002-004 cylinder head - wfservices.bizwfservices.biz/manuals/cummins isb cylinder head.pdf · do...
TRANSCRIPT
002-004 Cylinder Head
Preparatory Steps
Remove
Clean and Inspect for Reuse
Pressure Test
Install
Finishing Steps
Preparatory Steps
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
WARNING
Coolant is toxic Keep away from children and pets If not reused dispose of in accordance
SMALL | MEDIUM | LARGE
Next
with local environmental regulations
WARNING
Wait until the temperature is below 50degC [120degF] to avoid personal injury from hot coolant
Disconnect the batteries Refer to the OEM service manual
Drain the coolant Refer to Procedure 008-018 in Section 8
Remove all water and heater hoses Refer to Procedure 008-045 in Section 8
Remove
Remove the turbocharger Refer to Procedure 010-033 in Section 10
Remove the exhaust manifold Refer to Procedure 011-007 in Section 11
SMALL | MEDIUM | LARGE
Previous Next
Remove the rocker lever cover and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Remove the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Disconnect the high-pressure fuel lines from the cylinder head Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel connector tubes Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
NOTE Make sure the manifold cover is in proper orientation for installation
Remove the intake manifold cover Refer to Procedure 010-023 in Section 10
Remove the intake heater (if equipped) Refer to Procedure 010-029 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
NOTE Removal is easier if the crankshaft pulley is loosened before removing the belt
Remove the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner bracket Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Omit this step if the fan bracket is not attached to the cylinder head
Remove the fan hub assembly Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Loosen the alternator link mounting bolt and water inlet connection capscrews
Remove the alternator bracket mounting capscrews and pivot the alternator away from the engine Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the thermostat housing assembly and bracket from the engine Refer to Procedure 008-013 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the cylinder head capscrews in the sequence shown
SMALL | MEDIUM | LARGE
Previous Next
WARNING
The component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Remove the cylinder head and the
SMALL | MEDIUM | LARGE
Previous Next
cylinder head gasket from the cylinder block
Clean and Inspect for Reuse
Use an injector bore brush Part Number 3822509 or equivalent to clean the carbon from the injector nozzle seat
SMALL | MEDIUM | LARGE
Previous Next
Scrape the gasket material from all gasket surfaces on the head
SMALL | MEDIUM | LARGE
Previous Next
Disassemble the cylinder head Refer to
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
with local environmental regulations
WARNING
Wait until the temperature is below 50degC [120degF] to avoid personal injury from hot coolant
Disconnect the batteries Refer to the OEM service manual
Drain the coolant Refer to Procedure 008-018 in Section 8
Remove all water and heater hoses Refer to Procedure 008-045 in Section 8
Remove
Remove the turbocharger Refer to Procedure 010-033 in Section 10
Remove the exhaust manifold Refer to Procedure 011-007 in Section 11
SMALL | MEDIUM | LARGE
Previous Next
Remove the rocker lever cover and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Remove the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Disconnect the high-pressure fuel lines from the cylinder head Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel connector tubes Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
NOTE Make sure the manifold cover is in proper orientation for installation
Remove the intake manifold cover Refer to Procedure 010-023 in Section 10
Remove the intake heater (if equipped) Refer to Procedure 010-029 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
NOTE Removal is easier if the crankshaft pulley is loosened before removing the belt
Remove the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner bracket Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Omit this step if the fan bracket is not attached to the cylinder head
Remove the fan hub assembly Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Loosen the alternator link mounting bolt and water inlet connection capscrews
Remove the alternator bracket mounting capscrews and pivot the alternator away from the engine Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the thermostat housing assembly and bracket from the engine Refer to Procedure 008-013 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the cylinder head capscrews in the sequence shown
SMALL | MEDIUM | LARGE
Previous Next
WARNING
The component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Remove the cylinder head and the
SMALL | MEDIUM | LARGE
Previous Next
cylinder head gasket from the cylinder block
Clean and Inspect for Reuse
Use an injector bore brush Part Number 3822509 or equivalent to clean the carbon from the injector nozzle seat
