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3 Service Manual

 (4021540) B3.3 and QSB3.3 Service Manual

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  Front 001-006   Bearings, Main

  Section i - Introduction
  Section E - Engine and System Identification
  Section F - Familiarization
  Section TS - Troubleshooting Symptoms
  Section TT - Troubleshooting Symptoms (New Format)
  Section DS - Engine Disassembly - Group 00
Preparatory Steps
  Section AS - Engine Assembly - Group 00
  Section 0 - Product - Group 00
  Section 1 - Cylinder Block - Group 01
  (11-022-001_01) Service Tools  WARNING 
  (11-001-004) Balancer
  (11-001-005) Bearings, Connecting Rod
  (11-001-006-tr) Bearings, Main To reduce the possibility of
  (11-001-007-tr) Bearings, Thrust personal injury, avoid direct
  (11-001-008-tr) Camshaft contact of hot oil with your
  (11-001-010-tr) Camshaft Bushings skin.
  (11-001-012) Camshaft Gear (Camshaft Installed)
  (11-001-014) Connecting Rod
  (11-001-016-tr) Crankshaft  WARNING 
  (11-001-018) Crankshaft Gear, Front (Crankshaft Installed)
  (11-001-022-tr) Crankshaft Pulley
  (11-001-023-tr) Crankshaft Seal, Front Some state and federal
  (11-001-024-tr) Crankshaft Seal, Rear agencies have determined
  (11-001-026) Cylinder Block that used engine oil can be
  (11-001-031-tr) Gear Cover, Front
carcinogenic and cause
  (11-001-036-tr) Idler Gear, Camshaft
reproductive toxicity. Avoid
  (11-001-043) Piston
  (11-001-047) Piston Rings
inhalation of vapors,
  (11-001-054-tr) Piston and Connecting Rod Assembly ingestion, and prolonged
  (11-001-055) Gear Train Backlash, Front contact with used engine oil. If
  (11-001-056-tr) Camshaft Thrust Bearing not reused, dispose of in
  Section 2 - Cylinder Head - Group 02
accordance with local
environmental regulations.
  Section 3 - Rocker Levers - Group 03
  Section 4 - Cam Followers/Tappets - Group 04
Drain the lubricating oil
  Section 5 - Fuel System - Group 05 from the engine. Refer to
  Section 6 - Injectors and Fuel Lines - Group 06 Procedure 007-037.
  Section 7 - Lubricating Oil System - Group 07 Remove the lubricating oil
pan. Refer to Procedure
  Section 8 - Cooling System - Group 08
007-025.
  Section 9 - Drive Units - Group 09 Remove the lubricating oil
  Section 10 - Air Intake System - Group 10 suction tube. Refer to
  Section 11 - Exhaust System - Group 11 Procedure 007-035.
  Section 13 - Electrical Equipment - Group 13
  Section 14 - Engine Testing - Group 14
  Section 16 - Mounting Adaptations - Group 16
  Section 17 - Miscellaneous - Group 17
  Section L - Service Literature
  Section V - Specifications
  Back

Copyright © 2000-2010 Cummins Inc. All rights reserved

Remove

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

NOTE: The end play

measurement is necessary for
determining the wear of the
thrust bearing and abnormal
wear of the crankshaft.

Measure the crankshaft end play

using a dial indicator, Part
Number 3824564, or equivalent,
and magnetic base, Part Number
3377399, or equivalent.

Crankshaft End Play

mm in
0.131 MIN 0.0052
0.351 MAX 0.0138

NOTE: Mark the thrust

bearings so the bearings can
be installed in the correct
position during assembly.

NOTE: The main bearing cap

mounting capscrews must be
replaced after each use.

Remove the mounting

capscrews of the main bearing
cap.

Remove the main bearing cap

and lower bearing.

Clean and Inspect for Reuse

 WARNING 

When using solvents, acids,

or alkaline materials for
cleaning, follow the
manufacturer's
recommendations for use.
Wear goggles and protective
clothing to reduce the
possibility of personal injury.

 WARNING 

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Wear appropriate eye and

face protection when using
compressed air. Flying debris
and dirt can cause bodily
injury.

 CAUTION 

Do not use a scraper or a wire

brush. The bearings can be
damaged.

NOTE: Make sure the bearings

are marked for location. The
bearings must be installed in
their original locations, if used
again.

Use solvent and a soft bristle

brush to clean bearings.

Dry with compressed air.

Inspect all main bearing caps and

main bearing crankshaft journals
for dents, cracks, deep scoring,
overheating, and other damage.

Determine the size of the main

bearing removed and obtain the
same size for installation.

Refer to Part Reuse Guidelines,

Bulletin 3810303, for the
dimensions of the standard and
undersize main bearing journals.

Refer to Procedure 001-016 for

crankshaft measurement
specifications.

NOTE: If the crankshaft

journals or main caps are
damaged, the engine will need
to be removed to complete the
overhaul.

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Inspect the crankshaft journals

for deep scratches, indications of
overheating, and other damage.

Install

 CAUTION 

Confirm that there is no dirt or

dust stuck to the rear face of
the bearing before installation.
Remove debris behind the
bearing before installation.

Coat the inside face of the bearing

with clean SAE30 engine
lubricating oil before installation.
The number stamped on the main
bearing cap must be the same as
the number stamped on the
cylinder block.

Align the protrusion in the lower

main bearing with the notch in the
cap.

Install the lower main bearing into

the main bearing cap.

NOTE: New main bearing

mounting capscrews must be
used.

The casting number or cast arrow

on the main bearing cap must
face toward the front of the
engine.

Coat the capscrew threads and

seat face with clean SAE30
engine lubricating oil.

Position the main bearing caps

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and capscrews.

 CAUTION 

Install each thrust bearing with

the oil groove on the outside.
Failure to do so will cause
engine damage.

 CAUTION 

Do not let the thrust bearings

slip out of place. Engine
damage will result if the thrust
bearings are not properly
installed.

The casting number or cast arrow

on the main bearing cap must face
toward the front of the engine. The
thrust bearing is located on the
main bearing closest to the rear of
the engine (number 5). Align the
lower thrust bearing with the
dowel pin.

Install the upper thrust bearing.

Tighten the mounting capscrews

in the order shown in the
illustration.

Torque 113 n.m   [83 ft-
Step 1
Value: lb]
Loosen all
  Step 2 capscrews
completely.
132 n.m   [98 ft-
  Step 3
lb]

 
After the mounting capscrews are
tightened, make sure the
crankshaft rotates smoothly.

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Finishing Steps

Install the lubricating oil

suction tube. Refer to
Procedure 007-035.
Install the lubricating oil
pan. Refer to Procedure
007-025.
Fill the engine with
lubricating oil. Refer to
Procedure 007-037.
Operate the engine and
check for leaks.

