic Offices Central Milton Keynes MKS SEL England Telephone: 0908-66001 Delco-Remy P.O. Box 2439 Anderson, IN 46018 USA. Telephone: (317) 646-7838 Nippendenso of Los Angeles 3900 Via Oro Avenue Long Beach, CA 90810 Telephone: (800) 222-6352Section 13 Electrical it Gi 13 B Series Shop Manual Equipment Group Alternator Inspection (13-01) Visually inspect the alternator for obvious damage such as a broken or cracked housing. Damaged fan blades or pulleys and worn mounting holes in the alternator end frames. Starter Inspection (13-02) Visually inspect the gear (1) for cracked or broken teeth. Visually inspect the drive bushing (2) and the gear shatt (3) for excessive wear or damage. Visually inspect the terminal posts (4) for loose or broken NOTE: If the starting motor parts are damaged or the posts are loose or damaged, the starting motor must be repaired or rebuilt. Refer to the electircal equipment manufacturers specifications to rebuild the starting motor. Alternator Inspection (13-01) Page 13-3Section 14 Engine Testing Group 14 B Series Shop Manual Page 14-1 Section 14 - Engine Testing - Group 14 Section Contents Page Biowby Measurement. 14-7 Blowby Conversion Chart (6.613 mm [0.224 inj Orifice). 14-7 Chassis Dynamometer Operation sects seco 14-20 Engine Painting ...... . 14-28 Engine Dynamometer Test Engine Run-t nenensonneene 14-14 Engine Dynamometer Test Performance Checking 14-18 Engine Dynamometer Test Installation of the Engine 14-8 Engine Run-In Procedure - (Chassis Dynamometer) ......... 14-25 Engine Run-In Procedure “‘In Chassis’? (On- and Off-1 Highway v4 Vehicles) 14-27 Off-Highway «2.2... 14-27 On-Highway ' 14-27 Engine Storage Long Term 14-31 Removing the Engine from Long-Term Storage .. 14-34 Engine Storage Short Term 14.29 Removing the Engine from Short erm | Storage 14-31 Engine Testing Engine Side Views... . 14-5 Engine Testing General information. 14-6 ieneral Engine Test Specifications. 14-6 Engine Testing Service Tools suitseeteeenee 14-2 General Engine Test Procedures (Chassis Dynamometer) 14-22Engine Testing Service Tools 2 Page 14- Engine Testing - Service Tools Section 14 Engine Testing Group 14 B Series Shop Manual The following special tools are recommended to perform procedures in Group 14. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins ‘Authorized Repair Location. Tool No. Tool Description Too! Illustration Vacuum Gauge ‘| Check the fuel filter restriction during the engine performance| = st-as4 —_|test: Hose Adapter, Part No.ST-434-2, and vacuum gauge, PartNo.ST- 424-12, are used to perform the test. oboe Pressure Gauge Use to measure the engine intake manifold pressure. ‘$7-1273 ee | Filter Wrench Use to remove or tighten spin-on lubricating oil or fuel filters. 3375049 |Blowby Checking Tool Use to check engine crankcase blowby. 3822476 1 come ‘Water Manometer Used with the blowby check tool to measure engine crankcase} i statis — |Pressure. | 3375275 Pressure Gauge (0-160 psi) Used to measure lubricating oil pressure.Sectlon 14 Engine Testing Group 14 B Series Shop Manual Too! No. Tool Description Engine Testing Service Tools Page 14-3 Too! Illustration Digital Opticat Tachometer Used to measure engine speed (RPM). 3377462Engine Testing Engine Side Views Section 14 Engine Testing Group 4, Pageiea B Series Shop Manus} Engine Testing - Engine Side Views Fuel Pump SideSection 14 Engine Testing Group 14 Engine Testing Engine Side Views B Series Shop Manual Page 14-5 Engine Testing - Engine Side Views Fuel ination NozzesEngine Testing General Information Section 14 Engine Testing Group 14 Page 14-6 B Series Shop Manual % Engine Testing - General Information The engine test us a combination of an engine run-in and a performance check. The engine run-in procedure provides an operating period that allows the engine parts to achieve a final finish and fit. The performance check provides an opportunity to perform final adjustments needed to optimize the engine performance ‘An engmne test can be performed using either an engine dynamometer or a chassis dynamometer. If a dyna. mometer is not available, an engine test must be porformed in a manner that simulates a dynamometer test, Check the dynamometer before beginning the test. The dynamometer must have the capability to test the performance of the engine when the engine Is operating at the maximum RPM and horsepower range (full power). ‘The engine crankcase pressure, often referred to as engine blowby, is an important factor that indicates when the piston rings have achieved the correct finish and fit. Rapid changes of blowby or values that exceed specifications more than 50 percent indicate that something is wrong. The engine test must be discontinued until the cause has been determined and corrected. General Engine Test Specifications Maintain the following limits during a chassis dynamometer test: Intake Restriction (Maximum) * Clean Filter (light duty).. (medium duty) . (heavy duty) . ee .254 mm Hz0 [10 in. H,0} 305 mm H,0 [12 in. H,0] 381 mm 20 [15 in. H,0] © Dirty Filter (light duty) ...ccescsesseneeen 335 mm [25 in. (medium duty)... 635 mm [25 in] (heavy duty)... ...635 mm [25 in} Exhaust Back Pressure (maximum) secenaetieeeeeeee 76mm Hg [3.0 in. Hg} : cence tT 4 mm Hg [4.5 in. Hg] 182 mm Hg [6.0 1p Hg] * Industrial. + EPA Certified * Oxidation Catalyst Blowby* (at Given Speed, 100% Load) New (L/Min) Worn (L/Min) 4B @ 2200 18 38 4B @ 2500 20 40 4B @ 2800 23 46 ABT/4BTA/B3.9 @ 2200 45 90 4BT/4BTAIB3.9 @ 2500 St 102 ABT/4BTA/B3.9 @ 2800 s7 n4 6B @ 2200 26 52 68 @ 2500 30 60 68 @ 2600 34 68 6ET/EBTA/BS.9 @ 2200 63 126 6BT/SBTA/BS.9 @ 2500 76 152 6BT/6BTAB5.9 @ 2800 85 170 “Blowby checking tool, Part No. 3822476, has a special 5.613.mm [0.221 in.] orifice that must be-used to get an accurate reading Oil Pressure * Low Idle (minimum allowable) .....-.0 + Rated Speed (minimum allowable) - Fuel Filter Restriction (Maximum pressure drop across filter) # Dirty Filter sscesssrncnstnraeerey - en Fuel Return Restriction (Maximum) cose 69 kPa [10 psi} 207 kPa [30 psi] 35 kpa [5 psi] 518 mm Hg [20.4 in hg] NOTE: Due to variations in ratings of different engine models, refor to the specific engine dala sheet for the particular engine model being tested.Section 14- Engine-Testing Group 14 8 Serles Shop Manual Blowby Measurement Blowby Measurement Page 14-7 Blowby ts generally recorded in liters/minute, but a water manometer may be used to measure blowby from the breather tube after fabricating the following adaptation: 1 Plug the end of the straight portion of a pipe tee. = 2. Drill an orifice in the plug {refer to the Blowby Con- version Chart below for the appropriate orifice size) 3. Connect the open straight portion of the pipe tee to the breather tube. 4. Connect a water. manometer to the 90 degree outlet. To Mano-moter Crankease Breather Tube §. Use the Blowby Conversion Chart to convert the ma- Pipe Tee nometer reading to liters/minute. adhoss vg with Ortce Adapted Reducer, wate Blowby Conversion Chart (5.613 mm [0.221 In} Orifice) Inches of Water Liters/Minute Inches of Water Liters/Minute 1 27 19 121 2 40 20 124 3 4g 2 128 4 58 22 131 5 64 23 135 6 71 24 137 7 76 25 140 8 81 26 144 9 86 az 147 10 90 28 150 aM 94 29 154 12 98 30 187 13, 402 a 160 14 105 32 163 15 109 33 166 16 n2 34 169 47 5 35 172 18 18Engine Dynamometer Test Installation of the Engine (14-01) Section 14 Engine Testing Group 14 Page 14-8 ose gs fap B Series Shop Manual Engine Dynamometer Test - Installa- tion of the Engine (14-01) Use engine lifting fixture, Part No. ST 125, to install the engine to the test stand. Align and connect the dyna. mometer. Refer to the manufacturer's instructions for aligning and testing the engine. NOTE: Make sure the dynamometer capacity ts sufficient to permit testing at 100 percent of the engine rated horsepower. if the capacity is not enough, the testing procedure must be modified to match the restrictions of the dynamometer, Install the coolant temperature sensor. Minimum Gauge Capacity" 107°C [225°F| Connect the coolant supply to the water inlet connection (1). Connect the coolant return to the water outlet connection 2) Install the drain plugs, close alll the water drain cocks, and make sure all the clamps and fittings are tight Connect the vent tube to the vent connection on the thermostat housing. Fill the cooling system with coolant to the bottom of the fill neck 1n the radiator fill (or expansion) tank, NOTE: Maximum Fill Rate 1s 14 Litersimin [3.5 U.S, gallons/min}Section 14 Engine Testing Group 14 Engine Dynamometer Test Installation of the Engine (14-01) Page 14-9 B Series Shop Manual Inspect the engine for coolant leaks at connections, fit- tings, plates, and plugs. Repair as necessary. Connect a water manometer to the turbocharger air inlet Pipe to test air restnction. NOTE: The manometer connection must be installed at a 30 degree angle to the air flow in a straight section of pipe, one pipe diameter before the turbocharger. NOTE: A vacuum gauge can be used in place of the water manometer. Minimum Gauge Capacity: 760 mm H,0 [30 in. H.0] Connect a mercury manometer to a straight section of the exhaust piping near the turbocharger outlet to check 6x- haust restriction NOTE: A pressure gauge can be used in place of the mer- cury rhanometer, NOTE: For automotive applications, a tapped hole 1s pro- vided on the inlet side of the catalyst to check exhaust restriction. Minimum Gauge Capacity: 254 mm Hg. [10 in. Hg.] Attach the lubricating oil temperature sensor in one of the locations on the side of the engine as shown. Mi 180°C [300°F] imum Gauge Capaci © ovsganeEngine Dynamometer Test _tnstallation of the Engine Page 14-10 00059 Section 14 Engine Testing Group 14! (14-01) B Series Shop Manual Attach the lubricating oil pressure sensor to the mam oil rifle drilling in the cylinder block. Minimum Gauge Capacity” 1034 KPa [150 psi) Caution: The fubricating oll system must be primed before operating the engine after it has been rebuilt to avoid internal damage. Do not prime the system from the bypass filter head if an external pressure pump ts used, Damage to the bypass filter will result. To prime the system using external pressure, connect the supply to the tapped hole in the main oil Use a pump capable of supplying 210 kPa [30 psi] con- tinuous pressure. Connect the pump to the port on the main oil rifle as shown, Use clean 15W-40 oil to prime the system until the oil pressure registers on the gauge. Remove the oil supply tube, and instal! the plug. Make sure the lubricating oil has had time to drain to the pan, and fill the engine to the high mark as measured on the dipstickSegtion 14° Engine Tasting Group 14 B Series Shop Manual If an.external pressure. pump 1s not available, prime the lubneating system according to the following procedure. Fill the engine with oil to the high level mark on the dipstick. Disconnect the turbocharger lubricating oil supply tube. Pour 50 oc to 60 ¢¢ [2.0 fl.02. 03.0 fl.oz.Jof clean 1SW-40 oll into the turbocharger oil supply hole. Connect the oll supply tube to the turbocharger Caution: Mechanical over-tightening can distort the threads or damage the filter element seal. Fill the lubricating oil filter with clean 15W-40 oil Screw the filter onto the filter head fitting unti! the gasket contacts the filter head surface. Tighten the filter according to the manufacturer's specifications. To make sure the lubscating oil pump 1s providing ade- quate oil to the engine, first disconnect any wires leading to the fuel pump solenoid. Engine Dynamometer Test Installation of the Engine (14-01) Page 14-11Engine Dynamometer Tést Page 14-12 Signe +¥e to % Turn A hs B Series Shop Manual Installation of the Engine (14-01) Section 14 Engine Testing Group q Caution: Do not crank the starting motor for periods _ longer than 30 seconds. Excessive heat will damage the starting motor. Crank the engine until the oil pressure gauge indicates system pressure. NOTE: Allow 2 minutes between the 30-second cranking periods s0 the starting motor can cool. NOTE: If pressure is not indicated, find and correct the problem before continuing. Allow the lubricating oil to drain into the oi! pan, and measure the oil level with the dipstick. Add oil as necessary to bring the level to the high level mack. ~ Lubricate the gasket on the fuel filter with clean 15W-40 oil, Fill, the fuel filter with,clean fuel. ‘Screw the fuel filter onto the filter head-until the gasket contacts the filter head surface. Tighten the filter an additional 1/2 to 3/4 turn.Section 14 Engine Testing Group 14 Engine Dynamometer Test Installation of the Engine (14-01) B Senes Shop Manual Page 14-1, Make sure the voltage supply matches that of the fuel pump solenoid before connecting the electrical wires to it Attach the throttle control rod onto the fuel pump throttle lever. $1273 Ql To determine the amount of turbocharger boost and aftercooler/charge att cooler restriction install intake