SMALL | MEDIUM | LARGE
Previous Next
Scrape the gasket material from all gasket surfaces on the head
SMALL | MEDIUM | LARGE
Previous Next
Disassemble the cylinder head Refer to
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Remove the rocker lever cover and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Remove the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Disconnect the high-pressure fuel lines from the cylinder head Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel connector tubes Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
NOTE Make sure the manifold cover is in proper orientation for installation
Remove the intake manifold cover Refer to Procedure 010-023 in Section 10
Remove the intake heater (if equipped) Refer to Procedure 010-029 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
NOTE Removal is easier if the crankshaft pulley is loosened before removing the belt
Remove the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner bracket Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Omit this step if the fan bracket is not attached to the cylinder head
Remove the fan hub assembly Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Loosen the alternator link mounting bolt and water inlet connection capscrews
Remove the alternator bracket mounting capscrews and pivot the alternator away from the engine Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the thermostat housing assembly and bracket from the engine Refer to Procedure 008-013 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the cylinder head capscrews in the sequence shown
SMALL | MEDIUM | LARGE
Previous Next
WARNING
The component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Remove the cylinder head and the
SMALL | MEDIUM | LARGE
Previous Next
cylinder head gasket from the cylinder block
Clean and Inspect for Reuse
Use an injector bore brush Part Number 3822509 or equivalent to clean the carbon from the injector nozzle seat
SMALL | MEDIUM | LARGE
Previous Next
Scrape the gasket material from all gasket surfaces on the head
SMALL | MEDIUM | LARGE
Previous Next
Disassemble the cylinder head Refer to
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Previous Next
Remove the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Disconnect the high-pressure fuel lines from the cylinder head Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the fuel connector tubes Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
NOTE Make sure the manifold cover is in proper orientation for installation
Remove the intake manifold cover Refer to Procedure 010-023 in Section 10
Remove the intake heater (if equipped) Refer to Procedure 010-029 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
NOTE Removal is easier if the crankshaft pulley is loosened before removing the belt
Remove the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner bracket Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Omit this step if the fan bracket is not attached to the cylinder head
Remove the fan hub assembly Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Loosen the alternator link mounting bolt and water inlet connection capscrews
Remove the alternator bracket mounting capscrews and pivot the alternator away from the engine Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the thermostat housing assembly and bracket from the engine Refer to Procedure 008-013 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the cylinder head capscrews in the sequence shown
SMALL | MEDIUM | LARGE
Previous Next
WARNING
The component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Remove the cylinder head and the
SMALL | MEDIUM | LARGE
Previous Next
cylinder head gasket from the cylinder block
Clean and Inspect for Reuse
Use an injector bore brush Part Number 3822509 or equivalent to clean the carbon from the injector nozzle seat
SMALL | MEDIUM | LARGE
Previous Next
Scrape the gasket material from all gasket surfaces on the head
SMALL | MEDIUM | LARGE
Previous Next
Disassemble the cylinder head Refer to
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Remove the fuel connector tubes Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Remove the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
NOTE Make sure the manifold cover is in proper orientation for installation
Remove the intake manifold cover Refer to Procedure 010-023 in Section 10
Remove the intake heater (if equipped) Refer to Procedure 010-029 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
NOTE Removal is easier if the crankshaft pulley is loosened before removing the belt
Remove the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner bracket Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Omit this step if the fan bracket is not attached to the cylinder head
Remove the fan hub assembly Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Loosen the alternator link mounting bolt and water inlet connection capscrews