Last Modified:  09-Jan-2006

Copyright © 2000-2010  Cummins Inc.  All rights reserved.

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 (4021540) B3.3 and QSB3.3 Service Manual

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Manual Change History

Help With Printing

  Front 001-054   Piston and Connecting Rod

  Section i - Introduction
Assembly
  Section E - Engine and System Identification
  Section F - Familiarization
  Section TS - Troubleshooting Symptoms
  Section TT - Troubleshooting Symptoms (New Format)
  Section DS - Engine Disassembly - Group 00
  Section AS - Engine Assembly - Group 00 General Information
  Section 0 - Product - Group 00
  Section 1 - Cylinder Block - Group 01
  (11-022-001_01) Service Tools
  (11-001-004) Balancer
There are a number of power-
  (11-001-005) Bearings, Connecting Rod
  (11-001-006-tr) Bearings, Main
related problems, including
  (11-001-007-tr) Bearings, Thrust excessive lubricating oil
  (11-001-008-tr) Camshaft consumption, smoke, blowby,
  (11-001-010-tr) Camshaft Bushings and poor performance, that can
  (11-001-012) Camshaft Gear (Camshaft Installed) be caused by inadequate
  (11-001-014) Connecting Rod sealing between the piston
  (11-001-016-tr) Crankshaft rings and the cylinder walls. A
  (11-001-018) Crankshaft Gear, Front (Crankshaft Installed)
blowby measurement can help
  (11-001-022-tr) Crankshaft Pulley
  (11-001-023-tr) Crankshaft Seal, Front
detect the problem. Refer to
  (11-001-024-tr) Crankshaft Seal, Rear Procedure 014-010 (Crankcase
  (11-001-026) Cylinder Block Blowby, Measure) in Section
  (11-001-031-tr) Gear Cover, Front 14.
  (11-001-036-tr) Idler Gear, Camshaft
  (11-001-043) Piston
  (11-001-047) Piston Rings
  (11-001-054-tr) Piston and Connecting Rod Assembly
  (11-001-055) Gear Train Backlash, Front
  (11-001-056-tr) Camshaft Thrust Bearing
 
A free-floating, hollow piston pin
  Section 2 - Cylinder Head - Group 02 is used to attach the piston to
  Section 3 - Rocker Levers - Group 03 the connecting rod. Lubricating
  Section 4 - Cam Followers/Tappets - Group 04 the pin and journal is
accomplished by residual spray
  Section 5 - Fuel System - Group 05
from piston cooling.
  Section 6 - Injectors and Fuel Lines - Group 06
  Section 7 - Lubricating Oil System - Group 07
  Section 8 - Cooling System - Group 08
  Section 9 - Drive Units - Group 09
  Section 10 - Air Intake System - Group 10
  Section 11 - Exhaust System - Group 11
  Section 13 - Electrical Equipment - Group 13
  Section 14 - Engine Testing - Group 14
  Section 16 - Mounting Adaptations - Group 16
  Section 17 - Miscellaneous - Group 17
  Section L - Service Literature Preparatory Steps
  Section V - Specifications
  Back

Copyright © 2000-2010 Cummins Inc. All rights reserved

 WARNING 

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

To reduce the possibility of

personal injury, avoid direct
contact of hot oil with your
skin.

 WARNING 

Some state and federal

agencies have determined
that used engine oil can be
carcinogenic and cause
reproductive toxicity. Avoid
inhalation of vapors,
ingestion, and prolonged
contact with used engine oil.
If not reused, dispose of in
accordance with local
environmental regulations.

 WARNING 

Do not remove the pressure

cap from a hot engine. Wait
until the coolant temperature
is below 50°C [120°F] before
removing the pressure cap.
Heated coolant spray or
steam can cause personal
injury

 WARNING 

Coolant is toxic. Keep away

from children and pets. If not
reused, dispose of in
accordance with local
environmental regulations.

Drain the lubricating oil.

Refer to Procedure 007-
037 (Lubricating Oil
System) in Section 7.
Drain the coolant. Refer
to Procedure 008-018
(Cooling System) in
Section 8.
Remove the lubricating oil
pan. Refer to Procedure
007-025 (Lubricating Oil
Pan) in Section 7.
Remove the cylinder
head. Refer to Procedure
002-004 (Cylinder Head)
in Section 2.

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Remove

Rotate the crankshaft with an

engine barring tool until the
pistons are below the carbon
deposits, which are found
above the ring travel area.

 CAUTION 

Do not use emery cloth or

sandpaper to remove carbon
from the cylinder bores.
Aluminum oxide or silicon
particles from these
materials can cause serious
engine damage.

Use a scraper or a blunt-edged

instrument to loosen the carbon
deposits. Do not damage the
cylinder with the scraper.

Remove the remaining carbon

deposits with an abrasive pad,
Part Number 3823258 or
equivalent.

 WARNING 

Wear appropriate eye and

face protection when using
compressed air. Flying

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debris and dirt can cause

personal injury

 CAUTION 

Do not use the steel wire

wheel in the piston travel
area. Operate the wheel in a
circular motion to remove the
deposits. An inferior quality
wire wheel will lose steel
bristles during operation,
thus causing additional
contamination.

An alternative method to
remove the carbon ridge is to
use a high-quality steel wire
wheel installed in a drill or die
grinder.

 
Mark each piston according to
the cylinder location.

On pistons with anodized

coatings, do not stamp the
anodized coating on the outer
rim.

Rotate the crankshaft to

position the connecting rod
caps at bottom dead center for
removal.

Mark each connecting rod and

connecting rod cap according
to the cylinder number location.

 
NOTE: Do not remove the
capscrews from the
connecting rods at this time.

Loosen the connecting rod

capscrews.

Use a rubber hammer to hit the

connecting rod capscrews to
loosen the caps.

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Remove the connecting rod

capscrews.

Remove the connecting rod

cap.

Remove the lower connecting

rod bearing.

Mark the cylinder number and

the letter “L” (lower) on the flat
surface of the bearing tang.

Push the connecting rod and

piston assembly out of the
cylinder bore. Care must be
taken not to damage the
connecting rod or bearing.

Remove the upper rod bearing.

 
Mark the cylinder number and
the letter “U” (upper) on the flat
surface of the bearing tang.

 
The piston and connecting rod
assemblies must be installed in
the same cylinder number from
which they were removed, to
provide proper fit of worn mating
surfaces, if parts are reused.

Use a tag to mark the cylinder

number from which each piston
and rod assembly were
removed.

Place the rod and piston

assemblies in a container
designed to protect them from
damage.

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Disassemble

Use piston ring expander, Part

Number 3823137 or equivalent,
to remove the piston rings.

Remove the piston pin retaining

rings.

NOTE: Heating the piston is

not required.

Remove the piston pin.

Remove the connecting rod

from the piston.