man- gy fold pressure gauges, Part No, ST 1273 in the turbo- (45> charger outlet and the intake manifold. aA ciggah Part No. 3822676 For accurate engine crankcase blowby measurement, in- sert a blowby checking tool in the crankcase breather vent. Connect a water manometer to the blowby tool Part No. 3822676. A pressure gauge can be used in place of the manometer. Minimum Gauge Capacity: 1270 mm Hz0 [50 in. H,0) Brogan Part No, ST-434 To measure fuel filler zestriction, connect vacuum gauge, Part No. ST-434, to the injection pump inlet line. Minimum Gauge Capacity» 760 mm Hg [30 in. Hg}Page 14-14 cpsvove Dynamometer Test Engine Run-in (14-02) 945 kPa 517 kPa 10 mae psi] —\ uve Section 14 Engine Testint B Senes Group 1. op Manual | To be able to unload the compressor, connect a source of compressed air to the unloader (1). This air line must contain a valve between the source and the unloader, NOTE: All air compressors manulactwred by Cummins En. gine Company, Inc. must be loaded during enginerar-in. All air compressors must be unloaded during the engine per. formance check. NOTE: The compressed ait load in the accompanying illus. tration must be attached to the air compressor outlet (2), gS To provide a toad on the air compressor, connect an air tank to the compressor outlet (2), using steel tubing or a high temperature hose (1). Install an air regulator (3) that can maintain tank air pres- sure of 345 kPa to 517 KPa [50 psi to 75 psi] at both the minimum and the maximum engine RPM, Hose Temperature (Minimum): 260°C [500°F] Inspect the voltage rating on the starting motor before installing the electrical wiring. Attach electrical wires to the starting motor and the bat- tenes, if used. NOTE: If another method of starting the engine 1s used, follow the manufacturer's instructions to make the neces- sary connections, Engine Dynamometer Test - Engine Run-In (14-02) ‘The engine run-in period allows the tester to detect as- sembly errors and to make final adjustments needed for performance that meets specifications. NOTE: The amount of time specified for the following engine run-in phases are minimums. Additional time can be used at each phase except engine idle periods, if so desired,Section 14 Engine Testing Group 14 B Series Shop Manual Measurements from these indicators and gauges must be observed closely during all phases of the engine run-in period. Refer to page 14-6 for specifications and accept- able readings To correctly evaluate the-engine performance, this addi- tional measurement must be observed during engine run-in phases. fs good practice to observe these measurements even ifengine performance meets specifications. If engine per- farmance does not meet specifications, these measure- ments can indicate possible | reasons — for under-performance. Caution: Do not crank the engine for more than 30 seconds. Excesswe heat will damage the starting motor. Crank the engine and observe the oif pressure when the engine starts. If the engine fails to start within 30 seconds, allow the starting motor to cool for 2 minutes before crank- ing the engine again. Engine Dynamometer Test Engine Run-In (14-02) Page 14-15 Kr Lube Ol Temp. Temp. Biowby Intake Manifold Pressure (Turbocharger Boost) Fuel in Resterction Exh. Back Pros. Air iniet Restriction Fuel Drain Pres. Also: Coolant Prosaure| 99006Engine Dynamometer Test Page 14-16 Engine Run-In (14-02) A e.901v4 1200 Test Load 70°C [160°F] Section 14 Engine Testing Group 14 '@ Series Shop Manual Caution: If the {ubricating olf pressure is not within spec- fications, shut off the engine immediately. Either ex. cessively low or excessively high oil pressure will cause engine damage. Engine oil pressure must be at feast 69 kPa [10 psi] at 700 RPM, Correct the problem if the oil pressure 1s not within specifications. Caution: Do not operate the engine at idle'speed longer than specified during engine run-in. Excessive carbon formation will cause damage to the engine. Operate the engine at approximately 700 RPM for 3 to 5 minutes, Listen for unusual noises; watch for coolant, fuel, and lubricating oil leaks; and check for correct engine oper- ation in general. NOTE: Repair all leaks or component problems before con- tinuing the engine run-in. Move the throttle to obtain 1,200 RPM engine speed, and set the test load to 25 percent of the torque peak load. Operate the engine at this speed and load level until the coolant temperature 1s 70°C {160°F). Check all gauges and record the data. NOTE: Do not proceed to the next step until a steady blowby reading 1s obtained.Section 14 Engine-Testing Group 14 B Series Shop Manual Operate the engine at this speed and load level for 2 minutes. Check all gauges and record the data, NOTE: Do not proceed to the next step until blowby 1s stable and within specifications. Maintain the engine speed at torque peak RPM, increase the dynamometer foad to 75 percent of torque peak load. Operate the engine at this speed and load level for 2 minutes. Check all gauges and record the data. NOTE: Do not proceed to the next step until blowby is stable and within spe: Move the throttle fever to its fully opened position, and increase the dynamometer load until the engine speed is at torque peak RPM. Operate the engine at this speed and load level for 10 minutes or until the blowby becomes stable and within specifications. Check all gauges and record the data, Reduce the dynamometer load until the engine speed inereases to the engine's rated RPM Operate the engine at rated RPM for 5 minutes. Check all gauges and record the data. Engine Dynamometer Test @ Engine Run-In (14-02) Page 14-17 Torque Peak 2x (Test Load) (50% Rated Load) 2 Minutes Torque Peak 3x (Test Load) (75% Rated Load) . * 2 Minutes Full Throttle Torque Peak Maximum Load 10 Minutes out Full Throttle Rated Maximum Load at Rated Speed 5 MinutesEngine Dynamometer Test. Performance Checking (14-03) Section 14 Engine Testing Group 14 Page 14-18 8 Series Shop Manual | Caution: Shutting off the engine immediately after op. erating at full load wili damage the turbocharger and internal components. Always allow the engine to caol before shutting it off. Remove the dynamometer load completely, and operate the engine at 700 RPM for 3 to 5 minutes. This period will allow the turbocharger and other components to cool. Shut off the engine. Engine Dynamometer Test - Perfor- mance Checking (14-03) Make sure the.atr compressor will be unloaded during the performance check. Apply regulated air pressure of 655 kPa [95 psi] to the alr compressor unloader (1). Caution: Do not crank the engine for more than 30 seconds. Excessive heat will damage the starting motor. Crank the engine and observe the oil pressure when the engine starts. if the engine fails to start within 30 seconds, allow the stesting motor to coo! for 2 minutes before crank- ing the engine again.Section 14 Engine Testing - Group 14 Engine'Dynamometer Test Performance Checking (14-03) B Senes Shop Manual Page 14-19 Caution: {f the lubricating oll pressure is not within specifications, shut off the engine immediately. Either excessively low or excessively high oil pressure will cause engine damage. Correct the problem if oll pressure is not within specifications. Engine oil pressure must be a minimum of 69 kPa [10 psi} at approximately 700 RPM. Make’ sure the engine is at operating temperature. Move the throttle lever to the “FULL OPEN” position. Adjust the dynarnometer load until the engine maintains the rated RPM Allow the readings to stabilize. Read the horsepower. Check all the gauges, and record the readings. NOTE: The horsepower reading will not be accurate if the (ubricating oil temperature and fuel temperature are not within specifications, —— Temperature - Temperature Lubricating Oil Temperature: MIN 90°C [190°F] 90°C [190°F] 32°C [90°F} Fuel Temperature: MAX 42°C [108°F] Check all gauges and record the data. Caution: Do not shut off the engine immediately ater it has been loaded. it must be allowed to sufficiently cool. A Remove the dynamometer load completely, and operate 3 to 5 Minutes the engine at idle speed for 3 to 5 minutes. Thes will allow the turbocharger and other components to ool. NOTE: Idle periods longer than 5 minutes are to be avoided Shut off the engine after the cool-down period.Chassis Dynamometer Operation (14-04) Section 14 Engine-Testing Group 14 Bage 1420 B Series Shop Manual If power specifications are not met, refer to 8 Series Troubleshooting and Repair Manual, Bulletin No. 3810486, Remove all test instrumentation. Remove the engine from . NOTE: If the engine 1s to be stored temporarily and does not have permanent-type antifreeze, it 1s necessary to drain all S> coolant. Drain locations are identified on the engine side views, Pages 14-4 and 14-5, Prepare the engine for Engine Painting (14-08) or Engine SES Storage (14-09) or (14-10). Chassis Dynamometer - Operation (14-04) The performance of’an engine installed in on-highway vehicles can be tested on a chassis dynamometer. NOTE: Due to driveline efficiency and engine-driven acces- sories, the engine horsepower when measured at the reat wheels will be reduced’by approximately * 20 percent for single axle vehicles ‘+ 25 percent for tandem axle vehicles NOTE: These percentages are used for engine run-in only and are not to be used as absolute figures. Caution: Follow all the vehicle manufacturer's safety A precautions before installing or operating @ vehicle on a SE Chasers dynamometer. aeSection 14 Engine Testing Group 14 B Series Shop Manual Caution: Low profile radial tires are more sensitive to heat than bias ply tires. Excessive operating time at full load can damage tires due to overheating, Check the manufacturer's recommendations for the maximum lowable chassis dynamometer operating time. Follow the general safety precautions listed below while operating the chassis dynamometer * Use tires that have more than 160 kilometers [100 miles] on them. Do not use new tires, + Do not use recapped tires or tires of different sizes, or designs. + Make sure the tires are inflated to the manufactur- e's specifications, + Remove all rocks or other material {rom the tread of all tires that will be rotating on the dynamometer rollers, ‘* Make sure there 1s correct overhead clearance for exhaust stacks, air detlectors, or other attachments above the cab. Chassis Dynamometer Operation (14-04) Page 14-21 igorGeneral Engine Test Procedures (Chassis Dynamometer) (14-05) Section 14 Engine Testing Group 14 Page 14-22 'B Series Shop Manual * Carefully position the vehicle on the rollers. Caution: To prevent damage to the chassis dynamom- eter, there must be some slack in the tension of the tie-down chains. * Attach the tie-down chains to the rear of the vehicle, and put wheel chocks in front of the. front wheels, ‘* Adjust the vehicle and dynamometer room exhaust system to make sure all exhaust gases are removed from the room. * Reter to the chassis dynamometer and vehicle aS manufacturer's recommendations and specifica- tions for testing procedures. General Engine Test Procedures - (Chassis Dynamometer) (14-05) The following procedure assumes that the lubricating off and fuel systems were correctly primed, the dipstick cali- brated, and the engine filled to the correct levels with oil and coolant during installation of the engine into the chas- sis. If these sytems were not serviced during installation of the engine, refer to Engine Dynamometer Test _Instal- lation of the Engine (14-01) for instructions on priming the lubricating oil and the fuel systems and calibrating the dipstick. Refer to the latest B Series Operation and Main- tenance Manual, Bulletin No. 3810205, for instructions on filling the lubricating oil and the cooling systems. t S — The number of instruments and gauges required to per- __F Ny form a chassis dynamometer test will vary according to the type and the capability of the test equipment used. | Refer to pages 14-4 and 14-5 for the correct system pres- ‘sure and temperature gauge connecting locations.Section 14 - Engine Testing - Group 14 General Engine Test Procedures - (Chassis Dynamomoter) (14-08 ge 14-2: 8 Serles Shop Manual To correctly monitor an engine’s performance, record the following parameters: Lubricating oil pressure (vehicle instrument panel} Coolant temperature (vehicle instrument panel) Coolant pressure Turbocharger outlet pressure Exhaust restriction Intake manifold pressure Inlet aie restriction Blowby Engine speed (RPM) (vehicle instrument panel) Whee! horsepower (WHP) (dynamometer controls) Measure the coolant pressure at the cylinder head, rear fuel pump side. Minimum Gauge Capacity: 418 kPa [60 psil Measure turbocharger ouliet pressure and intake mani- fold pressure. ‘The drop in pressure accross the aftercooler/charge air cooler must no! exceed 21 kPa [3 psi. Connect a water manometer to the turbocharger air iniet pipe to test air restriction. NOTE: The manometer