Remove the alternator bracket mounting capscrews and pivot the alternator away from the engine Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the thermostat housing assembly and bracket from the engine Refer to Procedure 008-013 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the cylinder head capscrews in the sequence shown
SMALL | MEDIUM | LARGE
Previous Next
WARNING
The component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Remove the cylinder head and the
SMALL | MEDIUM | LARGE
Previous Next
cylinder head gasket from the cylinder block
Clean and Inspect for Reuse
Use an injector bore brush Part Number 3822509 or equivalent to clean the carbon from the injector nozzle seat
SMALL | MEDIUM | LARGE
Previous Next
Scrape the gasket material from all gasket surfaces on the head
SMALL | MEDIUM | LARGE
Previous Next
Disassemble the cylinder head Refer to
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
NOTE Removal is easier if the crankshaft pulley is loosened before removing the belt
Remove the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the belt tensioner bracket Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Omit this step if the fan bracket is not attached to the cylinder head
Remove the fan hub assembly Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Loosen the alternator link mounting bolt and water inlet connection capscrews
Remove the alternator bracket mounting capscrews and pivot the alternator away from the engine Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the thermostat housing assembly and bracket from the engine Refer to Procedure 008-013 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the cylinder head capscrews in the sequence shown
SMALL | MEDIUM | LARGE
Previous Next
WARNING
The component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Remove the cylinder head and the
SMALL | MEDIUM | LARGE
Previous Next
cylinder head gasket from the cylinder block
Clean and Inspect for Reuse
Use an injector bore brush Part Number 3822509 or equivalent to clean the carbon from the injector nozzle seat
SMALL | MEDIUM | LARGE
Previous Next
Scrape the gasket material from all gasket surfaces on the head
SMALL | MEDIUM | LARGE
Previous Next
Disassemble the cylinder head Refer to
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Previous Next
NOTE Omit this step if the fan bracket is not attached to the cylinder head
Remove the fan hub assembly Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Loosen the alternator link mounting bolt and water inlet connection capscrews
Remove the alternator bracket mounting capscrews and pivot the alternator away from the engine Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Remove the thermostat housing assembly and bracket from the engine Refer to Procedure 008-013 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the cylinder head capscrews in the sequence shown
SMALL | MEDIUM | LARGE
Previous Next
WARNING
The component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Remove the cylinder head and the
SMALL | MEDIUM | LARGE
Previous Next
cylinder head gasket from the cylinder block
Clean and Inspect for Reuse
Use an injector bore brush Part Number 3822509 or equivalent to clean the carbon from the injector nozzle seat
SMALL | MEDIUM | LARGE
Previous Next
Scrape the gasket material from all gasket surfaces on the head
SMALL | MEDIUM | LARGE
Previous Next
Disassemble the cylinder head Refer to
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Remove the thermostat housing assembly and bracket from the engine Refer to Procedure 008-013 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Remove the cylinder head capscrews in the sequence shown
SMALL | MEDIUM | LARGE
Previous Next
WARNING
The component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Remove the cylinder head and the
SMALL | MEDIUM | LARGE
Previous Next
cylinder head gasket from the cylinder block
Clean and Inspect for Reuse
Use an injector bore brush Part Number 3822509 or equivalent to clean the carbon from the injector nozzle seat
SMALL | MEDIUM | LARGE
Previous Next
Scrape the gasket material from all gasket surfaces on the head
SMALL | MEDIUM | LARGE
Previous Next
Disassemble the cylinder head Refer to
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
cylinder head gasket from the cylinder block
Clean and Inspect for Reuse
Use an injector bore brush Part Number 3822509 or equivalent to clean the carbon from the injector nozzle seat
SMALL | MEDIUM | LARGE
Previous Next
Scrape the gasket material from all gasket surfaces on the head
SMALL | MEDIUM | LARGE
Previous Next
Disassemble the cylinder head Refer to
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Procedure 002-020 in Section 2
Scrape the gasket material from all gasket surfaces on the block and head
SMALL | MEDIUM | LARGE
Previous Next
NOTE Excessive deposits can be cleaned in an acid tank but the expansion plugs must be removed first
Clean the buildup of deposits from the coolant passages
SMALL | MEDIUM | LARGE
Previous Next
WARNING
When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendations for use Wear goggles and protective clothing to avoid personal injury
Clean the cylinder head combustion deck with a Scotch-Britetrade pad or equivalent and solvent