Assemble

Make sure the “F” marking on

the piston skirt and the numbers

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on the connecting rod and cap

are oriented as illustrated. The
piston bowl must be oriented
toward the intake side of the
engine.

Install the retaining ring in the

pin groove on the front side of
the piston.

Lubricate the pin and pin bores

with clean 15W-40 engine
lubricating oil.

NOTE: Pistons do not require

heating to install the pin;
however, the pistons do need
to be at room temperature or
above.

Install the connecting rod.

Install the piston pin.

Install the second retaining ring.

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Use the piston ring expander,

Part Number 3823137 or
equivalent, to install the piston
rings. Refer to Procedure 001-
047 (Piston Rings) in Section 1.

Install

 CAUTION 

The connecting rods and

connecting rod caps are not
interchangeable. The
connecting rods and
connecting rod caps are
machined as an assembly.
Failure will result if the
connecting rods and caps are
mixed.

When rebuilding an engine with

the original cylinder block,
crankshaft, and pistons, make
sure the pistons are installed in
their original cylinders.

If replacing the piston(s), make

sure the replacement piston(s)
are the same grade as the
original piston(s).

If a new cylinder block or

crankshaft is used, the piston
grading procedure must be
performed to determine the
proper piston grade for each
cylinder.

Install the bearing shells into both

the connecting rod and the
connecting rod cap.

Make sure the tangs on the

bearing shells are in the slot of
the connecting rod cap and
connecting rod.

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Lubricate the connecting rod

bearings with clean lubricating
engine oil.

Immerse the pistons in clean

15W-40 engine lubricating oil
until the rings are covered.

Allow the excess oil to drip off the

assembly.

Position the rings so that the ring

gaps are 120 degrees apart.

 
 CAUTION 

If using a strap type ring

compressor, make sure the
inside end of the strap does not
hook on a ring gap and break
the ring.

Use piston ring compressor, Part

Number 3164330 or equivalent, to
compress the rings.

Lubricate the cylinder bore with

clean 15W-40 engine lubricating

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oil.

The cylinder block must be clean

before assembly.

Inspect the cylinder bores for

reuse. Refer to Procedure 001-
026 (Cylinder Block) in Section 1.

 
Position the connecting rod
journal for the piston to be
installed to bottom dead center
(BDC).

Take care to not damage the

cylinder wall when inserting the
connecting rod.

Carefully push the piston into the

bore while guiding the
connecting rod to the crankshaft
journal.

Lubricate the threads and

underside of the connecting rod
capscrew heads with clean 15W-
40 lubricating engine oil.

 CAUTION 

The number stamped on the

rod and cap at the parting line
must match and be installed
facing the exhaust side of the
engine.

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Install the connecting rod cap

and capscrews.

Tighten the two capscrews in

alternating sequence.

Torque 39 n.m   [29 ft-
Step 1
Value: lb]
Rotate
each
  Step 2 capscrew
90
degrees.

NOTE: Do not measure the

clearance between the
connecting rod cap and
crankshaft.

Measure the side clearance

between the connecting rod and
crankshaft.

Connecting Rod Cap Side

Clearance
mm in
0.20 MIN 0.0079
0.40 MAX 0.0160

 CAUTION 

To reduce the possibility of

engine damage, the crankshaft
must rotate freely.

 CAUTION 

If the connecting rod is not

properly oriented (tang
opposite the camshaft), it will
contact the camshaft and lock
the engine.

Check for freedom of rotation as

the connecting rod caps are
installed. If the crankshaft does
not rotate freely, check the
installation of the connecting rod
bearings and the bearing size.

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Finishing Steps

Install the cylinder head.

Refer to Procedure 002-
004 (Cylinder Head) in
Section 2.
Install the lubricating oil
pan and gasket. Refer to
Procedure 007-025
(Lubricating Oil Pan) in
Section 7.
Fill the cooling system.
Refer to Procedure 008-
018 (Cooling System) in
Section 8.
Fill the engine with
lubricating oil. Refer to
Procedure 007-037
(Lubricating Oil System)
in Section 7.
Operate the engine to
normal operating
temperature and check for
leaks.

Last Modified:  27-Sep-2007

Copyright © 2000-2010  Cummins Inc.  All rights reserved.

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 (4021540) B3.3 and QSB3.3 Service Manual

Search Manual     Search

Manual Change History

Help With Printing 016-006   Flywheel Housing

  Front
  Section i - Introduction
  Section E - Engine and System Identification
  Section F - Familiarization
  Section TS - Troubleshooting Symptoms Preparatory Steps
  Section TT - Troubleshooting Symptoms (New Format)
  Section DS - Engine Disassembly - Group 00
  Section AS - Engine Assembly - Group 00
  Section 0 - Product - Group 00
  Section 1 - Cylinder Block - Group 01
  (11-022-001_01) Service Tools
 WARNING 
  (11-001-004) Balancer
  (11-001-005) Bearings, Connecting Rod
  (11-001-006-tr) Bearings, Main
  (11-001-007-tr) Bearings, Thrust This component or
  (11-001-008-tr) Camshaft assembly weighs
  (11-001-010-tr) Camshaft Bushings greater than 23 kg [50
  (11-001-012) Camshaft Gear (Camshaft Installed) lb]. To prevent serious
  (11-001-014) Connecting Rod personal injury, be
  (11-001-016-tr) Crankshaft
sure to have
  (11-001-018) Crankshaft Gear, Front (Crankshaft Installed)
  (11-001-022-tr) Crankshaft Pulley
assistance or use
  (11-001-023-tr) Crankshaft Seal, Front appropriate lifting
  (11-001-024-tr) Crankshaft Seal, Rear equipment to lift this
  (11-001-026) Cylinder Block component or
  (11-001-031-tr) Gear Cover, Front assembly.
  (11-001-036-tr) Idler Gear, Camshaft
  (11-001-043) Piston
  (11-001-047) Piston Rings
  (11-001-054-tr) Piston and Connecting Rod Assembly
  (11-001-055) Gear Train Backlash, Front  WARNING 
  (11-001-056-tr) Camshaft Thrust Bearing

  Section 2 - Cylinder Head - Group 02

  Section 3 - Rocker Levers - Group 03
  Section 4 - Cam Followers/Tappets - Group 04
Batteries can emit
explosive gases. To
  Section 5 - Fuel System - Group 05
reduce the possibility
  Section 6 - Injectors and Fuel Lines - Group 06 of personal injury,
  Section 7 - Lubricating Oil System - Group 07 always ventilate the
  Section 8 - Cooling System - Group 08 compartment before
servicing the batteries.
  Section 9 - Drive Units - Group 09
To reduce the
  Section 10 - Air Intake System - Group 10 possibility of arcing,
  Section 11 - Exhaust System - Group 11 remove the negative (-
  Section 13 - Electrical Equipment - Group 13 ) battery cable first and
  Section 14 - Engine Testing - Group 14
attach the negative (-)
battery cable last.
  Section 16 - Mounting Adaptations - Group 16
  Section 17 - Miscellaneous - Group 17
  Section L - Service Literature
  Section V - Specifications

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 WARNING 
  Back

Copyright © 2000-2010 Cummins Inc. All rights reserved

Acid is extremely
dangerous and can
damage the machinery
and can also cause
serious burns. Always
provide a tank of
strong soda water as a
neutralizing agent
when servicing the
batteries. Wear
goggles and protective
clothing to reduce the
possibility of serious
personal injury.