connection must be installed ata 90 degree angle to the air flow in a straight section of pipe, one pipe diameter before the turbocharger. NOTE: A vacuum gauge can be used in place of the water manometer. Minimum Gauge Capacity: 760 mm H,0 {30 in. H,0] p00tveGeneral’ Engine Test Procedures (Chassis Dynamometer) (14-05) Section 14. Engine Testing Group 14 Page 14-24 B Series Shop Manual Measure the blowby by installing blowby checking tool in the crankcase breather vent. Connect the blowby tool to a water manometer. NOTE: Excessive blowby indicates a turbocharger malfunc tion or an engine internal components malfunction, allowing combustion gases to enter the crankcase. Minimum Gauge Capacity’ 1270 mm H,0 [50 in. H,0] NOTE: It a sudden increase in blowby occurs, or if blowby ‘exceeds the maximum allowable limit during any run-in step, return to the previous step and continue the run-in. If blowby does not reach an acceptable level, discontinue the run-in and determine the cause. NOTE: Avoid long idle periods. Operate the engine at low idle only tong enough (3 to 5 minutes) to check for correct oll pressure and any fuel, oil, water, or air leaks. Cautlon: Do not allow the engine speed to exceed 1,000 RPM before run-in. The internal components can be damaged.Section 14 Engine Testing Group 14 Engine Run-In Procedure (Chassis Dynamometer) (14-08) B Senes Shop Manual Page 14-25 Caution: Do not shut off the engine immediately after the fast step of the run-in 1s completed. Allow the engine to cool by operating at low idle for a minimum of 3 min- utes to avoid internal component damage. Engine Run-In Procedure - (Chassis -Dynamometer) (14-06) Caution: Refer to General Engine Test Procedures {Chassis Dynamometer) (14-05) before operating the en- gine to avoid internal component damage. NOTE: Reter to Chassis Dynamometer Operation on page 14-19 for general operating procedures and safety precau- tions. NOTE: Operate the vehicle in a gear that produces a road speed of 90 to 95 km/h [ 55 to 60 mph]. Operate the engine at 1,200 RPM and 25 percent of torque peak load until the water temperature reaches 70°C {160°F}. Operate the engine al 1,200 RPM and 40 percent of toraue peak load for 2 minutes. Check the gauges, and @&) record the readings.Engine Run-In Procedure (Chassis Dynamometer} (14-06) Page 14-26 k RPM. © Section 14 Engine Testing Group 14 B Series Shop Manual q Operate the engine at 1,500 APM and 65 percent of | torque peak load for 5 minutes. Check the gauges, ang record the readings. ‘Operate the engine at torque peak RPM and full foad for 4 minutes. Check the gauges, and record the readings. NOTE: Refer to the engine data sheet for the torque peak RPM of the engine model being tested. Operate the engine at rated speed (RPM) and ful load for 4 minutes. Check the gauges, and record the readings. Compare the readings to those published on the appro- priate engine data sheet Caution: Do not shut off the engine immediately atter the run-in 1s completed. Allow the engine to cool by operating it et low idle for a minimum of 3 minutes to avoid internal component damage. Maka sure*all instrumentation «s removed before remov- Ing the vehicle from the dynamometer.Section 14 Engine Testing Group 14 B Series Shop Manual Engine Run-in Procedure ‘‘In Chassis’” - (On- and Off-Highway Vehicles) (14-07) On-Highway Caution: Refer to General Engine Test Procedures (Chassis Dynamometer) (14-05) before operating the engine to avoid internal component damage. Operate the engine at 1,500 to 1,800 RPM in high gear for the first 80 to 160 kilometers [50 10 100 miles] after rebuild. NOTE: Do not idle the engine for more than 5 minutes at any one time during the first 160 kilometers [100 miles} of operation. Off-Highway Caution: Refer to General Engine Test Procedures (Chassis Oynamometer) (14-05) before operating.the en- gine to avoid internal component damage. Operate the engine as follows during the first 3 hours after rebuild: 1 Do not dle the engine for more than § minutes at any one time. 2, Operate the engine at 75 percent throttle while loaded. Engine Run-In Procedure “In Chassis’ (14-07) Page 14-27 1500 A lok a>] Hours Hours (holo —> foo Hours HoursEngine Painting (14-08) Section 14 Engine Testing Group 14 Page 14-28 B Series Shop Manual 3. Do not operate the engine at rated speed (RPM) and tull foad for more than 5 minutes at any one time. Hours Hours Engine - Painting (14-08) Remove all belts from the engine. & Cover the following parts of the engine: + Exhaust and intake openings ‘* Electrical components * Fuel iniet and drain connections * Any exposed fittings, threads, and electrical wire terminals, Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam can cause serious personal injury. Use steam to clean the engine, and dry with compressed alr, NOTE: Make sure all engine surfaces are clean and dry before painting the engine Protect the following components from the paint: All dataplates *-Valve and injector set marks, * Exhaust manifold ‘Turbocharger turbine housing Flywheel Flywheel housing transmission mounting surfaceSection 14 - Engine Testing - Group 14 B Series Shop ual Paint the engine. Engine Storage - Short Term (14-09) NOTE: This procedure describes the correct method of pre- paring an engine for short-term (1 to 6 months) storage, Operate the engine at high idle until the coolant tem- perature reaches 70°C [160°F]. Shut off the engine. Remove the fuel tube to the engine fuel filter and the injector return tube. NOTE: Fuel system preservative oil must meet Federal Speci- fication VV-L-800C. (Example: Daubert Chemical NoxRust No. 518.) Fill two containers, one with diesel fuel and the other with the preservative oil. Put both fuel tubes into the container of diesel fuel. Start the engine. When it is operating smoothly, put the fuel supply tube into the container of preservative oi, Remove the injector return tube from the diesel fuel con- tainer. When preservative oil flows from the tube, shut off the engine. Install the fuel supply tube to the fuel filter, and put a cap on all other fuel tubes. Be ay tap Se f jine Storage - Short Term (14-09) Engi gs ¢ beEngine Storage Short Term (14-09) Page 14-30 we Section 14 Engine Testing Group 14 B Series Shop Manual Drain the lubricating oil pan, the oil filters, and the fuel filter, Install the drain plug into the oil pan, and install the filter cans, Tighten according to specifications. Disconnect the electrical wires from the fuel pump solenoid. Drain the coolant passages and jackets, NOTE: It 1s not necessary to drain the coolant if it is a permanent-type antifreeze with a rust inhibitor. Do not drain the coolant if the engine is installed in a vehicle. Look the engine over closely, and cover all openings with tape to prevent dirt and moisture from entering. Install a warning tag which alerts others of no oil in the engine and that it must not be started.Section 14 Engine Testing Group 14 B Series Shop Manua\ Store the engine in a dry area of even temperature. Rotate the crankshaft two to three revolutions every 3 to 4 weeks use the barring gear, Part No. 3904682 to rotate the crankshatt. Removing the Engine from Short-Term Storage Remove the tape from all openings, and remove the warn ing tag. Refill the oil filters with clean 15W-40 oil, and prime the lubrication system. Refer to Engine Dynamometer Test Engine Run-in. Use clean diese! fuel to flush the preservative oil from the fuel system, and fill the fuel filter again Connect the electrical winng to the fuel pump solenoid. Prime and vent the fuel system Engine Storage - Long Term (14-10) This procedure describes the correct method of prepar- ng an engine for long-term (6 to 24 months) storage. NOTE; If the engine has been stored for 24 months, the cooling system must be flushed with a solvent. Repeat the flushing procedure a second time. Engine Storage Long Term (14-10) Page Was NOVEMBER SMTWT F 5 ae aSEngine Storage Long Term (14-10) Page 14-32 ap Group 14 Section 14 Engine Testin hop Manual B Series Operate the engine at the high idle throttle position untit the coolant temperature ts 70°C [160°F]. Shut off the engine. Drain the fubricating oil pan. Install the drain plug, and fill the oil pan to the high level mark on the dipstick with preservative oil. NOTE: Lubricating system preservative oil must meet Mili- tary Specification MIL-L-21260 Type PE30-1 SAE 20. (Ex- ample: Shell 66202.) Disconnect the fuel supply tube at the fuel filter and the injector return tube at @ convenient place. NOTE: Fuel system preservative oil must meet Federal Spec fication VV-L-800C. (Example: Daubert Chemical NoxRust No. 518.) Fill two containers, one with diese! fuel and the other with preservative oil. Put both fuel tubes into the container of diesel fuel Start the engine and, when. operating smoothly, put the fuel supply tube into the container of preservative oil Remove the injector return tube from the diesel fuel con- tainer. When the preservative oil flows from the tube, shut off the engine. Connect the fuel supply tube to the fuel filter, and put a cap on the ends of all the other fuel tubes.Sectlon 14 Engine Testing Group 14 B Series Shop Manual Drain the preservative oil from the lubricating oif pan and the oil filters. install the drain plug. Drain and flush the cooling system, using a water-soluble rust inhibitor, Remove the aftercooler assembly and the exhaust mant- fold. Refer to Engine Disassembly (00-01), Spray’ preservative oil into the intake and the exhaust ports of the cylinder head and into the aftercooler housing and the exhaust manifold Install the aftercooler assembly and the exhaust mani- fold. Reter to Engine Assembly. Remove the rocker housing covers, and spray the rocker levers, valve springs, valve stems, valve guides, and the push rods with preservative oil. Install the rocker housing cover. Spray preservative oil into the intake port of the air com pressor and on all exposed metal surfaces that are not painted NOTE: Use a preservative compound that meets Military Specification MIL-C-16137C Type P-2 Grade 1 or 2. Cover all openings with heavy paper and tape to prevent entrance of dint and moisture. Put a warning tag on the engine which contains the fol- lowing information: * Date the engine was prepared for storage. © Crankshaft must not be rotated, * Coolant has been drained. + Engine must not be operated. Store the engine in a dry area of even temperature. avi Qe SS SS Engine Storage Long Term (14-10) Page 14.33Engine Storage Long Term (14-10) Page 14-34 Geo Section 14 Engine Testing Group 14 B Sertes Shop Manual _ Removing the Engine from Long-Term Storage. Remove the paper and the tape from all openings. Remove the warning tag. Flush the fuel system with clean diesel fuel to remove preservative oil Rotate the water pump to make sure it hasn't rusted in place. Rotate the crankshaft two complete revolutions to make sure the piston rings are free and no foreign objects are in the engine.Section 14 Engine Testing Group 14 B Series Shop Manual Engine Storage Long Term (14:10) Page 14-35 Remove the intake manifold cover or aftercooler and vi- sually inspect the lower vaive stem area for presence of rust. An accumulation of rust requires disassembly and rebi of the cylinder head. Install the drive belt or belts. Remove a plug from the matn oil rifle drilling and flush the preservative oil from the engine by pumping 4 liters of light mineral oil into the oil rifle. Rotate the crankshaft three or four revolutions as the engine Is flushed. Install the plug. Remove the oil drain plug and allow the mineral oil to drain from the engine. Install drain plug, & g0me Mineral Oil QeEngine Storage Long Term (14-10) Page 14-36 90020 or START Re gis Section 14 Engine Testing Group 14 B Series Shop Manus} Remove the lubricating oil filter. Install a new filter ac cording to the manufacturer's specifications. Pressure fill the engine with 1SW40 lubricating oil through the 1.8 inch pipe tap on the side of the oil filter housing directly below the turbocharger oil supply connection. Use 207 kPa (30 psi) to pressure fill the System with a minimum of 3.6 L (1 U.S. gal). Reinstall the drain plug and fill the oil pan to the high mark on the dipstick, Caution: Make sure the engine does not start when you crank the engine by disconnecting the fuel solenoid or positioning the shut down lever in the stop position. Use the starter to crank the engine for a maximum of 30 seconds, with two minute intervals, until oil pressure reg- iSters on the Jubricaling oil pressure gauge. a~Section 14 Engine Testing Group 14 B Senes Shop Manual Install a new coolant filter if so equipped. Fill the cooling system with a mixture of 50% water and 50% ethylene- alycol type antifreeze. Adjust the valve clearance according to the procedure in the applicable service manual. Tighten all capscrews, plugs and fittings as necessary. Engine Storage Long Term (14-10) Page 14-37Section 16 - Mounting Adaptations Group 16 B Senes Shop Manual Page 16-1 Section 16 - Mounting Adaptations - Group 16 Section Contents Page 16-3 16-4 165 16-4 16-6 16-2 16-2 16-2 162 Fiywheel and Ring Gear Inspection .. Flywheel Housing Assembly ‘Wet Clutch Application ...... Flywheel Housing Inspection..... Front Support Cleaning and Inspection. General Information... Flywheel ang Ring Gear. Flywheel Housing: Front Support Ring Gear Replacement. 