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
WARNING
Wear protective eye covering while cleaning carbon deposits to prevent injury
NOTE An inferior quality wire wheel will loose steel bristles during operation causing additional contamination
Inspect the area within 32 mm [0125 in] of the combustion seal ring diameter Any wear that can be felt with a fingernail within the 32 mm [0125 in] area is unacceptable making the cylinder head not reusable Wear beyond this 32 mm [0125 in] 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 die grinder
SMALL | MEDIUM | LARGE
Previous Next
WARNING
Wear appropriate eye and face protection when using compressed air Flying debris and dirt can cause
SMALL | MEDIUM | LARGE
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
bodily injury
Wash the cylinder head in a hot soapy water solution
Rinse the cylinder head with clean water
Dry the cylinder head with compressed air
Previous Next
CAUTION
Do not use caustic or acid solutions to clean the cylinder head capscrews
Use a petroleum-based solvent to clean the capscrews
Clean the capscrews thoroughly with a wire brush a soft wire wheel or use a non-abrasive bead blast to remove deposits from the shank and threads
SMALL | MEDIUM | LARGE
Previous Next
Clean the valves Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Previous Next
Use a straightedge and feeler gauge to measure the overall flatness of the cylinder block combustion deck
The overall flatness end-to-end and side-to-side must not exceed 0075 mm [0003 in]
Inspect the combustion deck for any localized dips or imperfections If present the cylinder block head deck must be ground
SMALL | MEDIUM | LARGE
Previous Next
The reuse guidelines for a cylinder head with a crack extending from the injector bore to the intake valve seat are as follows
If the crack does not extend into the valve seat the cylinder head is reusable
SMALL | MEDIUM | LARGE
Previous Next
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
If the crack extends into or through the valve seat the cylinder head must be repaired by installing a valve seat insert Reference the Alternative Repair Manual B and C Series Engines Bulletin 3666109
SMALL | MEDIUM | LARGE
Previous Next
Use a straightedge and a feeler gauge to inspect the cylinder head combustion surface for flatness
Cylinder Head Flatness
mm in
End-to-End 0305 MAX 0012
Side-to-Side
0076 MAX 0003
SMALL | MEDIUM | LARGE
Previous Next
Inspect the cylinder head capscrews for damaged threads corroded surfaces or a reduced diameter (due to capscrew stretching)
SMALL | MEDIUM | LARGE
Previous Next
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Do not reuse cylinder head capscrews under the following conditions
Visible corrosion or pitting exceeds 1 sq cm [0155 sq in] in area
Example
a Acceptable is 9525 x 9525 mm [38 x 38 in]
b Unacceptable is 12700 x 12700 mm [frac12 x frac12 in]
Visible corrosion or pitting exceeds 012 mm [0005 in] in depth
SMALL | MEDIUM | LARGE
Previous Next
Visible corrosion or pitting is located within 32 mm [18-in] of the fillet
Stretched beyond ldquofree-lengthrdquo maximum Reference the measurement in the next step
SMALL | MEDIUM | LARGE
Previous Next
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
NOTE If the capscrews are not damaged they can be reused throughout the life of the engine unless the specified free- length measurement is exceeded
Use a capscrew length guage Part Number 3825140 or equivalent 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
SMALL | MEDIUM | LARGE
Previous Next
If the end of the capscrew touches the foot of the gauge the capscrew is too long and must be discarded
Capscrew Free Length
mm in
1321 MAX 520
SMALL | MEDIUM | LARGE
Previous Next
Pressure Test
CAUTION
Do not pressure test the cylinder head with the valves and valve
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
springs installed Water entering the cylinder head cannot be dried thoroughly and will damage the valve guides and valve stems
Remove the valves and valve springs Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
NOTE A cylinder head test fixture can be fabricated from a flat piece of steel or aluminum Reference the following table for test fixture dimensions
Test Fixture Dimensions
16 mm Thickness 0625 in
749 mm Length 295 in
193 mm Width 76 in
NOTE Use the cylinder head gasket as a pattern for drilling the capscrew holes
NOTE An additional piece of metal will need to be machined to cover the thermostat housing
SMALL | MEDIUM | LARGE
Previous Next
Install the cylinder head water test fixture
Install a new head gasket Install the test plate Install the following
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
26 - 180 mm-long B Series head capscrews Cummins Part Number 3920781
26 - M12 x 175 hex flange nuts Cummins Part Number 3900781
52 - 12 mm washers Cummins Part Number 3900269
NOTE Cummins Inc recommends a washer be placed between each capscrew and the head and between each nut and test plate This will prevent mutilation on the surface of the cylinder head
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the nuts