Remove the
drivetrain
components. Refer
to the OEM service
manual.
Disconnect the
battery cables.
Refer to the OEM
service manual.
Remove the
flywheel. Refer to
Procedure 016-005
in Section 16.
Remove the starter
motor. Refer to
Procedure 013-020
in Section 13.

Remove

 WARNING 

This component or
assembly weighs
greater than 23 kg [50

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

lb]. To prevent serious

personal injury, be
sure to have
assistance or use
appropriate lifting
equipment to lift this
component or
assembly.

Remove the 11 mounting

capscrews.

Remove the flywheel

housing.

Remove the rear

crankshaft oil seal from
the flywheel housing.
Refer to Procedure 001-
024 in Section 1.

Clean and Inspect for Reuse

 WARNING 

When using a steam

cleaner, wear
protective clothing, as
well as safety glasses
or a face shield. Hot
steam can cause
serious personal injury.

 WARNING 

When using solvents,

acids, or alkaline
materials for cleaning,
follow the
manufacturer's

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

recommendations for
use. Wear goggles, as
well as protective
clothing, to reduce the
possibility of personal
injury.

 WARNING 

Wear appropriate eye

and face protection
when using
compressed air. Flying
debris and dirt can
cause personal injury.

Use steam or solvent to

clean the flywheel
housing.

Dry with compressed air.

Inspect the flywheel

housing for cracks,
especially in the bolt
pattern area.

Inspect the rear face of

the cylinder block and
flywheel housing
mounting surface for
cleanliness and raised
nicks or burrs.

Use fine crocus cloth to

remove small nicks and
burrs.

Inspect for damaged

threads commonly caused
by cross-threaded
capscrews or installing an
incorrect capscrew.
Helicoils are available to
repair damaged threads.

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

Install

Dry Clutch Applications

NOTE: The sealant
called for in the
following step may
appear different than
what was originally
used to build the
engine.

Install the crankshaft oil

seal into the flywheel
housing. Refer to
Procedure 001-024 in
Section 1.

Apply a 1.5 to 2.0 mm

[0.06 to 0.08 in] wide
bead of sealant, Part
Number 3164070, to the
back side of the flywheel
housing, as illustrated.

NOTE: Install the
flywheel housing within
10 minutes of applying
the sealant or it will not
seal correctly. Once
installed, allow the
sealant to dry for 30
minutes before running
the engine.

NOTE: Make sure the

crankshaft oil seal is
not damaged during
installation.

Lubricate the crankshaft

oil seal with Lubriplate™
105, or equivalent.

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

Install the flywheel

housing over the two
dowel pins.

Tighten the flywheel

housing mounting
capscrews in the
sequence shown in the
illustration.

Torque
Value:  69  n.m  [51 ft-lb]

Wet Clutch Applications

Perform all the steps in

the procedure for the dry
clutch application, in
addition to the following:

Coat the flywheel housing

drain plug with pipe
sealant, Part Number
3375068, or equivalent.

Install the drain plug into

the hole at the bottom of
the flywheel housing.

Tighten the drain plug.

Use the following
procedure for plug sizes
and torque specifications.
Refer to Procedure 017-
007 in Section 17

Apply pipe sealant, Part

Number 3375068, or
equivalent, to the plug
threads.

Install the plug into the

tachometer drive access
hole.

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

Coat the threads of the

mounting capscrews with
Loctite™ 277, or
equivalent.

Install and tighten the

capscrews.

Torque
Value:  69  n.m  [51 ft-lb]

Measure

Bore Alignment

Attach the dial indicator

gauge, Part Number
3376050, or equivalent, to
the crankshaft. The dial
indicator can be mounted
by any method that holds
the extension bar of the
indicator rigid, so it does
not sag. If the bar sags or
the indicator slips, the
readings obtained will not
be accurate.

Position the indicator in the

6-o'clock position, and
zero (0) the gauge.

Slowly rotate the

crankshaft. Record the
readings obtained at the 9-
o'clock, 12-o'clock, and 3-
o'clock positions as [a], [b],
and [c]. Check zero (0) at
the 6-o'clock position
again.

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

The values for (a), (b), and

(c) can be positive or
negative. Refer to the
accompanying illustration
to determine the correct
sign when recording these
values.

 CAUTION 

Do not force the

crankshaft beyond the
point where the bearing
clearance has been
removed. Do not pry
against the flywheel
housing. Failure to do so
can cause false bearing
clearance readings.

Rotate the crankshaft until

the dial indicator is at the
12-o'clock position and
zero (0) the gauge.

Using a pry bar, raise the

rear of the crankshaft to its
upper limit. Record the
value as (d). This is the
vertical bearing clearance
adjustment and will always
be positive.

 
Determine the values for the
“total vertical” and “total
horizontal” values.

The total horizontal is equal

to the 9-o'clock reading (a),
minus the three-o'clock
reading (c).

The total vertical is equal to

the 12-o'clock reading (b),
plus the bearing clearance
(d).

Example:

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

6-o'clock = ref = 0

9-o'clock = (a) = 0.004

12-o'clock = (b) = 0.003

3-o'clock = (c) = -0.002

The total horizontal value

equals 0.006 and the total
vertical value equals 0.005.

Mark the total horizontal

value on the horizontal side
of the chart and the total
vertical on the vertical side
of the chart.

Using a straightedge, find

the intersection point of the
total horizontal and total
vertical values. The
intersection point must fall
within the shaded area for
the flywheel housing
concentricity to be within
specification.

Using the total horizontal

and total vertical values
from the previous example,
the intersection point falls
within the shaded area.
Therefore, the flywheel
housing concentricity is
within specification.

If the intersection point

falls outside the shaded
area, the ring dowels must
be removed and the
housing repositioned.

The ring dowels are not

required to maintain
concentricity of the
housing; the clamping
force of the capscrews
holds the housing in place.

After the ring dowels are

discarded, install the
flywheel housing on the

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

engine.

To position the housing,

tighten the capscrews
enough to hold the
flywheel housing in place,
but loose enough to allow
small movement when
struck lightly with a mallet.

Check the concentricity

again. When the
concentricity is within
specification, tighten the
capscrews to the specified
torque value.