16-3General information Section 16 Mounting Adaptations Group 16 Page 16-2 B Series Shop Manual General Information Flywheel Housing The thachieel housings are available in diferent sizes and styles forthe various applications. Ring dowels are used to locate the housing within 0.20 mm (0.008 in} total indicated runout. Service housings are drilfed for the dowels and re-dowelling is not required. Check the appropriate paris book and the engine parts listing for the correct part number for the engine application being serviced. Flywheet and Ring Gear The flywheel 1s available only as an assembly The assembly includes the flywheel and the ring gear The cing gear 1s available for service. Front Support Several different types of front engine mounts are available, depending upon specific applications.Section 16 Mounting Adaptations - Group 16 B Sertes Shop Manual Flywheel and Ring Gear Inspection (16-01) Check the ring gear teeth for wear or damage. Use the dye penetrant method to check the mounting holes for cracks. Check the clutch face surface for cracks or dam- age. If equipped with a flexplate, check the flexplate for cracks or damage. NOTE: If the ring gear teeth are worn or damged, the ring gear must be replaced Ring Gear Replacement (16-02) Brass Drift Pin Warning: Wear eye protection when you drive the gear from the flywheel. Do not use a steel drift pin. Use the drift pin to drive the ning gear from the flywheel. NOTE: The ring gear on flexplate applications cannot be replaced as a separate unit. The entire flexplate assembly must be replaced Heat the new ring gear for 20 minutes in an oven pre- heated to 127°C [260°F], Warning: Wear protective gloves when you install the heated gear. Instail the gear. The gear must be installed so the bevel on the teeth ts toward the crankshait side of the flywheel. @ A Flywheel and Ring Gear Inspection (16-01 Page 16. 26 Minutes, magonInspan Section 16 Mounting Adaptetions - Group 16 B Series Shop Manual Flywheel Housing Inspection (16-03) Inspect the flywheel housing for cracks, especially in the bolt pattern area. D\_ Inspect for damaged threads commonly caused by cross & threaded capscrews or installing an incorrect capscrew, Heli-coils are available to repair damaged threads. Flywheel Housing Assembly (16-04) RQ] 3/8 Inch Square Drive Coat the drain plug with KW Copper Coat® and install, gb Torque Value ap Castiron 65Nem [42 fb] ® Aluminum 35 Nem [26 ftib} ‘Screwdriver Q Install the plastic plug in the tach probe hole. SDNSection 16 Mounting Adaptations Group 16 Flywheel Housing Assembly (76-04) B Series Shop Manual Page 16-5 Install the expanding plug in-the barring tool hole. Coat both sides of the inspection plate gasket with KW ‘Copper Coat 13 mm Q] \_/ ] EEE YD Install the inspection plate. \ 2. 0 Tighten, to 24 Nem {18 ft-lbs} hy N Wee “TY > | | 4/9 Wy)_| Wet Clutch Application Perform all the steps in the procedure for dry clutch m- “7 Stallation sn addition to the following: Coat the flywheel housing drain plug with pipe sealant ‘and install in the hole in the bottom of the flywheel hous ing. SS Tighten the piug Refer to the pipe plug tarque values in Section 10 for different plug sizes. iFront Support Cleaning and Inspection (16-05) Page 165" " Section 16 Mounting Adaptations Group 1| 9S eones ‘Shop Mahusl The capscrew holes on the mounting pads are drilled through. Coat set screws with Loctite™ 277 and install into holes. ‘Set Screw Installation Depth a in 0.00 MIN 0.000 3.00 MAX 0.118 Front Support - Cleaning and Inspec- tion (16-05) Use solvent. Clean the part. @ Check the part for cracks or damage.Section V_ Engine Component Specifications Group 18 B Series Section V - Engine Component Specifications - Group 18 Section Contents Page V-t Page vai V8 v.32 1 V-8t Capscrew Markings and Torque Values... Component Specifications and Torque Values. Ar intake System... Combustion Air System. Compressed Air System Torque Vaiues 2. M83 Cylinder Block Rebuild Specifications o VA6 Cylinder Block Torque Values... v.22 Cylinder Head, Rebulld Specifications v-23 Cylinder Head’ Torque Values V.25 Electncal System + V-34 Engine Assembly - v-10 Engine Assembly Specifications. ......scenwe ns : V6 Engine Testing Test Specifications mo vas Fan Hub | Specifications .. vat Fuel System... + V-26 Lubricating Gil System Spacitications v.28 Rocker Levers and Pedestals... + V-25 Tappet and Push Rods....... : + V-26 Thermostat, Coolant Operating Temperature . V81 Drive Belt Tension 7 peace VASE Engine Component Torque Values .. .. - V8, V4, VS . V-39 Newton-Meter to Foot-Pound Conversion Chart...... . ‘Capscrew Markings and Torque Values U.S. Customary .. Pipe Plug Torque Values... Specifications ‘General Information Tap-Drill Chart U.S. Customary & Metric... Weight and Measures Conversion Factors v40 . VA2 v2 v.43 .. V-38Specifications General Information Section V_ Engine Component Specifications Group 18 Page V-2 B Series Specifications -.General Information This specification section contains the engine specifications for the B series engines. A detailed Engine Component Torque Value sheet is provided in addition to a summary listing with reduced line art of the key specifications from each section 1s included. ew900gzSaction V_ Engine Component Specifications Group 18 Engine Component Torque Values B Series Page V-3, Engine Component Torque Values Socket or Wrench Ref, Size Torque No. — MM[Inch] Nem IFttb] 1 10 Attercooler Mounting. 24 1 18) 2 {5/16} Aftercooler Water Hose Clamp... 5 (4 3 [15/16] Alternator Pulley .. 80 { 59] 4 1301 [3/4] Alternator Link (Delco 15-20-27 Si)... 43 [32] 5 16 Alternator Mounting Bolt 15 SI... 43 32) 5 18 Altenator Mounting Bolt and Nut 20-27 SI 7 { 57] 6 13 Alternator Support (Upper)... . 24 [ 18] 7 23 ‘Balancer Mounting... 50 [ 36) (Alternately Tighten. 80 { 58] In Three Steps) 175, [129] 8 Allen 8mm Balancer Idler Gear .. 43 [ 32) 9 Allen mm Belt Tensioner Flat Bracket .. 24 { 18) 10 18 Belt Tensioner Mounting 43 { 32] Camshaft Bolt, 27 | 20) Rotate 180 Degrees 1 13 24 { 18] [3/8] Coolant Heater. 12 [ 9) 12 12 Connecting Rod Bol 35 [ 26) {Alternately Tighten .. 70 (51) In Three Steps) ...... 100 [ 73} 13 15 Crankshaft Damper & Pulley... 125 [ 92] 4 18 ‘Cylinder Head Mounting . we Step 1 (All) 90 [ 66] 7 ne tep 2 (All). Recheck to 90 [ 66) . Step 3 (Long Capscrews) 120 [ 90] Step 4 Recheck (Long Capscrews Only) 120 190) Step 5 aly Rotate 90° 15 15/16} Crossover Clamp... 5 1 4) 16 13 Exhaust Manifold. 43 { 32} 7 13 Exhaust Outlet Pipe Brkt, Mounting - 43 { 32] 18 13 Exhaust Outfet Pipe, Flanged.. 24 [ 18] 19 (7/16) Exhaust Outlet Pipe, V Band Clamp 8 t 6 20 10 Fan Bracket Mounting.......... 24 [ 18) 21 13 Fan Pulley. . Pr [ 18) 22 19 Flywheel 137 [101] 23 15 Flywheel Housing . 7 [ 57] 24 13 Flywheel Housing Access Cover 24 [ 18) 18 [1/2 Fiywheel Housing Plug .. 36 ( 25) 26 - Front Cover Cap vce... —Hand Tighten— 27 18 Front Engine Support Mounting « 7 [ 57) 28 ft 1/8] Front Engine Support (Barrel) . 350 [257] 29 7 Fue! Banjo Screw (In Fuel Pump). 32 [ 24] 30.17 Fuel Banjo Screw (In Head) ... 24 [ 18) 310 Fual Banjo Screw (In Injector) 9 [7] 320 Fual Vent Screw (In Banjo).. 9 33 80-95 Fuel Filter : 3/4 Turn Atter Contact 34 14 Fuel Low Pressure Supply (Litt Pump Outlet). 24 { 18} 35 24 Fuel Filter Adapter Nut....... u . 32 ( 24] 36 O17, Fuel Line Fitting (High Press).. 24 (18)Engine Component Torque Value: Page V-4 Socket or Wrench Ref. Size No. MM{Inch] 3722 10 (9/16) 3813 24 22 3310 40 10 4 10 42 24 43 10 15/8] “4 10 4 18 46 23 47 15 4875-85 4910 5017 si 47 52 10 5319 S413 8513 56 10 5715 5B 13 15 89 (3/4) (15/16) 60 8 6113 62 [14] 630 64 10 6 10 66 10 67 T-25 Torx 10 68 15 Engine Component Torque Values Fuel Pump Drive Gear (With Pump Unlocked) Bosch (Rotary), Lucas CAV, Stanadyne DB4, Nippondenso..... Bosch (P3000, P7100) .. Fuel Pump Lock (Bosch) . Fuel Pump Unlock (Bosch .. . fees Fuel Pump Lock (CAV) (Stanadyne DB4) Fuel Pump Unlock (CAV) (Stanadyne DB4) essen Fuel Pump Mounting Nut (Bosch Rotary) (Stanaayne. Fuel Pump Mig. Nut (Nippondenso) Fuel Pump Mig. Nut (Lucas CAV)... Fuel Pump Mtg. Nut (Bosch tn-Lina) -...o...- Fuel Pump Solenoid (Bosch VE) (CAV). Fuel Pump Support Bracket... Geer Cover. . Gear Housing-to-Block Injector Retaining Nut... Intake Manifold Cover Intake Heater Plug Lift Pump Mounting/Cover Plate. Lifting Bracket (Rear). . — Main Bearing Cap........ : Step 1 . . soseesStep 2 Step 3 Fill Tube Mounting... Oll Fitter... . Gil Cooler Assembly Oil Pan Drain Plug... Oil Pan Heater Plug Oil Pan Mounting... Oil Pressure Regulator Plug “ . il Pump Mounting... . . Oil Suction Tube (Flange). en Oil Suction Tube Brace PTO Adapter... PTO Adapter Cover Plate (A Drive). PTO Adapter Cover Plate (B Dew)... PTO Gear Nut A Drive PTO Gear Nut 8 Drive Rear Seal Mounting .. Rocker Support... Rocker Lever Nut Starter Mounting . Tach Drive Retainer. vn Tappet Cover/Fuel Drain Lina Supports . Thermostat Housing, ssvstnnseseesnnne Tinaing Pin Flange Mounting. Turbocharger Compressor Housing V-8and. Turbocharger Mounting Nut. 2 Section V_ Engine Component Specifications Group 18 B Series Torque Nem IFt-ib] 65 [48] 123 [ 92} 165 [122] 30 [22] 13 1 10) 12 [9 12 {91 24 (18) 43 [ 32] 30 [ 22] 43 {32} 43 [ 32] 15 [1] 24 [ 18) 24 [ 18) 24 { 18) 60 [ 44] 24 [ 18] 125 { 90) 24 { 18) 7 { 87] 60 ( 44] 119 { 88] 176 {129} 43 { 32] 3/4 Turn After Contact 24 [18] 80 { 60] 80 | 60) 24 { 18) 80 { 60] 24 [ 18) 24 [ 18] 24 { 18) 77 ( 57] 43 [ 32] 7 [57] 400 { 74] 134 [100] 9 {7 24 [18] 34 [ 25) 43 [ 32] 3 {2 24 1 18] 24 [18] & ( 4) 85 { 6 43 (32) ™Section V_ Engine Component Specifications Group 18 B Series Ref. No. 69 ” 72 73 Socket or Wrench Size MMiInch] 13 [5/8] 13 13 3/8) 13 15 Engine Component Torque Values Torque Nem Turbocharger Oil Drain Tube .... . 24 Turbocharger Oil Supply (Both Ends) 35 ‘Turbocharger Turbine Housing 20 Water Hose Clamps 45 Water Inlet Connection. 43 Water Inlet Plugs... 24 Water Pump Mounting .... 24 Valve Cover..... 24 Valve Cover Oil Fill Engine Component Torque Values Page V-5 IFt-tb] [ 18) [ 26) [ 15) { 4] { 32) 38) [ 18] [ 18} Hand TightenComponent Specifications and Torque Values Section V_ Engine Component Specifications Group 18 Page V-8 B Series Component or Assembly (Procedure) _Flef.No./Steps Meine usT Component Specifications and Torque Values Engine Assembly - Specifications Gylinder Bores Cylinder Bore ID. 102.000 mm MIN. 4.0157 in 102116mm = MAX 4.0203 in Cylinder Bore Out of Round 0.035mm MAX 0.0014 in Cylinder Bore Taper 0.076 mm MAX 0.003 in Crankshatt End Clearance A 0,102 mm MIN, 0.004 in 0.432 mm MAX 0.017 in ssdbineh Oil Pressure Regulating Spring * Spring Free Length 1891 Engines A 60.6 mm MIN 2.985 10 1984 Engines 86.0 mm MIN 2.598 in * Sonng Tension at 38.50 mm [1,646 1] Height (A) 1981 Engines 08.0N = MIN 24.51 {6} 1994 Engines, ai2N MIN, BLT Flywheel Housing Bore I.0. |. SAE No, 2 4478mm MAX 17.631 3409.7 mm MAX — 16.19 1 Flywheel Housing Bore Alignment TIR 020mm + MAX — 0.008in Flywheel Housing Face Alignment TIR SAE No. 2 0.20 mm MAX 0.008 in 3 0.20 mm MAX 0.008 inSection V_ Engine Component Specifications Group 18 Component Specifications and Torque Values B Senes Page V-7 Component or Assembly (Procedure) RefNo /Stepe Meine us. Flywheel Face Runout TIR Radius mm in 254 10 0.254 MAX 0.010. 