Torque Value 80 nm [59 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
injury use a hoist or get assistance to lift this component
Connect a regulated air supply hose to the test fixture plate
Apply air pressure
Measurements
kpa psi
Air Pressure 276 40
Use a nylon lifting strap and a hoist to place the cylinder head in a tank of heated water
Measurements
celsius fahrenheit
Temperature 60 140
NOTE The cylinder head must be completely submerged in the water
SMALL | MEDIUM | LARGE
Previous Next
Inspect the head Bubbles indicate an air leak
If the cylinder head leaks it must be repaired or replaced
SMALL | MEDIUM | LARGE
Previous Next
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Remove the test fixture
Use compressed air to dry cylinder head
Assemble the cylinder head Refer to Procedure 002-020 in Section 2
SMALL | MEDIUM | LARGE
Previous Next
Install
CAUTION
Make sure the gasket is correctly aligned with the holes in the cylinder block Damage to the cylinder block can occur if the gasket is not aligned correctly
Inspect the cylinder head gasket for cracks in the silicone covering Replace the gasket if cracks are present
Position the cylinder head gasket over the dowels
SMALL | MEDIUM | LARGE
Previous Next
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
WARNING
This component weighs 23 kg [50 lb] or more To avoid personal injury use a hoist or get assistance to lift the component
Carefully put the cylinder head on the cylinder block and seat it onto the dowels
SMALL | MEDIUM | LARGE
Previous Next
Lubricate the threads and under the heads on the cylinder head mounting capscrews with clean engine oil
Install the capscrews and tighten finger-tight
SMALL | MEDIUM | LARGE
Previous Next
Use the illustrated sequence to tighten the cylinder head capscrews
Tighten the capscrews
Torque Value All Capscrews
1 80 nm [59 ft-lb] 2 105 nm [77 ft-lb] 3 Recheck All - 105 Nbullm [77 ft-lb]
SMALL | MEDIUM | LARGE
Previous Next
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
4 Rotate 90 degrees clock-wise
Install the push rods Refer to Procedure 004-014 in Section 4
SMALL | MEDIUM | LARGE
Previous Next
Install the crossheads and rocker levers Refer to Procedure 003-008 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Adjust the valve clearance Refer to Procedure 003-004 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Install the injectors Refer to Procedure 006-026 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the gasket and rocker lever cover Refer to Procedure 003-011 in Section 3
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel supply lines Refer to Procedure 006-024 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Install the fuel drain lines Refer to Procedure 006-013 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the fuel connectors Refer to Procedure 006-052 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the manifold cover plate Refer to Procedure 010-023 in Section 10
Install the fuel filter head Refer to Procedure 006-018 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Install high-pressure fuel lines Refer to Procedure 006-051 in Section 6
SMALL | MEDIUM | LARGE
Previous Next
Install the exhaust manifold Refer to Procedure 011-007 in Section 11
Install the turbocharger Refer to Procedure 010-033 in Section 10
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub Refer to Procedure 008-036 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Install the fan hub pulley Refer to Procedure 008-039 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Install the tensioner bracket to the cylinder head Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the belt tensioner Refer to Procedure 013-021 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
Install the drive belt Refer to Procedure 008-002 in Section 8
SMALL | MEDIUM | LARGE
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Previous Next
Assemble the alternator bracket to the thermostat housing Refer to Procedure 013-003 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Check the alternator pulley with a straightedge to make sure it is aligned with the other pulleys and is parallel to the front face of the block
Install the alternator Refer to Procedure 013-001 in Section 13
SMALL | MEDIUM | LARGE
Previous Next
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
NOTE Wrench size and torque value is determined by the make and model of alternator Refer to the OEM service manual
Tighten all capscrews in the following sequence
Alternator-to-alternator bracket capscrew
Lower brace-to-alternator capscrew
Alternator-to-water inlet capscrew
Water inlet-to-block capscrews
SMALL | MEDIUM | LARGE
Previous Next
Finishing Steps
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 all water and heater hoses Refer to Procedure 008-045 in Section 8
Fill the engine with coolant
SMALL | MEDIUM | LARGE
Previous
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved
Refer to Procedure 008-018 in Section 8
Connect the batteries Refer to the OEM service manual
Operate the engine and check for leaks
Last Modified 05-Jan-2012 Copyright copy 2000-2010 Cummins Inc All rights reserved