Measurements
  mm in
Flywheel
Housing
0.35 0.014
Bore
Alignment

Face Alignment

 CAUTION 

The dial indicator tip

must not enter the
capscrew holes, or the
gauge will be damaged.

Install the dial indicator

gauge, Part Number
3376050, or equivalent, as
illustrated.

NOTE: The extension bar

for the indicator must be
rigid for an accurate
reading. It must not sag.
Position the indicator at
the 12-o'clock position.
Adjust the dial until the
needle points to zero (0).

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

NOTE: The crankshaft
must be pushed toward
the front of the engine to
remove the crankshaft
end clearance each time
a position is measured.

Slowly rotate the

crankshaft.

Record the readings at the

3-o'clock, 6-o'clock, and 9-
o'clock positions.

Continue to rotate the

crankshaft until the
indicator is at the 12-
o'clock position. Check the
indicator to make sure the
needle points to zero (0). If
it does not, the readings
will be incorrect.

Determine the total

indicator reading (TIR).

Example: mm in
12 o'clock 0.00 0.000
3 o'clock +0.08 +0.003
6 o'clock -0.05 -0.002
9 o'clock +0.08 +0.003
Equals
0.13 0.005
TIR

The maximum allowable

total indicator reading
(TIR) is determined by the
diameter of the housing
bore. If out of
specifications, replace the
housing.

Measurements

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

  mm in
Flywheel
Housing
0.30 0.012
Face
Alignment

Finishing Steps

 WARNING 

This component or
assembly weighs
greater than 23 kg [50
lb]. To prevent serious
personal injury, be
sure to have
assistance or use
appropriate lifting
equipment to lift this
component or
assembly.

 WARNING 

Batteries can emit

explosive gases. To
reduce the possibility
of personal injury,
always ventilate the
compartment before
servicing the batteries.
To reduce the
possibility of arcing,
remove the negative (-
) battery cable first and
attach the negative (-)
battery cable last.

Install the starter

motor. Refer to
Procedure 013-020

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

in Section 13.
Install the flywheel.
Refer to Procedure
016-005 in Section
16.
Connect the battery
cables. Refer to the
OEM service
manual.
Install the drivetrain
components. Refer
to the OEM service
manual.
Operate the engine
and check for leaks.

Last Modified:  14-Nov-2011

Copyright © 2000-2010  Cummins Inc.  All rights reserved.

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 (4021540) B3.3 and QSB3.3 Service Manual

Search Manual     Search

Manual Change History

Help With Printing 016-005   Flywheel

  Front
  Section i - Introduction
  Section E - Engine and System Identification
  Section F - Familiarization
  Section TS - Troubleshooting Symptoms
Install
  Section TT - Troubleshooting Symptoms (New Format)
  Section DS - Engine Disassembly - Group 00
  Section AS - Engine Assembly - Group 00
  (11-004-015-shopas) Tappet
Install the guide pins, Part Number
  (11-001-007-shopas) Bearings, Thrust 3376696, or equivalent, into the
  (11-001-016-shopas) Crankshaft empty capscrew holes 180
  (11-001-006-shopas) Bearings, Main degrees apart.
  (11-001-054-shopas) Piston and Connecting Rod Assembly
  (11-001-010-shopas) Camshaft Bushings Determine the capscrew thread
  (11-001-056-shopas) Camshaft Thrust Bearing design and size, and install two T-
  (11-001-008-shopas) Camshaft handles in the flywheel 180
  (11-001-036-shopas) Idler Gear, Camshaft degrees apart on a horizontal
  (11-001-024-shopas) Crankshaft Seal, Rear
plane.
  (11-016-006-shopas) Flywheel Housing
  (11-016-005-shopas) Flywheel
Install the coupling, retaining
  (11-007-031-shopas) Lubricating Oil Pump
  (11-001-023-shopas) Crankshaft Seal, Front
plate, and flywheel.
  (11-001-031-shopas) Gear Cover, Front
  (11-001-022-shopas) Crankshaft Pulley Coat all capscrews with clean
  (11-007-035-shopas) Lubricating Oil Suction Tube (Block-Mounted) lubricating engine oil.
  (11-007-025-shopas) Lubricating Oil Pan
  (11-009-021-shopas) PTO, Front Install four of the six mounting
  (11-002-004-shopas) Cylinder Head capscrews into the flywheel. Hand
  (11-004-014-shopas) Push Rods or Tubes tighten.
  (11-003-009-shopas) Rocker Lever Assembly
  (11-003-004-shopas) Overhead Set Remove the guide pins and install
  (11-003-011-shopas) Rocker Lever Cover the remaining two mounting
  (11-008-023-shopas) Engine Coolant Heater
capscrews. Hand tighten.
  (11-010-023-shopas) Air Intake Manifold
  (11-003-018-shopas) Crankcase Breather Tube
  (11-005-014-shopas) Fuel Injection Pump, Rotary
  (11-005-012-shopas) Fuel Injection Pumps, In-Line
  (11-005-016-shopas) Fuel Pump
  (11-005-043-shopas) Fuel Shutoff Valve
  (11-006-026-shopas) Injector Tighten the mounting capscrews
  (11-006-060-shopas) Fuel Rail in the sequence shown in the
  (11-006-061-shopas) Fuel Pressure Relief Valve illustration.
  (11-006-013-shopas) Fuel Drain Lines
  (11-006-051-shopas) Injector Supply Lines (High Pressure)
  (11-010-072-shopas) Air Intake Manifold Heater Torque 108 n.m   [80 ft-
Step 1
  (11-006-024-shopas) Fuel Supply Lines Value: lb]
  (11-011-007-shopas) Exhaust Manifold, Dry
191 n.m   [141 ft-
  (11-010-033-shopas) Turbocharger   Step 2
  (11-010-043-shopas) Turbocharger Exhaust Outlet lb]
  (11-010-045-shopas) Turbocharger Oil Drain Line
  (11-010-046-shopas) Turbocharger Oil Supply Line
  (11-010-080-shopas) Air Intake Connection
  (11-010-019-shopas) Air Crossover
  (11-008-062-shopas) Water Pump
  (11-008-013-shopas) Coolant Thermostat
  (11-008-014-shopas) Coolant Thermostat Housing
Last Modified:  12-Apr-2006
  (11-007-011-shopas) Lubricating Oil Dipstick Tube
  (11-013-003-shopas) Alternator Bracket
  (11-013-001-shopas) Alternator Copyright © 2000-2010  Cummins Inc.  All rights reserved.
  (11-008-089-shopas) Fan Pulley
  (11-008-040-shopas) Fan, Cooling

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  (11-008-002-shopas) Drive Belt, Cooling Fan