205 8 0.203 MAX 0.008 161 7 0.152 MAX 0.006 187 6 ©0152. MAK 0.008 133 5 0.152 MAX 0.006 Flywheel Bore Runout TIR 0.127 MAK (0.0050 Ol Control Ring End Gap The two-piece oll ring must be installed with the expander gap 180 degrees from the oil ring gap. fing ap trae Ges - ‘Top Ring Gap. Naturally Aspirated 0.25 mm MIN 0.010 [=A 058 mm Mix 002m be ve «Top Ring Gap Turbocharged oaomm OI Geren ») SA 0.70 mm. MAX = 6.028in [Na A « Intermediate Ring Gap 0.25 mm MIN 0010 |SeaeagagSoxZ4l gear Gabh ee Sean aN 2g Connecting Rod Side Clearance 0.100 mm MIN 0.004 in Y = oasomn = Max orem (AT Note: The rod must move freely from side-to-side. i Gq esc t ext0dd- 0.330 mm. MAX 0.013 inComponent Specifications and Torque Values Section V Engine Component Specifications Group 18 Page V-8 B Sories ‘Component or Assembly (Procedure) Ref.No./Steps__ Metne Us. Camshatt Geer Backlash A 0.076 mm. MIN 0.003 in 0.330 mm MAX — 0.013 in Lubneating Oll Pump Gear Back! A 0.076 mm MIN 0.003 in 0.330 mm MAX 0.013 in Lubricating Ol! Pump idler Gear Backlash A 0.076 mm MIN 0.0031n 0.330 mm. MAX 0.013 in Balancer Geer Backlash AtoO — 0.088 mm MIN 0.003 0.420 mm. MAX = 0.017 1n BtoC — 0.153mm MIN 0.006 in 0.355 mm. MAX 0.054 in AtoC 0.088 mm MIN 0.003 in 0.420 mm MAX = 0.017 0 Balencer End Cloarance E 0.13 mm MIN 0.005 mn 0.63 mm MAX — 0.024in F 0.675 mm MIN 0.003 in 0.175 mm MAX — 0.007 in [] Balancer Torque Value and Sequence 1 50.Nem 36 ftlb 2 80 Nem 58 tt 3 176 Nem, 129 fil 71.8 mm MAX 2.81510 1221 mm MAX = 48071 162.8 mm MAX = 7.201 inSection V- Engine Component Specifications Group 18 Component Specifications and Torque Values B Series, Page V-9 Component or Assembly (Procedure) Ref.No.JSteps _ Motrle Us Vibration Damper Index line out of alignment A 1.588 mm MAX 0.0825 in . Missing rubber member chunks B 3.175 mm MAX 0.1250 in (@ soon Valve Stem to Rocker Lever Clearances Intake 0.25 mm 0.010 n Exhaust 0.51 mm 0.020 in Locknut 34 Nem 25 fib Valve Adjustment Procedure Partorm Step A of the valve set procedure with cylinder No. 1 at TOC compression stroke (timing pin will engage). Step A. Four Cylinder Step A Six Cylinder Perform Step B af the valve set procedure with cylindar No. 1 at TOC plus 360 degrees (timing pin will not engage), Mark the crankshaft and gear cover. Rotate the crankshaft one {ull tum in the direction of engine rotation, Step'B Four Cylinder Step B Six Cylinder‘Component Specifications and Torque Values Section V_ Engine Component Specifications Group 18 Page V-16 eres Component or Assembly (Procedure) RefNo [Steps Meine us Belt Tension = Fan Drive Belt Tension 267 N MIN 60 tof 578N MAX 130 Ibf Engine Assembly - Capscrew Torque Values Main Bearing Capscrew Torque Value and Sequence 1 60 Nem 44 lb 2 119 Nem 88 fb 3 178 Nem 128 fel Oll. Pressure Regulator Retainer Plug 80 Nem 60 fel Rear Seal Cover Mounting 9Nem 84 intb Flywheel Housing Cepscrews 77 Nem 57 felb Note: Tighten the capscrews in the sequence shown Ring Gear Replacement Heat the new ring gear for 20 minutes in an oven preheated to 127°C (260°F| Flywheel Mounting Capscrews 197 Nem 401 fib Tighten in the sequence snownSection V. Engine Component Specifications Group 18 Component Specitications and Torque Values B Senes Page V-11 ‘Component or Assembly (Procedure) Aef.No/Steps Matric Us. Flywheel Housing Access Cover 24 Nem 18 fet Flywheel Housing Plug 36.Nem 27 fb Connecting Rod Bolt 1 95 Nem 26 ftlb 2 70 Nem 82 ftlb 3 100 Nem 74 ftp Gear Housing Mounting Capscrews 24Nem 18 ttl Lubricating Oil, Pan Note: Tighten the capscrews in the sequence shown. Start at the center of the oll-pan and alternate toward both ends. 24 Nem 18 tb ESTESSTEOTS ‘pB0006 Camshaft Thrust Plate Capscrew 24.Nem 18 tbComponent Specifications and Torque Values Section V_ Engine Component Specifications Group 18 Page V-12 B Series. ‘Component of Assembly (Procedure) _Aet.No/Stepa Maine US. Oil Pump Mounting Capscrews 24 Nem 18 felb Tighten in the sequence shown linder Head Mounting Capscrew ghten Capscrews in the Sequence shown) Step 1 90 Nem 66 tb Step 2. Recheck to 90 Nem 66 tip Step 3 (Long capscrews only) 420 Nem 90 ftp Step 4 {Long capscrews only) Rechack to 120 Nem 90 tb Step 5 Rotate 8) degrees Gear Cover Capscrows 24Nem 18 fib Front Engine Support Mounting 77 Nem 87 fb Crankshaft Pulley Capscrew 125 Nem 92 fulb Rocker Cover Capscrews 24 Nem 48 felb Rocker Pedestal Capcrews (8 mm) 24.Nem 18 felbSection V Engine Component Specifications Group 18 Component Specifications and Torque Values B Series Page V-13 ‘Component or Assembly (Procedure) Ref.NoJSteps Metre US Starting Motor Mounting Capscrews 43 Nem 82 ftlb Injection Pump Mounting Nuts Nippondenso 43. Nem 32 Hb Lucas CAV, Bosch (Rotary), Stanadyne O84 30 Nem 22 ttlb Bosch (in-Line) 43 Nem 32 fei Fuel Transfer Pump Mounting Capscrews 24 Nem 18 feb Injection Pump Drive Gear Nut Bosch (Rotary), Lucas CAV, Stanadyne DB4 65 Nem 48 ftp Nippondenso 123 Nem 92 Hb Bosch (P3000,.P7100) 165 Nem 122 fell, panes Fan Hub Mounting Capscrews 24.Nem 18 ttb Fan Hub Pulley Mounting Capscrews Bmm 24 Nem 18 ft 1omm = 43.Nem 32 tel ‘Thermostat Housing Mounting Capscrews. 24. Nem 18 fibComponent Specifications and Torque Values Section V_ Engine Component Specifications - Group 18 Senes Page V-14 Component of Assembly (Procedure) Ref_No/Steps Meine os Coolant Inlet Connection 43 Nem 32 fib Water Pump Mounting Capscrews 24 Nem 18 fib ll Cooler Mounting Capscrews 24.Nem 18 fb Ol Fill Tube Capecrows 43 Nem 82 feb Ol Fitter, 3/4 Turn after contact 43 Nem 32 Fup Exhaust Manifold Cepscrews Note: Tighten the capscrews in the sequence shown. Attercooler Inspection inspect the housing and core for damage. Check the core for leaks: * Plug the bottom inlet tube Water temperature at 60°C [140°F} Pressurize the core to 483 kPa [70 psi] and submerge in a container of water.Section V_ Engine Component Specifications Group 18 Component Specifications and Torque. Values B Series Page V-15 Component or Assembly (Procedure) Ref.No./Steps _ Metne US. Aftercooler Capsorews 24. Nem 18 fll Note: Tighten the capscrews in the sequence shown. eo oon0 08 ( = oo =i . ascaneh Air Intake Manifold Cepscrews 24.Nem 18 fib Note: Tighten the capscrews in the sequence shown. ig cap: a e2e2e2008 eooesee Liting Bracket (Rear) 77 Nem 57 telb Alternator Mounting Bracket Capscrews 24.Nem 18 th Alternator Assembly Torque Sequence Note: Tighten the capscrews in the sequence shown. ‘Turbocharger Mounting Nuts 43. Nem 92 fb ‘Turbocharger Oil Drain Tube Mounting Capscrew 26.Nem 18 fibComponent Specifications and Torque Values Section V_ Engine Component Specifications Group 18 Page V-16 BSeres — Component or Assembly (Procedure) Ref.No/Steps Metre US. Turbocharger Air Crossover Hose Clamps 5.Nem 46 nb Turbocharger Oil Drain Line Hose Clamps 6 Nem 59 nb Turbocharger Turbine Housing Capscrews 20 Nem 15 ftlb ‘Turbocharger Compressor Housing * Diffuser Plate Cepscrews 8.5 Nem 75 1nd + V Band Glamp (Silver Plated Nut) 8.5 Nem 75 sel Turbocharger Oil Supply Line Connection 35 Nem 26 thib Cylinder Block - Rebuild Specifications Cylinder Bore Diameter 102.000mm = MIN 4.0187 1n 102.116mm = MAX — 4.0203 in Qut-ofRoundness 0.035 mm = MAX — 0.0014 in Taper 0.076 mm = MAX 0.003 1n Main Beanng Diemeter (Beanngs installed) With Capscrews b] 83.108 mm = MAX 3.27720n Tightened to 176 Nem [130Section V_ Engine Component Specifications Group 18 Component Specifications and Torque Values B Serres ge V-17 Component or Assembly (Procedure) Aet.No./Steps Metric oS Main Bearing Bore {.D. (Without Bearmgs} With Capscrows Tightened to 176 Nem [130 ft-lb] 87.982 mm MIN, 3.4839 1n BB.018mm = MAX 3.4653.n Main Olt Pressure Regulator Valve Bore 18.30 mm MIN, 0.7205 1n to. 18.35 mim MAX 0.7224 in Camshatt Bore Diameter s7.222mm = MIN 2.25281n {umber ¥ bore without bushing) §7.288mm = MAX 2.2543 in, Number 1 bore with bushing installed) Bato7mm = MIN. 2.1808 in 4146mm = MAX 2.4917 in Camshatt Bore Diameter $4.086mm = MIN 2.1295 10 All Journals Except No. 1 Ba.tedmm = MAX 2.1324 in Cylinder Block Overall Flatness + End-to-end 9.076 min MAK 0.0031n * Side-to-side 0.081 mm = MAX 0.002 in Valve Tappet Bore Diameter 16.000mm = MIN 0.63010 16.055mm MAX 0.682 0 Crankshaft Front and Rear Oil Seal Wear 0.25 mm MAX — 0.010.n GrooveComponent Specifications and Torque Values Section V_ Engine Component Specifications Group 18 Page V-18 B Sens ‘Component or Assembly (Procedure) _Ref.No./Steps_~ Metric US. Ti Crankshaft Connecting Rod Journal 0.0. 68.962mm = MIN 2.7150 m 69.019mm = MAX 2.7170 in Out of roundness 0,050 mm MAX 0.002 in A , Taper 0.013 mm MAX 0.005 in Bearing clearance 0.114 me MAX 0.0045 in concn Crankshaft Main Bearing Journal Diameter 82.962 mm MIN 9.2662 in 83.013 mm = MAX 3.2682 in (Out of roundess 0.050 mm MAX “0.002 in Taper 0.013 mm MAX. 0.005 in Bearnng clearance 0.119 mm MAX 0.0047 in Crankahaft Thrust Face Width 37475mm = MIN 1.4754. 37.602 mm = MAX 1/4804 in Crankshaft Rear Oil Seal Flange 0.0. 128975mm = MIN, S.11711n 190.025 mm = MAX 5.1194 in Cronkshatt Damper Pilot 0.0, 18926mm = MIN. 0.745010 19.000 mm = MAX 0.7480 in Main Bearing Shell Thickness (Standard) 2.438 mm MIN 0.0960 in 2464 mm MAX —0.09701n Crankshaft Thrust Beanng Flange Thickness 2.45 mm MIN, 0.086 in 255 mm MAX 0.100n mbeodnahSection V_ Engine Component Specifications Group-18 Component Specifications and Torque Values B Series Page V-19 ‘Component or Assembly (Procedure) Metre US. Connecting Rod Bearing Thickness 4,955 mm MIN 0.07691 (tandard) 1.868 mm MAX 0.075 1n Crankshaft Gear Bore 1.0. 63.910 mm MIN 2.5161 in 63.ea4mm = MAX 2.5171 in Crankshaft Gear Journal 0.0. 63.987mm = MIN 2.519210 64.006mm = MAX 2.51990 Crankshatt Pulley Crankshaft Pilot Bore 19.05 mm MN, 0.7500 in 1D. 19.15 mm MAX 0.7539 in stun Connecting Rad Piston Pin Bore 1.D. Bushing Removed 42.987mm = MIN. 1.6824 in 49.013 mm = MAX .6934 in Bushing Installed (1991 Engines) 40.083mm = MIN. 4.876919 40.076mm = MAX 1.87781 Bushing Installed (1804 Engines) 40.019mm MIN 1.57561 40.042mm = MAX 1.57651 Connecting Rod Crankshaft Bore ILD. (Bearings Installed} 68.081mm = MIN. 2.7185 in 69.103 mm = MAX 2.7208 in (Boanngs Removes) 72.987 mm = MIN 2.8735 1n 73.013mm = MAX 2.8745 in exon Connecting Red Length 191.975mm MIN. 7.5581 in 192.028 mm © MAX — 7.5600 in Connecting Rad Alignmer * (With Bushing) 0.15 mm MAX 0.006 inComponent Specifications and Torque Values Section V Engine Component Speci ns Group 18 Page V-20 B Senes Component or Assembly (Procedure) Ref.No./Steps Metric US. Connectind Rod Twist: owt Bushing) 0.1mm MAX 0.008 in Camshaft Bearing Journal Diameter $3.962mm MIN. 2.124510 Baorsmm = MAX 2.1268 in eG ot} coven Camshatt Gear Mounting Surtace 0.0. 41.575 mm MIN. 1.6368 419593mm = MAX 1.6375 n eatoann n Camshaft Thrust Beanng Journal 0.0. 45.550 mm MIN 1.7933 in 48.780 mm = MAX. 1.8012:m extnaron Camshaft Diameter at Peak of Intake 47.040 mm MIN 1.852 in \ the Lobe 47492 mm = MAX. 1.870in Exhaust 46.770mm MIN. 4841 in 47.222 mm = MAX 1.858 in Foal Transler 2550mm = MIN. 1.338 1n q Pump 36.26 mm MAX 1428in For turbochargers with a senal number after and including 84068, Turbocharger Radial Clearance 0.90 mm MIN 0.01210 0.48 mm MAX 0.018 in Wastegate Rod Travel at the Following Wastegate Applied Pressure 0.33 mm Min 0.019 in 43 mm Max 0.080 in Wastegate , Engine HP Applied Year Rating Application Pressure To 0 Aatomotive (4B) 133 KPa TTS psl] 1391 190-230 Automotive 158 kPa [22.2 psi) 1994 160-175 Avtomot 189 kPa [19.8 psi] 1994 180-230 Automotive 198 kPa [28.7 psi) 1994 All Industral 191 kPa (27.7 psi} Intake Air Restriction (Rated Speed and Load) Naturally Aspirated Engine 508mm H,0 MAX 201m HO. + Turbocharged Engine 835 mm HO MAX 25 in H20Section V_ Engine Component Specifications Group 18 Component Specifications and Torque Values B Sores Page V-33 Component or Assembly (Procedure) _Ref.No./Steps Metric US. Charge Aur Cooler Differential Pressure Across Cooler 2t kPa Max. 3 pst Exhaust Air Restriction (Rated Speed and Load) 76.2mmHg MAX 3in Hg (Naluraly aspirated engines are checked at fated saeed and no load) Automotive With Catalyst 143 mmHg MAX $5in Hg Automotive Without Catalyst ase4mmH9 MAX 6.0 mHg Exhaust Manifold Flatness 010mm MAX 0,004 n Compressed Air System Torque Values Air Compressor Mounting Nuts 77 Nem 87 tel Aur Compressor Support Capserews 24 Nem 18 tei ‘Aur Compressor Oil Suppy Line 45.Nem 12 (eb 18 te Air Compressor Coolant Lines 24 NemComponent Specifications and Torque Values Section ¥ Engine Component Specifications Group 18 Page V-34 B Series Component or Assembly (Procedure) RefNo /Steps Metric US. Electrical System Staring Motor Mounting Capscrews 43 Nem 32 ftp Coolant Heater 12.Nem 408 ino ar UA VA Alternator Mounting Bracket Dimension Delco 10/1SI 55.72 mm 23/16 1in Motorola 100 Amp 81 mm 3.3/8 in Delco 20/2781 98 mm 37/8 in Lucas 78 mm 3in Alternator Assembly Torque Sequence Belt Tensioner Capscrew Alternator Link ‘8 mm Capscrew 40 mm Capscrew Alternator Mounting Bolt Delco 10 to 1581, Lucas, Motorola and Bosch Delco 20sI, 27SI, 2981 1 Alternator-to-alternator bracket capscrew. 2, Lower brace-to-alternator capscrew. 3, Alternator-to-water inlet capscrew. 4, Water inletto-block capscrews, 43 Nem 32 fib A 24 Nem 18 ftlb 8 43 Nem 32 feb 43. Nem 82 fib 80 Nem 59 ft-lbSection V Engine Component Specifications Group 18 Component Specifications and Torque Values B Series Page V-35 ‘Component or Assembly (Procedure) _Ref.No./Steps Metric US. Alternator Bracket Mounting Capscrews 24Nem 18 ftlb 8mm Alternator Pulley Nut a0 Nem 59 feb Batteries State of Charge anny sue] Spee Gan] Specitic Gravity State of Shane’ | arte ate at 27°C [80°F] Charge aa ae © 21 1,200 to 1.220 50% =. eae. 1,170 to 1190 25% J ee THO to 1 130, Discharged — | Bisranor [01-30] Engine Testing - Test Specifications Note: The specitications and instructions {or testing the engine are provided in the Shop Manuel, Bulletin No. 2810206. Refer to Engine Testing Group 14, Page 14-1 Rooge-Drive Belt Tension Section V_ Engine Component Specifications Group 18 Page V-36 B Senes Drive Belt Tension SAE Belt Size Belt Tension Gauge Belt Tension Belt Tension Range Part No. New Used* Click-type Burroughs N tot N Ibf .380 In. 3822524 620 140 270 to 490 60 to 110 440 in. (3822524 620 140 270 to 490 60 to 110 1210. 3822524 sT 1198 620 | 140 | 270 to 490 60 to 110 11/16 in. 3822524 ‘ST 1138 620 140 270 to 490 60 to 110 3/4 In, 3822524 ST 1138 620 140 270 to 490 60 to 110 7/8 in. 3822524” ‘ST 1138 620 140 270 to 490 60 to 110 4rib 3822524 ST 1138 620 140 270 to 490 60 to 110 5 rib (3822524 ST 1138 670 150 270 to 530 60 to 120 6 rib 3822525, ST 1293 710 160 290 to 580 65 to 130 8 rib 3822525, ST 1293 890 200 360 to 710 80 to 160 10 rib 3822525 3823198 110 | 250 | 440t0@90 | 100 to 200 12 rib (3822525, 3823138 1330 300 530 to 1070 120 to 240 * A belt 1s considered used if it has been in service for ten minutes or longer. * If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.Section V_ Engine Component Specifications Group 18 FRACTION, DECIMAL, MILLIMETER CONVERSIONS B Series Page V-37 FRACTION, DECIMAL, MILLIMETER CONVERSIONS 8 16 | 32 | 64 8 16] 32 | 64 THs. | THS. | NOS. | THS. | INCHES | MM | THs. | THS. | NDS. | THs. | INCHES | _MM 1 | 0.0156 | 0.097 33_| 0.6186 | 13.097 1 0.0313 | 0.794 17 05313 | 13.494 3_| 0046s | 1191 35 | 0.5469 | 13.691 1 |__| 0062s | 1588 9 0.5625 | 14.288 S| 007e1 | 1.984 37_|_os7er_| 14.684 3 o.oese | 2.381 19 0.5038_| 15.08 7 | 01094 | 2.78 39 | 0.6004 | 15.478 1 1280 | 3.175 | 5 0.6250 | 15.875 9 | 01406 | 3572 4i_| 0.6406 | 16.272 5 0.1563 | 3.969 21 0.6563 | 16.69 | 11 [_o17se | 4.366 43 | 0.6719 | 17.066 3 0.1875 | 4.763 1 0.6875 | 17.463 13 | 02081 | 5.159 45 | 0.7031 | 17.859 7 0.2168 | 5.556 23 7188 | 18.256 15 | 02300 | 5.953 47_| 0.7344 | 18.653 14 0.2500 | 6.350 | 3/4 _ 0.7500 | 19.050 17 | 0.2656 | 6.747 49_| 0.7656 | 19.447 9 02813 | 7144 25 0.7813 | 19.844 19 | 02969 | 7.541 at_ | 0.7969 [| 20.241 5 0.3125 | 7.938 13 0.8125 | 20.638 ai_|_oszar | 8.334 53_| 0.8281 | 21.034 " 0.3438 | 8.731 27 0.8438 | 21 431 23 | 0.3604 | 9.128 s5_| 0.8594 | 21.828 a 03750 | 9525 | 7 0.8750 | 22.225 25 [| 0.0906 | 9.922 - 57_| 0.8906 | 22.622 3 0.4063 | 10.319 29 0.9063 | 23.019 27_|_0ai9 | 10.716 59 | 09219 | 23.416 7 0.4375 | 11113 15 - 0.9375 | 23.813 23 [| _oasa1_| 11.509 61 | 0.9531 | 24.209 15 0.4688 | 11.906 Ea 0.9888 | 24.606 —_| 31 | oagaa [42.903 63 [ 0.9844 | 25.003 v2 0.5000 | 12.700 [ 1IN. ,0000_| 25.400 CONVERSION FACTOR: 1 INCH = 25.4MMWeight and Measures Conversion Factors Section V_ Engine Component Specifications Group 18 Page V-38 B Series Weight and Measures - Conversion Factors QUANTITY | U.S. CUSTOMARY METRIC FROM U.S. FROM METRIC | CUSTOMARY | TO U.S. TOMETRIC | CUSTOMARY MULTIPLY BY | MULTIPLY BY Unit Name | Abbr. Unit Name ‘Abbr. ‘Area sq. inch wn? 5g. millimeters _|_mm? 645.16 0.001550 | sq. centimeters | cm® 6.452 0.155 5g. foot ie sq, meter m 0.0929 10.764 Fuel pounds per Tbinp-hr | grams per gikwehr | 608.277 0.001645 Consumption | horsepower ‘lowatt hour hour Fuel miles per mpg kilometers per | -kmi/l 0.4251 2.352 Performance |_gatlon iter gallons per gpm Titers per ken 2.3527 0.4251 mile kilometer Force pounds force | bl Newton, N 4.4482 0.224809 Length inch 10) millimeters mm 25.40 (0.039370 foot ft millimeters mm 304.801 0.00328 Power horsepower: hp kilowatt kw 0.746 1.341 Pressure pounds force | pst kilopascal kPa 6.8048 0.145037 per sq. in inches of inHg | kilopascal kPa 3.3769 0.29813 mercury inches of in H20_| kilopascal KPa 0.2488 4.019289 water inches of inHg | millimeters mmHg | 25.40 0.039370 mercury ‘of mercury inches of in H20_ | millimeters mm H20 | 25.40 (0.088370 water of water bars) bars__|_kilopascals kPa 100.001 (0.00899 bars. bars | millimeters of | mmHg | 750.06 0.001833, mercury Temperature | fahrenheit °F centigrade °C (CF-32) = 1.8 | (18x °C) +32 Torque pound force fib Newton-meter | Nem 135582 0.737562 er foot pound force in Ib Newion-meter | Nem 0.113 8.850756 er inch Velocity miles/hour mph | kilometersihour | kph 1.6093 0.6214 Volume gallon (U.S) | ga. liter H 3.7853 0.264179 iquu cs Uiselacement [gallon tmp) | gal Titer H 4.546 0.219976 cubic inch in? iter 1 0.01639 61,02545 ‘cubic inch in? cubic om? 16.387 0.06102 centimeter Weight (mass) | pounds (avoir) | 1b kilograms kg 0.4506 2.204623 Work Bish Thermal | BTU joules 1 1054.5 0.000848 i Baiish Thermal | BTU Kilowat-hour | kw-hr 0.000283, 3414 nit horsepower phe | kilowat-hour | kw-hr 0.746 1.341 hoursSection V_ Engine Component Specifications Group 18 Newton-Meter to Foot-Pound Conversion Chart B Series Page V-39 Newton-Meter to Foot-Pound Conversion Chart Nem ft-lb Nem ftlb Nem tel 1 8.850756 in-lo 55 at 155 "4 5 44 in-lb 60 44 160 ns 6 53 in-lb 65 48 165 122 7 62 in-Ib 70 $2 170 125 8 71 in-lo 7 55 475 129 9 80 in-lb 80 59 180 133 10 89 in-lb 85 63 185 136 1 0.737562 tt-lb- 90 66 190 140 12 9 95 70 195 144 4 10 100 74 200 148 15 Wn 105 7 205 151 16 12 110 81 210 156 18 13 15 85 215 159 20 15 120 89 220 162 25 18 125 92 225 165 30 22 130 96 230 170 35 26 135 100 235 173 40 30 140 103 240 77 45 33 145, 107 245 180 50 37 150 1m 250 184 NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.Newton-Meter to Foot-Pound Conversion Chart Page V-40 Capscrew Markings and Torque Values - U.S. Customary ‘SAE Grade Number 5 é Capscrew Head Markings These are all SAE Grade 5 (3) line BQ Section V_ Engine Component Specifications Group 18 B Series Capscrew Torque Grade § Capscrew Capscrew Torque Grade 8 Capscrew Capscrew Body Size Cast Iron ‘Aluminum’ Cast Iron ‘Aluminum’ Nem fb Nem ftb Nem ftlb Nem tb W420 g 7 8 6 15 it 8 6 28 2 9 9 7 18 13 8 7 sé 18 20 15 18 12 30 2 16 12 24 23 7 19 44 33 24 18 14 3 16 40 30 25 20 55 40 25 20 24 40 30 35 25 60 48 35 25 m6 14 60 45 45 35 90 65 45 35 20 65 50 55 40 95 70 55 40 12 43 35 70 re 55 130 95 75 55 20 100 75 80 60 150 110 80 60 ane 12 435 100 110 80 190 140 +10 80 18 150 410 "5 85 210 185 15 85 58 11 180 135 150 110 255 190 150 110 18 210 155 160 120 290 215 160 120 aia 10 825 240 255 190 460 340 255 190 16 985 270 285 210 515 380 285 210 718 9 430 360 380 280 745 550 380 280 4 530 390 420 310 825 610 420 310 18 720 530 570 420 +100 820 570 420 650 480 14 800 590 650 480 1200 280Section V_ Engine Component Specifications Group 18 Capscrew Markings and Torque Values B Series Page V-41 Capscrew Markings and Torque Values Caution: When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong capscrews can result in engine damage. Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew. The following examples indicate how capscrews are identified: Metric M8-1.25 X 25 U.S. Customary [5/16 X 18 X 1-1/2] _MB ___1.25 25 5/16 18 12 Major Distance Tength Major Number Length Thread Between in Threas Threads in Diameter in Threads in Millimeters Diameter par Inch Inches Millimeters Millimeter In Inches NOTES: 1 Always use the torque values listed in the following tables when specific torque values are not available. 2. Do not use the torque values in place of those specified in other sections of this manual. 3. The torque values in the table are based on the use of lubricated threads. 4. When the ft-lb value 1s less than 10, give consideration to convert ng the ft-lb value to in-Ib to obtain a better torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-Ib.Pipe Plug Torque Values Section V Engine Component Specifications Group 18 Page V-42 8 Senes Pipe Plug Torque Values Size Torque: Torque Tn Gast Iron oF Thread Actual Thread 0.D. In Aluminum Components Steel Components: a aT Nem ft-lb Nem ft-lb 6 0.32 5 45 in-Ib 15 10, Ve 0.41 15 10 20 15 14 sd 20 15 25 20 38 0.68 25 20 35 25 12 0.85 35 25 55 40 3/4 1.05 45 35 75 55 1 1.32 60 45 95 70 114 1.66 7 55 15 85 12 1.90 85 65 135 100Section V Engine Component Specifications Graup 18 Tap-Drill Chart U.S, Customary & Metric B Series Page V-43 Tap-Drill Chart - U.S. Customary & Metric NOTE ON SELECTING TAP-DRILL SIZES: The tap dril sizes shown on thus card gve the theorexical tap drill size for approximately 60% ‘and 7566 of full thread depth. Generally itis recommended that drill sizes be selected in the 60% range as these sizes will provide about 80% of the potential holding power. Drill sizes in the 75% range are recommended for shallow hole tapping (iess than 1 1/2 times ihe hole diameter) in soft melals and mild steel. ep Sie aw She rit Tap ar Tap Sie Dar Te se Ste ae ec wee Sie we Tm] _Siee % za TSA 325m 135mm ree fe {gies sea | tne 8 20mm Yeonm Mises | 12850 oe |e is mises 13 7am 200mm usse9 | 480mm 2.700 Se 38068 Maseas | 208mm vou |za8? [50 Mow.2s | 275mm maior | 98.000 ‘ idem 34 25mm aaa aos | 8S Drom Form 8 | ane 2onm ssc 235mm per | 510 wus |Wiers | 420mm meses |uzeces | 218mm 1328 ane Yao 25 [ar | 800mm sere ates Be fag [a 2 ° 135mm 200m Laon 80mm sions 1Scorm Maseas Basen * wan 82000 Sen? [aw [SS 90mm 2 20mm 0 8 25mm 233mm ¢ 830mm mira ao few [2 ex | 500mm eis | eames | 206 mamas [anaes si 3 20mm wore | 2ad0m Summ a2 |) moods | mse wa a wero | Moats | 80mm nee 25mm ‘vse Seonm ese io 6 R then s wae [ses [230mm Mex S zomm ren 700m aici | Mims » 5 Va2rer fie tees su | mcr | 825mm wane 2s | 6250 micas aes 250mm S3onm mons Beonm pao [see [37 1420, ? 8 20mm uses Saomm Bonn oats [ore | tis su few |e were | wwon.25 ance — | 928em foes | 170m 25mm Sone r 73mm fee 3 2 somm 3 350m aaee maoes | wae eon ene 2 mon Bzamm aoe x 570mm 8.330m ex few fe 338mm meu | a0 f35c6¢ | Peomm : 8 somm 2 320mm Monts | 8somm aoe 5 Mase Soom 550mm Be ox a x v Somm ‘see Sonn tie wre | 609m 2 oem nes 320mm 5 8.3mm Mees ters [328m S100 mores Som 19 30 é theta w {e730 en? | 350mm wares E2aem 200m meas comm Macs 30mm 5 mex | Sage hie Mat 2 wes | 625mm fain | | me2xe 20. 35eun 350mm SSsem 620 x 2osomn 2 e miants | to2omm | | ret tue e22 ise va ¥ 20.780 dsomm res 6 domm fase mores |uaus | som a3 2 Sonn z tise Soamm snow |F varani7s fans | fosomm 2ireimm ae 600m tana | znee 2rae ase.7s | Som 6 miarss [Miae.25 | a%smm || zen 2'Sdmm tox” [2s Samm Sida 3s Noon 250m Sieomm tise tats m8 Sie ae axi2s | 75mm Weeuer Mowe — | 320mm M5075 390mm sree k n4asmm ve ie 2 6000 usimn | | wane 228mm 02 $30r0m Bie wauns | 220mm wore 2 sieee [H 75mm || 18 Shien mise | Eoomm moa as here | 00m Wom || zee 22750m tose | i ozo | ine was | 2300mm 2 310m anew | tee2 ver | ais see | Som see k Miog | 120m ase 23.36 ase) | ase | €z0mm Sia ‘agemm | | vate Saree to? ‘3 oe 120m anew auee Bonn Use ase 128mm tied fassons | 128tnm || mene Bosom aoe 133mm 13bem shew | ve rae ite ‘e t mavens | tte 2s | 12 75mm Wee 5 some Mian as sStonn " uM bhewe 26Section L Service Literature BSenes PageL 1 Section L - Service Literature Section Contents Additional Service Literature. Service Literature Ordenng Location. Service Publications Order Form...Additional Service Literature Section L Service Literature Page.L-2 B Seties Additional Service Literature The following publications can be purchased by filling in and mailing the Service Literature Order Form: Bulletin No, Title Of Publication 3666087 Troubleshooting and Repair Manual 3666017 B Serias Engine Shop Manual 3810234 B Series Alternative. Repair 3666029 4B Series Standard Repair Times 3666028 6B Series Standard Repair TimesSection L Service Literature B Series Service Literature Ordering Location Region United States and Canada U.K., Europe, Mid-East, Africa, and Eastern European Countries South and Central America (excluding Brazil and Mexico) @razil and Mexico Far East (excluding Australia and New Zealand) Australia and New Zealand Service Literature Ordering Location Page L-3 Ordering Location Cummins Distributors or Cummins Engine Co., Inc. Publishing Services CMC 40924 Box 3005 Columbus, IN 47202-3005 Cummins Engine Co.,‘Ltd. Royal Oak Way South Daventry Northants, NN11 5NU, England Cummins Americas, Inc. 18085 N.W. 52nd Avenue Hialeah, FL 33104 ‘Cummins Engine Co., Inc. International Parts Order Dept., MC 40931 Box 3005 Columbus, IN 47202-3005 Cummins Diesel Sales Corp. Literature Center 8 Tanjong Penjuru Jurong Industrial Estate Singapore ‘Cummins Diesel Australia Maroondah Highway P.O.B, 139 Ringwood 3134 Victoria, Australia Obtain current price information from your local Cummins Distributor or (for U.S.A.) by calling Cummins Toll Free Number 1-800-DIESELS (1-800-343-7357).Service Literature Order Form Use this form for prompt handling of your literature order from the factory item | umber Pubcation [auanity | "Bach"? | amount 1 ¢ i$ 2 3 4 5 6 Publications Total C1 Payment Enclosed, Make certified check or Indiana Residents: money order payable to Cummins Engine Co. Add 5% Sales Tax CO Please ship €.0.D. (U.S.A. only) Handling & Shipping Chg: No. Items X $1.50 Prices subject to change without notice. Order Total sFor factory orders, mail the Service Publications Order Form along with your ship-to address to: ‘Cummins Engine Co., Inc., Publishing Services (MC 41407) Box 3005, Columbus, IN 47202-3005. FROM: Name: Street Address: City: Country: State: Zip Code: SHIP TO: (Name and address where literature 1s to be shipped) Name: Street Address: city: State: — Zip Code: Country"Section C Component Manufacturers B Senes Page C-1 Section C.