  (11-007-003-shopas) Lubricating Oil Cooler
  (11-007-013-shopas) Lubricating Oil Filter (Spin-On)
  (11-006-017-shopas) Fuel Filter Head
  (11-006-015-shopas) Fuel Filter (Spin-On Type)
  (11-013-020-shopas) Starting Motor
  (11-008-018-shopas) Cooling System
  (11-007-037-shopas) Lubricating Oil System

  Section 0 - Product - Group 00

  Section 1 - Cylinder Block - Group 01
  Section 2 - Cylinder Head - Group 02
  Section 3 - Rocker Levers - Group 03
  Section 4 - Cam Followers/Tappets - Group 04
  Section 5 - Fuel System - Group 05
  Section 6 - Injectors and Fuel Lines - Group 06
  Section 7 - Lubricating Oil System - Group 07
  Section 8 - Cooling System - Group 08
  Section 9 - Drive Units - Group 09
  Section 10 - Air Intake System - Group 10
  Section 11 - Exhaust System - Group 11
  Section 13 - Electrical Equipment - Group 13
  Section 14 - Engine Testing - Group 14
  Section 16 - Mounting Adaptations - Group 16
  Section 17 - Miscellaneous - Group 17
  Section L - Service Literature
  Section V - Specifications
  Back

Copyright © 2000-2010 Cummins Inc. All rights reserved

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 (4021540) B3.3 and QSB3.3 Service Manual

Search Manual     Search

Manual Change History

Help With Printing 002-004   Cylinder Head

  Front
  Section i - Introduction
  Section E - Engine and System Identification
  Section F - Familiarization
  Section TS - Troubleshooting Symptoms
Preparatory Steps
  Section TT - Troubleshooting Symptoms (New Format)
  Section DS - Engine Disassembly - Group 00
  Section AS - Engine Assembly - Group 00
  Section 0 - Product - Group 00
  Section 1 - Cylinder Block - Group 01
  (11-022-001_01) Service Tools
 WARNING 
  (11-001-004) Balancer
  (11-001-005) Bearings, Connecting Rod
  (11-001-006-tr) Bearings, Main
  (11-001-007-tr) Bearings, Thrust To reduce the
  (11-001-008-tr) Camshaft possibility of personal
  (11-001-010-tr) Camshaft Bushings injury, avoid direct
  (11-001-012) Camshaft Gear (Camshaft Installed) contact of hot oil with
  (11-001-014) Connecting Rod your skin.
  (11-001-016-tr) Crankshaft
  (11-001-018) Crankshaft Gear, Front (Crankshaft Installed)
  (11-001-022-tr) Crankshaft Pulley
  (11-001-023-tr) Crankshaft Seal, Front
  (11-001-024-tr) Crankshaft Seal, Rear
  (11-001-026) Cylinder Block
 WARNING 
  (11-001-031-tr) Gear Cover, Front
  (11-001-036-tr) Idler Gear, Camshaft
  (11-001-043) Piston
  (11-001-047) Piston Rings Some state and
  (11-001-054-tr) Piston and Connecting Rod Assembly federal agencies have
  (11-001-055) Gear Train Backlash, Front determined that used
  (11-001-056-tr) Camshaft Thrust Bearing
engine oil can be
  Section 2 - Cylinder Head - Group 02 carcinogenic and
  (11-022-001_02) Service Tools cause reproductive
  (11-002-004-tr) Cylinder Head toxicity. Avoid
inhalation of vapors,
  Section 3 - Rocker Levers - Group 03
ingestion, and
  Section 4 - Cam Followers/Tappets - Group 04
prolonged contact
  Section 5 - Fuel System - Group 05 with used engine oil. If
  Section 6 - Injectors and Fuel Lines - Group 06 not reused, dispose of
  Section 7 - Lubricating Oil System - Group 07 in accordance with
local environmental
  Section 8 - Cooling System - Group 08
regulations.
  Section 9 - Drive Units - Group 09
  Section 10 - Air Intake System - Group 10
  Section 11 - Exhaust System - Group 11
  Section 13 - Electrical Equipment - Group 13  WARNING 
  Section 14 - Engine Testing - Group 14
  Section 16 - Mounting Adaptations - Group 16

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  Section 17 - Miscellaneous - Group 17

Do not remove the
  Section L - Service Literature
pressure cap from a
  Section V - Specifications hot engine. Wait until
  Back the coolant
temperature is below
Copyright © 2000-2010 Cummins Inc. All rights reserved 50°C [120°F] before
removing the
pressure cap. Heated
coolant spray or
steam can cause
personal injury.

 WARNING 

Coolant is toxic. Keep

away from children
and pets. If not
reused, dispose of in
accordance with local
environmental
regulations.

Drain the
lubricating engine
oil. Refer to
Procedure 007-037
in Section 7.
Drain the engine
coolant. Refer to
Procedure 008-018
in Section 8.
Remove the
cooling fan. Refer
to Procedure 008-
040 in Section 8.
Remove the fan
pulley. Refer to
Procedure 008-089
in Section 8.
Remove the
alternator. Refer to
Procedure 013-001
in Section 13.
Remove the
alternator bracket.
Refer to Procedure
013-003 in Section
13.
Remove the
coolant thermostat.
Refer to Procedure
008-013 in Section
8.
Remove the water

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pump. Refer to
Procedure 008-062
in Section 8.
Remove air inlet
connection. Refer
to Procedure 010-
022 in Section 10.
Remove the
turbocharger oil
supply line. Refer
to Procedure 010-
046 in Section 10.
Remove the
turbocharger drain
line. Refer to
Procedure 010-045
in Section 10.
Remove the
turbocharger inlet
connection. Refer
to Procedure 010-
044 in Section 10.
Remove the
turbocharger.
Refer to Procedure
010-033 in Section
10.
Remove the
exhaust manifold.
Refer to Procedure
011-007 in Section
11.
Remove the fuel
drain lines. Refer
to Procedure 006-
013 in Section 6.
Remove the high-
pressure fuel lines.
Refer to Procedure
006-051 in Section
6.
Remove the
injectors. Refer to
Procedure 006-026
in Section 6.
Remove the rocker
lever cover. Refer
to Procedure 003-
011 in Section 3.
Remove the rocker
lever assembly.
Refer to Procedure
003-009 in Section
3.
Remove the
pushrods/tubes.
Refer to Procedure
004-014 in Section
4.

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Remove

 WARNING 

This component
weighs 23 kg [50 lb]
or more. To reduce
the possibility of
personal injury, use a
hoist or get
assistance to lift this
component.

Remove the mounting

capscrews, cylinder
head assembly, and
gasket.

Discard the gasket.

Disassemble

Use a valve spring

compressor, Part
Number 3163292, or
equivalent, to compress
the valve spring(s), and
remove the valve collets.

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Loosen the spring and

remove the spring seat
and valve spring.