- Component Manufacturers Section Contents Page United States and United Kingdom Ottices.. Air Cylinders Air Heaters .. Arr Starting Motors Alternators .... Auxiliary Brakes .. Bolts ... . Clutches Coolant Heaters Drive Plates Electric Starting Motors Fan Clutches Fans ... Filters. Flexplates Fuel Warmers ... Gauges .. Governors Hydraulic and Power Steering jumps Oil Heaters ... Safety Controls Torque ConvertersUnited States and United Kingdom Offices Page C-2 United States and United Ki Sectlon C Gomponent Manufacturers B Seres igdom Offices NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins engines. Suppliers may be contacted directly for any specifications not covered in this manual. Aur Cylinders Bendix Lid. Douglas Road Kingswood Bristol England ‘Telephone: 0272-67181 Cateing Engneening 2101 Roberts Drive Broadview, iL 60153 Telephone: (312) 344-2034 Air Heaters Fleetguard, Inc, Route & Cookeville, TN 48501 Telephone: (615) 526-9555 Kim Hotstart Co. West 917 Broadway Spokane, WA 99210 Telephone: (509) 534-6171 Air Starting Motors. Ingetsoll Rand ‘Chorley New Road Horwich Bolton Lancashire England BL6 BIN Telephone: 0204-65544 Ingersoll-Rand Engine Starting Systems 888 Industrial Drive Elmmurst, IL 60128 Telephone: (312).30-3800 Start Master Air Starting Systems ‘A Division of Sycon Corporation P 0, Box 491 Manon, OH 43302 Telephone: (614) 382-5771 Alternators Robert Bosch Lid. P.O. Box 98 Broadwater Park North Orbital Road Denham Uxbnidge Middlesex UD9 SHG. England Telephone: 0895-839633 Butec Electrics Cleveland Road Leyland PRS 1XB Englend Telephone: 0744-21663, CAV Electrical Equipment P.O. Box 38 Warple Way London Ws 78S England Telephone: 01-74-3111 A.C, Deleo Components Group Civic Offices Sentral Milton Keynes MK9 3EL England Telephone: 0908-66001 Delco-Remy P.O. Box 2439 Anderson, (N 46018 Telephone: (317) 646-7838 Leece-Neville Corp, 1374. 5tst Si Cleveland, OH 44013, Telephone: (216) 431-0740 Auxiliary Brakes ‘The Jacobs Manutacturing Company Vehicle Equipment Division ‘22-East Dudley Town Road Bloomfield, C¥ 08002 Telephone: (203) 243-1441 Belts Dayco Rubber UK. Sheffield Street Stockport Chestire Ska 1RV England Telephone: 061-432-5163 T.B.A, Ind. Products P.O. Box 77 Wigan Lancashire “WIN2 4X) England ‘Telephone: 0942-59221 Bayeo Corp. Belt Technical Center P.O. Box 3258 ‘Springfield, MO 65804 Telephone: (417) 881-7440 Gates Rubber Company 8610 Crawtordsvile Road Suite 2002 Speedway, IN 46224 Telephone: (817) 248-0386 Goodyear Tire and Rubber Company 48 South Franklin Road Indianapolis, IN 46219 Telephone: (317) 888-4170 Clutches Advanced Drivetrain Corporation ‘938 South Mare Road Columbus, IN 47201 Telephone: (812) 377-8894 ‘Twin Diec International S.A, Chaussee de Namur Nivelles Belgum Telephone: 067-224941 ‘Twin Dise Clutch Co. Racine, Wi 53403 Telephone: (414) 634-1981 Coolant Heaters Fleetguard, Inc. Routeé Cookeville, TN.38501 Telephone: (615) 526-9651 Drive Plates Detrolt Diese! Allison Division of General Motors Corporation P.O. Box 894 Indianapolis, IN 46206 Telephone: (317) 244-1511 Electric Starting Motors Butec Electrics Cleveland Road Leyland, PRS 1XB England Telephone: 0744-21663 CAN Slectrcal Equipment P.O. Box 36 Warple Way London W3 78S England Telephone: 01-743-3111 A.C. Delco Components Group Cine Offices Central Milton Keynes. MK9 3EL England Telephone: 0908-66005 Delco-Remy, P.O. Box 2439 Anderson, IN 46018 Telephone: (317) 646-7838 Leece-Naville Corp. 1974 E, Stst Street Cleveland, OH 44013 Telephone: (216) 431-0740 Fans Teutlo Lid, Westwood Read Birmingham. 86 7J England Telephone: 021-857-4101 Hayes-Albion 1999 Wildwood Avenue Sackson, MI 48202 Telephone, (S17) 782-8421 Engineering Cooling Systems 201 W Carmel Drive Carmel, IN 46032 Telephone: (317) 846-0498 Brookside McCordsvitle, IN 48055 Telephone: ($17) 873-5099 Agrovent 8777 Purdue Ra. Indianapolis, IN 46268 Telephone: (317) 872-0030Section © Component Manufacturers B Series sKysor 1100 Wright Street Cadillac, MI 49601 Telephone: (616) 775-4681 Schwitzer 1125 Brookside Avenue P.O. Box 80-8 Indianapolis, IN 46206 Telaphone: (817) 269-3100 Fan Clutches ‘Advanced Drivetrain Corporation 983 South Marr Road Columbus, IN 47201 Telephone: (812) 377-8894 Holset Engineering Co, Ltd, P.0. Box § Tumbndge Huddersfield England Telephone: 0484-22244 Horton Industries, Inc. P.O. Box 9455 Minneapolis, MN 55440 Telephone: (612) 378-6410 Rockford Power Train, Inc. 1200 Windsor Road P.O. Box 2308 Rockford, iL 61192-2908 Telephone: (815) 633-7460 Transportation Components Group Facet Enterprises, Inc. Eirewra, NY 14993 Telephone: (607) 737-8212 Filters Fleoiguard International Corp. Cavalry Hill Industrial Park Weedon Northampton NN7 4TO England Telephone: 0327-41813 Fleetguard, Inc. Route 8 Cookeville, TN 38501 ‘Telephone: (615) 526-9551 Flexplates Corrugated Packing and Sheet Metal Hamsteriey. Newcastle Upon Tyne Telephone: 207-560-505 Detroit Diesel Allison Division of General Motors Corporation P.O. Box 294 Indianapolis, IN 46206 Telephone: (317) 244-1511 Detroit Diesel Allison Division of General Motors 96501 Van Born Road Romulus, Ml 48174 ‘Telephone: (313) 595-5711 Midwest Mig. Co 30161 Southfield Road Southfield, Mi 48076 ‘Telephone: (313) 642-5955 Fuel Warmers Fleetguard, Inc, Route 8 Cookeville, TN 38501 Telephone: (618) 526-9551 Gauges ALS. Oyifon industrial Estate Ystrad Mynach Hengoed Mid Glamorgan CF8 7xD England, Telephone: 0443-812791 Grasslin U.K. Ltd. Vale Rise Tonbridge Kent TNO 1TB England ‘Telephone: 0732-359868 Icknield Instruments Ltd. Jubilee Road Letchworth Herts England Telephone; 04626-5851 ‘Superb Too! and Gauge Co. 21 Princip Street Biemingharn Ba 61 England Telephone: 021-359-4876 Kabi Electrical and Plastics Granborne Road Pottors Bar Herts ENG JP England Telephone: 0707-53444 Datcon Instrument Go. P.O. Box 128 East Petersburg, BA 17520 Telephone: (717) 569-5713 Rochester Gauge of Texas 1137 Denton Onive Dallas, TX 75229, Telephone: (214) 241-2161 Governors Woodward Governors Lid. P.O, Box 18 663/664 Ajax Avenue Slough Bucks SLi 40D England Telephone: 0753-26835 Woodward Governor Co. 1000 E. Drake Road Fort Collins, CO 80522 Telephone: (303) 482-5811 Barber Colman Co. 1800 Rock Street Rockford, IL 61101 Telephone: (815) 877-0241 United States.and United Kingdom Offices Page C-3 United Technologies Diese! Systems 000 Jone Bivd. Oak Brook, IL 60521 Telephone: (312) 325-2020 Hydraulic and Power Steering Pumps Hobourn Eaton Lid. Priory Road Strood Rochester Kent Me2 28D Telephone: 0634-71773 Honeywell Control Systams Ltd. Honeywell House Chaties Square Bracknell Berks RG12 168 Telephone: 0344424555 Sundstrand Hydratec Ltd. Cheney Manor Trading Estate Swindon Wiltshire SN2 2PZ England Telephone: 0793-30101 Sperry Vickers 1401 Crooks Road Troy, Mi 48084 Telephone: (313) 280-3000 ZF P.O. Box 1240 Grafvonsoden Strasse 5-9 07070 Schwaebisch Gmuond West Germany Telephone: 7070-7171-31510 Oil Heaters Fleeiguard, Inc. Route 6 Gookeville, TN 38501 Telephone: (615) 526-9551 Kim Hotstart Co, West 917 Broadway Spokane, WA 99210 Telephone: (509) 534-6171 Safety Controls Teddington Industrial iment Windmill Road Sunburn on Thames Middlesex TWi6 7HF England Telephone: 09327-85500 The Nason Company 10388 Enterprise Drive Davisburg, MI 48018 ‘Telephone: (313) 625-5381 Torque Converters ‘Twin Disc International S.A. Chaussee de Namur Nivelles Belgium Telephone: 067-224941United States and United Kingdom Offices Page C-4 Twin Disc Clutch Co. Racine, WI 53403 Telephone: (814) 634-1981 Rockford Division Borg-Warner Corporation 1200 Windsor Road P.O. Box 7007 Rockford, IL 61125-7007 ‘Telephone: (815) 633-7460 Modine 1500 OeKoven Avenue Racine, WI $3407 Telephone: (414) 636-1640 Section © Component Manufacturers B SeriesAbout the Manual oon. Accessories Installation ae Accessories Removal. sons oo Accessory Drive Cleaning o4 ‘Accessory Drive Inspection a4 Accessory Drive Adapter Exploded View 92 ‘Accessory Drive Adaptor Assembly ..... os ‘Accessory Onve Adaptor Disassembly. ea ‘Additional Service Literature L2 Attercoale: Asaombly Cleaning end ingpection for Reuse. 106 Inspection. 106 Attarcooler Assembly - Rebuild... co 107 A Compressor Clasring and inspection for Reuse 123 IngpBCbOR rain vssennennennn 123 Air Crossov pection for Reuse... 10-8 loaning... 108 Ingpection. fev Alr Equipment General Information ‘Aur Compressor 122 Ale Intake Systom Expioded View... 102 Air Intake Systam General Information... TO so Alc Transfer Pipe Cleaning and tnapectin fr use 107 PleanIng sora 107 Inspection.. oo 10-8 Alternator installation . om Alternator Removal... : on ‘Aiternator Inspection . COI 188 Balancer Assembly. mcssnnnncsnnsse nnn nnn ns ‘st Balancer Disassembly. 148 Balancer Installation CLE ez Balancer Romoval Co 08s Locking the Balancer, nner O88 Measunng Backlash... * 035 ‘Measunng the End Piay “08s Removing the Balancer... 038 Belt Tensioner Inspection B10 Belt Tensioner installation... on SS oat Belt Tensloner Removal... csc. 19 Balt Tensioner and Fan Hub Exploded View...» 8S. Balt Tensioner and Fan Hub Generaf Intormation 88 Belt Tensioner i deonenenininrennnne, 8 Blowby Measurement... 47 Blowby Conversion Chart (5.613 mm [0.221 in Grlico), 147 ‘Camahatt Cleaning 129 Camshait_ Installation . 058 Camshah End Play Mazsuning 2m 038 Gamshant Goar Backlash Measuring 059 Camshatt Removal... nnn CIN ost Measuring Gear Lash : 931 Camshratt and Gear inspection... cnn $88 Camshatt Lobe Eege Detenoration (Breakdown) Cri +31 Camshaft Lobe Pitting Reuse Critena.... nes 190 Camshaft Bushing Installation 123 Camshaft Capscraw Installaticn NIE 138 Gamshatt Expansion Plug Instalistion. wenn V22 Camshatt Gear Replacement 134 Camshaft Gear Installation (Heated Gear Method) vances 1-34 Gamshatt Gear Insallaion (ih Speci Too 92388)... 138 Camshaft Gear Removal... co re Capserew Markings and Torque Values. vat Charge Ar Cooler (CAC) Clearing andinepecton for Reuse, 108 Cleaning. foe Ingpection so. CSEEEEEIN, 108 Charge Air Gosier (CAC) Pressure Testing. 109 Chassis Dynamometer Operation : 1420 Component Specifications and Torque Values ~.. VS ‘Air Inlake SySlOM eannneuneninnnnnanninannneeseacce WOR Combustion Aur System. vat Compressed Air System Torque Values. vasa Gylincer Block Rebuild Specifications UNI vas Cylinder Block Torque Values... vie Cylinder Head Rebuild Specifications wn. wo... 23, Gylinder Head Torque Valles... v.25, Electrical System . fnunnaeanes VS Engina Assembly Capserew Torque Values... we Engine Assombly Specifications Engine Testing Test Speciications Fan Hub Specifications pon Fuel System... Lubricating Gil Systam Specifications locker Levers and Pedestals ‘Tappet and Push Rods. Thermostat, Coolant Operating Tempera Connecting Rod Inspection wenn Crankshaft Cleaning. Crenkshatt Inspection... Grankshatt Installation. Granksheft Removal Crenkshatt End Play Measuring, Crankshaft Gear Replacoment. Gup Plug Replacement. -.ne.cun Gylinder Block Cleaning... Gylinder Block De-Glazing... Cylinder Block Disassembly. Cylinder Block Exploded View Gylinder Block General tnformation Camshaft... Grankshatt Gylindsr Block Ol Seals Fistons Vibration Damper cylinder Block Inapection....... Cylinder Block Precheck Before Disassembly Cylinder Block Prapare for Assembly... Cylinder Block Removing From the Rollover Stan: Gylinder Block Service Tools. Cylinder Block Storing. Cylinder Block Group inapaction Checklist Cylinder Head Assombly ss Gylinger Head Cleaning. Cylinder Head Disassembiy, Cylinder Head Installation... Qylindar Head Pracheck Beiore Disassembly Gylinder Head Removal. Cylinder Head Service Tools. Cylinder Heed Tightening: oo Cylinder Head Combustion Face Inspection... Cylinder Head Cracks Reuse Guidelines. Data Plate Replacement. Dipstick Removal Dipstick Tube Replacement Drive Belt Installation Dave Belt _Removs Drive Beit Tension Drive Units General information Accessory Drive Adapter Electrical Equipment General Information vnc... Engine Painting Engine Assembly... om Engine Component Torque Values . : Engine Diagram Automotive Engine Engine Disassembly... Engine Disassembly and Assembly ‘Assembly Disassembiy Ganeral Information Engine Disassembly and Assembly Service Toois. Engine Disaesembly Cheek List... Engine Dynamometer Test Engine Rur-in Engine Dynamometer Tesi Performance Checking Engine Dynemometer Test installation of the Engine Engine identification... Aulomotive Engine Dataplate Automotive Engine Nomanclaire Engine Dataplate Indusinal Engine Nomenclature Engine Runsin Procedure (Chassis Dynamometer) Engine RunIn Procedure “In Chassis” (On- and. Off-Highway Vehicl OftHighway On-Highway vad 1418 168 E2 e2 Es £2 £3 14-28 1427 1427 3427Index Page 2 Engine Storage _Long Term ..... soos VON Rlamoving the Engine from Long-Term Storage wes 1434 Engine Storage Short Tat een ere Removing the Engine tram Short Term Siorage : 1431 Engine Testing - Engine Side Views sn... 14.145 Engine Testing General information . seen HR General Engine Test Specifcations..c.cccnwewniesniwns V8 Engine Testing Service Tools. 142, Engine Weight ... wo oan OB Exhaust Manifold” Exploded View. oo 12 Exhaust Manifold Installation... 9105 Exhaust Manifold Remove ota Exhaust Manifold: Inspection... 1 Expansion and Pipo Plug Installatio 1.20 23 Exploded View... nnn Exploded View” Fuel System vo $8 Fan Hub Disassembly er Fan Hub Inspection a7 Fan Hub Installation. o.110 Fan Hub Removel on Fan Hub Assembly. 8B Fan Pulley Removsl . ono Filter Bypass Valve Repiace SO 78 Flywheel Installation a 089 Flywheel! Removal... sonnevnanntwnnnne O28 Flywheel and Ring Gear inspection 163 Flywheel Housing. Installation. . 89 Flywheel Housing Removal 02a Flywheel Housing Assembly... te4 Wet Clutch Application 185 Flywheel Housing Inspection. 16-4 Front Cover Installation... ost Front Cover Ramoval....-. oo oe Front Support Cleaning and inspection oo 166 Fuel Filter Removal on... otonmnunatens OME Fuel Filter Head Instaitation. - o-104 Fuel Filter Head Removal... CL 1s Fuel Lines Clean and Inspect 618 Fuel Dean Manifold... . 647 High Pressure Fuel Lines = 516 Low Pressure Fuel Lines ..scsononnsnnsnnaneannn 518 , Fuel Lines Installation... o-101 Fuel Orain Manifold. Installation... 102 High Pressure Fusl Lines Installation 0-108. Inyection Pump Supply Line Installation. s-swsessvscnevne 101 Injection Pump Vent Line Installation... 0-102 Fuel Lines REMOVAL snnnnsnnininronnnnnnnns OF Fuel Drain Manifold Removal... . 047 High Pressure Fuel Line Removal .wcwuewewnnes OF8 Low Pressure Fusl Lines Removal... fons O88 Fuel Pump Stud Replacement... 158 Fuel Tenster Pump “Cleaning and inapecing.. 613 Fuel Transfer Pump - General Informs 65 Fuol Transfer Pump Ic tion a 6S Fuel Tranter Pump Inetallation, 088 Fuel Transfer Purp Piston Style Rebilidanvnonnnnnnnn OE ‘Assombly, | 645 Cleaning, ee 615 Fuel Transier Pump Removal.» 028 Gear Housing Disassombly 158 Gear Housing Installation... 054 Gear Housing _Removel cons 084 Gear Housing and Timing Pin Assembly, Inspection vn 187 General Cleaning Instructions. i. ett Glass or Plastic Bead Claannag.... Mt Solvent and Acid Cleaning... ett Steam Cleaning Mit General Engine Specifications . 6 Batteries (Specitic Graviy).. ES Cooling System, =” Eloctncal System Es Fuel SYSIEM scr Coomnnnnnne EF General Engine Dae. . E68 lotake Aw and Exhaust System wn ssnnnnnnnnnns EF Lubnestion SY6t@M on Es General Engine Test Procedures (Chassis Dynamometei). 14-22 Goneral Informatlon ver srnsnnnninnrinenanasnines BS Exhaust Manifold een 13 Flywheel and Ring Gear . OT 82 Flywheel Housing. 162 Front Support. ae 162 General Information injectors... eo “Ba General Information Lubrication System... 78 ‘Oil Cooler Coro 78 General Information AbOUE FANS ..cccsnennenennns BVM General Repair Instructions . 110 9 General Safety Instructions Important Safety Notice... oar) : 64 m2 Generic Symbols .. Glossary of Terms How To Use The Manual Group Contents Index.. Metne Information Table of Contents... : “3 Musations.. oo Injection Pump General Informaticn . Injection Pump sdentification ... I Injection Pump Installation : on Injection Pumps Unlocking salman O74 Locked Timed Injection Pump” instalation. 0-72 Unlocked Bosch VE and P7100 Injection Purmp Installation .. 0-80 Unlocked CAV Injection Pump Installation .remnrau 0-76 Unlocked Stanadyne DB4 Injection Pump installation. O77 Injection Pump Removal (In-Line) 0-26 Imection Pump, Removal Rotary Type Pumps) xn O24 Ore Gear Removal. 026 Gear Lash Check 024 Locking the Pump icc oananeuesen, O85 Injection Pump Dataplate E4 Lucas CAV DPA dataplate location. on co ee Robert Bosch VE dataplate location Es Injection Pump Repairs Bosch VE... CUNY seas Delivery Valve Holder/Sealing Washer" Flopiacemsni S546 Fuel Inlet Adapter/Seal - Replacoment ‘Overflow Adepter/Sealing Ring Replacement... Shaft Saal Replacement... wo 515 ‘Shutdown Lever!Spring Replacement. 548 Shutdown Solenod Replacement. . I $7 Injection Pump Repairs Lucos CAV DPA 525 ‘Aulomalic Timing Advance Oisassembly 533 Back Leakage Valve Replacemenvnspection... ico. S26 Bleed Scrows/Sealing Washers Replacamont 528 Control Lever REplecOMENl warwnrsoneonronnavnnnncnnen $80 Fuso! inlot Fitting/Sealing Washar Aepiacemant.... 5.20 Locking ScrewiO-Ring Replacement. 528 Shutdown Lever!Spning Replacement 1 Sat Shuldown Solenoid Replacement. oe 527 Timing Advance Assembly... oe ve 585 ‘Timing Advance Components inspection 534 Vent Fiting/Seating Washer Inspectiors/Rapiacemant 329 Inyection Pump Repairs $39 Fuel Inlet Banjo Connector Replacemert, Bosch P7I00 .... 550 Fuel Pump Snut Off Lever Replacement, Bosch P7100... 5-52 Fuel Shut Off Solenoid Adjustment, Sosch P7100 551 Evel Shut Ot! Solenoid Bracket Raplacament, Bosch PIG)... 5-52 Fuel Shul Off Solenoid Replacement, Bosch P7100, 551 yection Pump Timing Nippondenso EPP... 54a Injection Pump Timing Stanadyne DB4 con $39) Pressure Reliol Velva and Sealing Waser Rapiecemen . Bosch P7100 548 Return Connection Replacament. Stanadyne DB4.,........... 540 Seal Replacement, Bosch P7100. “$50 Seals Replacement, Nippondenso EPS 5468 ‘Shut Down Lever or Spring fleplacement, Nippandensa EPS 5.46 ‘Shutdown Solanoid Inspection, Bosch P7100 558 Shutoff Solenoid Replacement, Stanadyne DBA. sae 4 Speed Droop agusiment Of Ename, Stanadyre 5 Be 53 Throttle Lever Replacement, Bosch P7I00, on $53. Injection Pump Timing Bosch VE. 521 Injector Assembly. nnn 610 Injector Clean and inspect... 68Injector Disassembly... 67 Injector Service Tools . 62 Injector Tegflng .oncnn : wo et, Chatter Test tinuaunnnnannan 613 Injector Group Exploded View... 63 Injector Nozzles Installation, 7 088 Injector Nozzles Removal, scne 0-20 KSB Electrical Solenoid Style General information. 56 Cold Start Timing Advance System (KSB) Electrical Solenoic Style, 86 VE Pump Timing Advance Prneiptes (With Electrical Solenoid KSB Installed). 58 59 VE Pump Timing Advance Principles (Without #88). nee 7 KSB Electrical Solenoid Style Inspection .n.wnnn sium S12 KSB Electrical Solenoid Inspection. S12 KSB Elecincal Sotenoid Siyie Wirng Harness Inspection... §-14 KSB (Remote Mounted) Installation. enone O08 KSB (Remote Mounted) Removal nue O18, Lifting Bracket Removsl Rear. . Ca Lube Pump Installation .....,...0.innonno oss Lube Pump Removal 032 Measuring Backlash. eon neuns oo ose Lubricating Ol Cooler Exploded View. wo 7S. Lubricating Oll Pump Exploded View... 7 Lubrication Oil Pump Ganeral Informatlon.n.s.ssscvwsnee 712 Manifold Cover Inataltation, 0100 ‘Altercooler Installation ann o-101 Manifold Cover “Removal O18 Altercooler Removal . ong Newton-Meter to Foot-Pound Conversion Chart vse Capscrw Markings and Torque Vals USS. Cusiom ay.) V40 Of Draining 39 Oil Cooler Cidsning.....nuse-vonnnnn LI 79 Oli Cooler inspection... III 78 ‘ll Cooler Instatlation 049 Oli Cooler Removal ....nnsonnonnn fonnnins O88 OU Filter tnetallation CS Ong ‘Ol Pan Installation ne o 0-88 Oil Pan Sealing Surfaces Sealants oss ‘Ol Pen Removal . ven 0:30 ll Pan and Suction Tubs Clearwng and inspect 74 ll Pan and Suction Tube Exploded View 72 ll Pan and Suction Tube General Information. 73 il Pump Inspection 713 Pipe Plug Torque Values CLINI waa. Pleton and Connecting Rad Asgambly 145 Piston and Connecting Rod Disassembly 0.0. tat Piston and Rod Ascomblles installation oa? Piston and Connecting Rod Assemblies insallation...-..-. 0-0 ision Grading For 1984 Automotive Appications Only... 0-47 Piston and Rod Assembliss Removal 037 Platon InspectlOn vcesvccnron 142 Piaton Pin Inepection CIE 1a Piston, Pin end Connecting Rod Cleaning - vat Piston'Rng Gap Checking... 7 2 48, Piston Rings Installation. a7 Pressure Regulator Valve Assembly... . 78 Pressure Regulator Valve Disassembly 77 Pressure Regulator Valve Inspection... 77 Push Reds Inspection... veut 44 Push Rods Installation : 0.93 Push Rode lemoval oz Rear Seal Installation. : CO 088 Rear Seat Housing Removal wo. ccscsseswnesrsnnuenrans O80 Fling Gear Replacement 163, Rocker Lever. Inspection an. onnancnnse 38. Rocker Lever Assembly Exploded View 232 Rocker Lever Assembly General Informatlon..csccwwnnous 24 Rocker Lever Pedestals Inspection... SI a Rocker Levers Assembly. a7 Rocker Levers Disassembly... eons oan 85 Rocker Levers Installation, oge Rocker Levers Removal 021 Rocker Levers and Pedestals Cleaning 38 Rod Besring Clearance Checking. 144 Rollover Stand Engine Mounting, oe Index Page 3 Rollover Stand Engine Removat..ennnisnneininnnerin ONG Rubber Element Vibration Dampar Cl pection. 1-38 Servige Literature Order Form . 4 Service Literature Ordering Location SO oe Service Tools. Injection PUMP... 52 Side OWFilt” Installation. oso Side Oi Fil - Removal... "0-28 Simbotos Usedos En Este Manual nnn ‘s Specifications General Information. ..ncccccnnneeinnnn, V2 Starter Installation. ong Starter Removal . oe os Starter Inspection. vn 188 ‘Steam Cleaning The Engine oo 08 Suction Tube Installation 087 Suction Tube Removsl oo oo 00. Symbote.... ¥6 Symboles Ulises Dans Ce Manuel ‘7 Tep-Drill Chart U.S. Customary & Metric. waa Tappat Cover instailatlon ... oe “070 028 Teppet Cover Removal... Tappets and Push Rods Exploded View. - 42 General Information. a 43 ‘Tappals and Push Rods’ General information. 43 Thermostat Inspection... Cena Thermostat Installation...» co os109) Thermostat Removal O12 Thermostat Housing Assembly Exploded View... en Thermostat Housing Assembly General information... 8-12 Timing Pin Installation. 059 Timing Pin Housing Removal... CO 3a Turboenerger Cleaning and inspection for “Reuse. 105 Inspection, fn . 108 Turbachergar installation 0-108 Turbocharger Removal CEL ota Turbocharger Drain Tube Removal ot Turbocharger Mounting Stud Replacement... cccuncuncrce M4 United States and United Kingdom Offices c3 Valve Inspection sonninnintenne 29 Valve Clearance Adjuatment “997 Valve Covers Installstion 0-100 Valve Covers Removal.. oo 028 Valve Guide Inspection Se Pa Valve Seat Inspection... nranninnnnnn ait Valve Seats Grinding 216 Calculating the Grading Dept . 246 Measuring the Valve Dept... -cnsnnnuewnn 246 Valve Spring Inspection . nuns BA Valve Tappets Inspection 44 Valve Tappets Installation w.ccsnnecenennne 0-42 Valve Tappets -Removal ose Valves Grinding... : III, as Vibration Damper installation. . 0-110 Vibration DamperiCrankshatt Pulley Romovai..,. 0-10 Water inlet Connection Installation ont Water inlat Connection Removal 029 Water Pump Exploded View ' 82 Water Pump General Information I 63 Pump Inspection vn a4 Water Pump lnstallation, 0-90 Weight and’ Messures, Gove wo O23 Weight and Measures Conversion Factors. v8Cummins Customized Parts Catalog Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic versions of paris catatogs that support general high volume parts content; Cummins Customized catalogs contain only the new factory parts that were used to build your engine The catalog cover, as well as the content, is customized with you in mind. You can use it in your shop, at your worksite, or as a coffee table book in your RV or boat. The cover contains your name, company name, address, and telephone number. Your name and engine model identification even appears on the catalog spine. Everybody will know that Cummins created a catalog specifically for you. This new catalog was designed to provide you with the exact information you need to order parts for your engine. This will be valuable for customers that do not have easy access to the Cummins Electronic Parts Catalog or the Cummins Parts Microfilm System. Additional Features of the Customized Catalog include: * Engine Configuration Data + Table of Contents + Separate Option and Parts Indexes * Service Kits (when applicable) + ReCon Part Numbers (when applicable) ORDERING THE CUSTOMIZED PARTS CATALOG Ordering by Telephone: North American customers can contact their Cummins Distributor or call Gannett Direct Marketing Services at 800-646-5609 and order by credit card. Outside North America order on-line or make an International call to Gannett at +-+-502-454-6660 Ordering On-Line The Customized Paris Catalog can be ordered On-Line from the Cummins Powerstore by credit card, Contact the Powerstore at WWW.CUMMINS.POWERSTORE.COM Contact GOMS or the CUMMINS POWERSTORE for the current price; Freight may be an additional expense. Information we need to take your Customized Parts Catalog Order. This information drives the cover content of the CPC. + Customer Name + Street Address * Company Name (optional) + Telephone No. * Credit Card No. + Cummins Engine Serial Number (located on the engine data plate) Unfortunately not all Cummins Engines can be supported by this parts catalog. Engines older than 1984 or newer than 3 months may not have the necessary parts information to compile a catalog. We will contact you if this occurs and explain why we are unable to fill your order. Customized Parts Catalogs are produced specifically for a single customer. This means they are not returnable for a refund. If we make an error and your catalog is not useable, we will correct that error by sending you a new catalog.