NOTE: When removing
the valve(s), mark them
in the location where
the valve was installed.
This will aid in the
assembly procedure.

Raise the cylinder head

and remove the valve.

Clean and Inspect for Reuse

 WARNING 

Wear appropriate eye

and face protection
when using
compressed air.
Flying debris and dirt
can cause personal
injury.

Inspect the area within

1/8-inch of the firing ring
diameter. Any wear that
can be felt with a
fingernail within the 1/8-
inch area is

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unacceptable, making
the cylinder head not
reusable. Wear beyond
this 1/8-inch area will
have no effect on future
combustion sealing and
the usability of the
cylinder head.

Clean carbon deposits

from the valve pockets
with a high quality steel
wire wheel installed in a
drill or a die grinder.

NOTE: An inferior
quality wire wheel will
lose steel bristles
during operation,
causing additional
contamination.

Wash the cylinder head

in a hot, soapy water
solution.

After rinsing, use

compressed air to dry
the cylinder head.

 WARNING 

When using solvents,

acids, or alkaline
materials for cleaning,
follow the
manufacturer's
recommendations for
use. Wear goggles
and protective
clothing to reduce the
possibility of personal
injury.

 CAUTION 

Do not use caustic or

acidic solutions to

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clean the cylinder

head capscrews. Use
of this type of solvent
can cause corrosion
to the capscrews.

Use a petroleum-based
solvent to clean the
capscrews.

Clean the capscrew

thoroughly with a wire
brush or a soft wire
wheel, or use a non-
abrasive bead blast to
remove deposits from
the shank and the
threads.

 
Inspect the cylinder head
for cracks.

If a crack is found, and the

crack does not extend into
the valve seat, the cylinder
head can be used again.

Measure the cylinder

head for surface flatness
(1).

Cylinder Head Flatness

(warping limit)

mm in
0.00 MIN 0.00
0.05 MAX 0.002

The maximum repair

limit on the cylinder head
is 0.30 mm [0.012 in].

Cylinder Head Capscrews

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

Inspect the cylinder head

capscrews for damaged
threads, corroded
surfaces, or a reduced
diameter (due to
capscrew stretching).

 
Do not use the cylinder
head capscrews again
under the following
conditions:

Corrosion or pitting
that exceeds 1 sq.
cm [0.155 sq. in] in
area
10 mm [3/8 in] x 10
mm [3/8 in] is an
acceptable area
13 mm [1/2 in] x 13
mm [1/2 in] is not an
acceptable area
Corrosion or pitting
that exceeds 0.12
mm [0.005 in] in
depth.

 
Corrosion or pitting is
located with 3.2 mm
[1/8 in] of the fillet
Corrosion or pitting is
located within 3.2
mm [1/8 in] of the
threads
Stretched beyond
“free length”
maximum. Reference
the following steps
for capscrew lengths.

If the capscrews are not

damaged, they can be
used again throughout
the life of the engine

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

unless the specified “free

length” is exceeded.

To check the capscrew

“free length”, place the
head of the capscrew in
the appropriate slot with
the flange against the
base of the slot. Refer to
the manufacturer's
specifications for the
correct size of the
cylinder head
capscrews.

 
If the end of the capscrew
touches the foot of the
gauge, the capscrew is too
long and must be
discarded and replaced.

Immediately after
cleaning and inspecting
the capscrew. Apply a
film of clean lubricating
engine oil to all
capscrews that are to be
used again.

Assemble

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Coat the stems of the

intake and exhaust valves
and the inside of the
valve guides with clean
lubricating engine oil.

Install the valve spring

and spring seat on the
valve stem.

Install the valve collet

onto the valve stem
groove while compressing
the valve spring with the
valve spring compressor,
Part Number 3163292, or
equivalent.

After releasing the valve

spring, tap the top of the
valve stem with a plastic
hammer to make sure the
valve cotter is completely
seated.

Measure the cylinder

head valve seat recession
(2).

Valve Seat Specifications

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

mm in
Intake 1.00 NOM 0.039
± ±
0.100 0.004
Exhaust 0.90 NOM 0.035
± ±
0.100 0.004

Repair limit on the intake

valve seat is 2.00 mm
0.079 in].

Repair limit on the

exhaust valve seat is 1.90
mm 0.075 in].

Valve seat angle (4) is 45

degrees with a tolerance
of ± 0° 15'. Repair limit
condition is judged by
vacuum test.

Measure the injector

nozzle protrusion (3) on
the cylinder head.

Injector Nozzle Protrusion

mm in
2.84 MIN 0.112
3.40 MAX 0.133

The tolerance allowance

on the nozzle protrusion
is 2.700 to 3.500 mm
[0.106 to 0.138 in].

Install

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 CAUTION 

Remove all carbon

and dirt from the
contact surfaces of
the cylinder block and
cylinder head.
Remove all burrs and
debris from the
cylinder block. Failure
to do so can result in
severe engine
damage.

Install a new cylinder

head gasket with the
“TOP” mark facing up.

 WARNING 

This component
weighs 23 kg [50 lb]
or more. To reduce
the possibility of
personal injury, use a
hoist or get
assistance to lift this
component.

Coat the capscrew(s)

threads with antiseize
compound, Part Number
3824879, or equivalent.

Install the cylinder head

using four head
capscrews as guides.

NOTE: The cylinder
head capscrews can be
used up to five times.
Make a punch mark on
the capscrew head

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each time the capscrew

is used. If there are
already five marks on
the capscrew head, the
capscrew must be
replaced.

Install the capscrews.

Tighten the capscrews in
the sequence shown.

Torque Value:

1. 69 n.m    [51 ft-lb]
2. 108 n.m    [80 ft-
lb]
3. Rotate 90
degrees

Finishing Steps

Install the
pushrods/tubes.
Refer to Procedure
004-014 in Section
4.
Install the rocker
lever assembly.
Refer to Procedure
003-009 in Section
3.
Install the rocker
lever cover. Refer
to Procedure 003-
011 in Section 3.
Install the injectors.
Refer to Procedure
006-026 in Section
6.
Install the high-
pressure fuel lines.
Refer to Procedure
006-051 in Section

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QuickServe Online | (4021540) B3.3 and QSB3.3 Service Manual

6.
Install the fuel drain
lines. Refer to
Procedure 006-013
in Section 6.
Install the exhaust
manifold. Refer to
Procedure 011-007
in Section 11.
Install the
turbocharger.
Refer to Procedure
010-033 in Section
10.
Install the
turbocharger inlet
connection. Refer
to Procedure 010-
044 in Section 10.
Install the
turbocharger oil
drain line. Refer to
Procedure 010-045
in Section 10.
Install the
turbocharger oil
supply line. Refer
to Procedure 010-
046 in Section 10.
Install the air inlet
connection. Refer
to Procedure 010-
022 in Section 10.
Install the water
pump. Refer to
Procedure 008-062
in Section 8.
Install the coolant
thermostat. Refer
to Procedure 008-
013 in Section 8.
Install the
alternator bracket.
Refer to Procedure
013-003 in Section
13.
Install the
alternator. Refer to
Procedure 013-001
in Section 13.
Install the fan
pulley. Refer to
Procedure 008-089
in Section 8.
Install the cooling
fan. Refer to
Procedure 008-040
in Section 8.
Fill the engine with

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coolant. Refer to
Procedure 008-018
in Section 8.
Fill the engine with
lubricating engine
oil. Refer to
Procedure 007-037
in Section 7.
Operate the engine
and check for
leaks.

Last Modified:  03-Jan-2012

Copyright © 2000-2010  Cummins Inc.  All rights reserved.

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 (4021540) B3.3 and QSB3.3 Service Manual

Search Manual     Search

Manual Change History

Help With Printing 002-004   Cylinder Head

  Front
  Section i - Introduction
  Section E - Engine and System Identification
  Section F - Familiarization
  Section TS - Troubleshooting Symptoms Install
  Section TT - Troubleshooting Symptoms (New Format)
  Section DS - Engine Disassembly - Group 00
  Section AS - Engine Assembly - Group 00
  (11-004-015-shopas) Tappet  CAUTION 
  (11-001-007-shopas) Bearings, Thrust
  (11-001-016-shopas) Crankshaft
  (11-001-006-shopas) Bearings, Main
  (11-001-054-shopas) Piston and Connecting Rod Assembly
  (11-001-010-shopas) Camshaft Bushings Remove all carbon and
  (11-001-056-shopas) Camshaft Thrust Bearing dirt from the contact
  (11-001-008-shopas) Camshaft surfaces of the cylinder
  (11-001-036-shopas) Idler Gear, Camshaft
block and cylinder
  (11-001-024-shopas) Crankshaft Seal, Rear
  (11-016-006-shopas) Flywheel Housing
head. Remove all burrs
  (11-016-005-shopas) Flywheel and debris from the
  (11-007-031-shopas) Lubricating Oil Pump cylinder block. Failure
  (11-001-023-shopas) Crankshaft Seal, Front to do so can result in
  (11-001-031-shopas) Gear Cover, Front severe engine damage.
  (11-001-022-shopas) Crankshaft Pulley
  (11-007-035-shopas) Lubricating Oil Suction Tube (Block-Mounted)
Install a new cylinder head
  (11-007-025-shopas) Lubricating Oil Pan
  (11-009-021-shopas) PTO, Front
gasket with the “TOP”
  (11-002-004-shopas) Cylinder Head mark facing up.
  (11-004-014-shopas) Push Rods or Tubes
  (11-003-009-shopas) Rocker Lever Assembly
  (11-003-004-shopas) Overhead Set
  (11-003-011-shopas) Rocker Lever Cover
  (11-008-023-shopas) Engine Coolant Heater
  (11-010-023-shopas) Air Intake Manifold
  (11-003-018-shopas) Crankcase Breather Tube  WARNING 
  (11-005-014-shopas) Fuel Injection Pump, Rotary
  (11-005-012-shopas) Fuel Injection Pumps, In-Line
  (11-005-016-shopas) Fuel Pump
  (11-005-043-shopas) Fuel Shutoff Valve
  (11-006-026-shopas) Injector
This component weighs
  (11-006-060-shopas) Fuel Rail 23 kg [50 lb] or more.
  (11-006-061-shopas) Fuel Pressure Relief Valve To reduce the
  (11-006-013-shopas) Fuel Drain Lines possibility of personal
  (11-006-051-shopas) Injector Supply Lines (High Pressure) injury, use a hoist or get
  (11-010-072-shopas) Air Intake Manifold Heater assistance to lift this
  (11-006-024-shopas) Fuel Supply Lines component.
  (11-011-007-shopas) Exhaust Manifold, Dry
  (11-010-033-shopas) Turbocharger
  (11-010-043-shopas) Turbocharger Exhaust Outlet Coat the capscrew(s)
  (11-010-045-shopas) Turbocharger Oil Drain Line threads with antiseize
  (11-010-046-shopas) Turbocharger Oil Supply Line compound, Part Number
  (11-010-080-shopas) Air Intake Connection 3824879, or equivalent.
  (11-010-019-shopas) Air Crossover
  (11-008-062-shopas) Water Pump Install the cylinder head
  (11-008-013-shopas) Coolant Thermostat using four head capscrews

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  (11-008-014-shopas) Coolant Thermostat Housing

as guides.
  (11-007-011-shopas) Lubricating Oil Dipstick Tube
  (11-013-003-shopas) Alternator Bracket
  (11-013-001-shopas) Alternator
  (11-008-089-shopas) Fan Pulley
  (11-008-040-shopas) Fan, Cooling
  (11-008-002-shopas) Drive Belt, Cooling Fan
  (11-007-003-shopas) Lubricating Oil Cooler NOTE: The cylinder head
  (11-007-013-shopas) Lubricating Oil Filter (Spin-On)
capscrews can be used
  (11-006-017-shopas) Fuel Filter Head
  (11-006-015-shopas) Fuel Filter (Spin-On Type)
up to five times. Make a
  (11-013-020-shopas) Starting Motor punch mark on the
  (11-008-018-shopas) Cooling System capscrew head each
  (11-007-037-shopas) Lubricating Oil System time the capscrew is
used. If there are already
  Section 0 - Product - Group 00
five marks on the
  Section 1 - Cylinder Block - Group 01
capscrew head, the
  Section 2 - Cylinder Head - Group 02 capscrew must be
  Section 3 - Rocker Levers - Group 03 replaced.
  Section 4 - Cam Followers/Tappets - Group 04
  Section 5 - Fuel System - Group 05
Install the capscrews.
Tighten the capscrews in
  Section 6 - Injectors and Fuel Lines - Group 06
the sequence shown.
  Section 7 - Lubricating Oil System - Group 07
  Section 8 - Cooling System - Group 08 Torque Value:
  Section 9 - Drive Units - Group 09
1. 69 n.m    [51 ft-lb]
  Section 10 - Air Intake System - Group 10 2. 108 n.m    [80 ft-lb]
  Section 11 - Exhaust System - Group 11 3. Rotate 90 degrees
  Section 13 - Electrical Equipment - Group 13
  Section 14 - Engine Testing - Group 14
  Section 16 - Mounting Adaptations - Group 16
  Section 17 - Miscellaneous - Group 17
  Section L - Service Literature
Last Modified:  03-Jan-2012
  Section V - Specifications
  Back Copyright © 2000-2010  Cummins Inc.  All rights reserved.

Copyright © 2000-2010 Cummins Inc. All rights reserved

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