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Cummins Inc.

Service Manual

Service Manual Signature, ISX and QSX15 Volume 2


Box 3005
Columbus, Indiana, U.S.A., 47202 Signature, ISX and QSX15
Registered Office Volume 2
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England

Copyright 2010
Cummins Inc.

Bulletin 3666239
Printed in U.S.A. 27-APRIL-2010 p41

302158_Cummins_Vol2.indd 1 5/11/10 9:37 AM


Service Manual
Signature, ISX, and QSX15
Volume 2

Copyright 2010 Bulletin 3666239


Cummins Inc. Printed 27-APRIL-2010
All rights reserved
Foreword
This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild
procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing
of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be
contacted directly for any information not covered in this manual.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
- Introduction.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild
procedures require the use of special service tools. Make sure the correct tools are used as described in the
procedures.
When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used
in place of the recommended item.
A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair)
are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office
listing is located in Service Literature (Section L).
Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement.
Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating
your comments.
The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between
your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS
(1-800-343-7357) toll free in the U.S. and Canada.
The latest technology and the highest quality components are used to manufacture Cummins engines. When
replacement parts are needed, we recommend using only genuine Cummins or ReCon exchange parts.
Table of Contents
Section

Introduction .............................................................................................................................................. i

Cylinder Head - Group 02 ......................................................................................................................... 2

Rocker Levers - Group 03 ........................................................................................................................ 3

Fuel System - Group 05 ........................................................................................................................... 5

Injectors and Fuel Lines - Group 06 ........................................................................................................ 6

Lubricating Oil System - Group 07 .......................................................................................................... 7

Cooling System - Group 08 ...................................................................................................................... 8

Drive Units - Group 09 .............................................................................................................................. 9

Air Intake System - Group 10 ................................................................................................................... 10

Exhaust System - Group 11 ..................................................................................................................... 11

Compressed Air System - Group 12 ........................................................................................................ 12

Electrical Equipment - Group 13 .............................................................................................................. 13

Engine Testing - Group 14 ....................................................................................................................... 14

Mounting Adaptations - Group 16 ............................................................................................................ 16

Vehicle Braking - Group 20 ...................................................................................................................... 20

Service Literature ..................................................................................................................................... L

Specifications ........................................................................................................................................... V

Back .......................................................................................................................................................... back


Signature, ISX, and QSX15 Eng [...]
Section i - Introduction Page i-a

Section i - Introduction
Section Contents
Page
About the Manual ...............................................................................................................................................i-1
General Information...........................................................................................................................................i-1
Acronyms and Abbreviations ...........................................................................................................................i-15
General Information..........................................................................................................................................i-15
General Cleaning Instructions ......................................................................................................................... i-10
Abrasive Pads and Abrasive Paper...................................................................................................................i-10
Definition of Clean............................................................................................................................................i-10
Fuel System.....................................................................................................................................................i-13
Gasket Surfaces...............................................................................................................................................i-11
Plastic Bead Cleaning......................................................................................................................................i-12
Solvent and Acid Cleaning................................................................................................................................i-11
Steam Cleaning................................................................................................................................................i-12
General Repair Instructions ...............................................................................................................................i-8
General Information...........................................................................................................................................i-8
Welding on a Vehicle with an Electronic Controlled Fuel System........................................................................i-9
General Safety Instructions ...............................................................................................................................i-6
Important Safety Notice......................................................................................................................................i-6
How to Use the Manual ......................................................................................................................................i-2
General Information...........................................................................................................................................i-2
Illustrations .........................................................................................................................................................i-5
General Information...........................................................................................................................................i-5
Symbols ..............................................................................................................................................................i-4
General Information...........................................................................................................................................i-4
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This Page Left Intentionally Blank


Signature, ISX, and QSX15 Eng [...] About the Manual
Section i - Introduction Page i-1

About the Manual


General Information
This Service Manual is intended to aid in determining the cause of engine related problems and to provide
recommended repair procedures. Additionally the manual is intended to aid mechanics in disassembly, inspecting
parts for reuse, rebuilding and assembly of components.
The manual is divided into sections. Each section is equivalent to a group used in Cummins' filmcard system. Some
sections contain reference numbers and procedure numbers. Reference numbers provide general information,
specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and reference
specific repair procedures for correcting the problem and describe specific rebuild procedures.
This manual does not contain fuel systems electronic troubleshooting. Use the troubleshooting trees in this manual,
if there are no electronic fault codes.
This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The
troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section are
in numerical order. However, the repair steps within a given procedure are organized in the order the repair must be
performed regardless of the numerical order of the steps. The user must use the contents pages or the index at the
back of the manual to locate specific topics when not using the troubleshooting trees.
How to Use the Manual Signature, ISX, and QSX15 Eng [...]
Page i-2 Section i - Introduction

How to Use the Manual


General Information
The troubleshooting and repair section of this manual is organized to provide an easy system installation and flow
from problem identification to problem correction.
System Installation
The installation guidelines section has been designed to provide instructions for installing the system. A technician
should read the instruction, learn the intent of the step, and install the component in a fashion that will comply to the
vehicle's configuration. Each deviation from the specific instructions provided in this procedure should be noted.
Refer to the OEM service manual for OEM specifications.
A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms,
Section (TS). The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and
directing the end user to the correct procedure for making the repair. Complete the following steps to locate and
correct the problem.

(Step 1) Locate the symptom on the Section Contents pages of


Section TS.
Reference to the page number where the
Troubleshooting Symptom Tree is found is made to the
right of the symptom tree title.
(Step 2) The left column of boxes in the Troubleshooting Symptom
Charts indicates a probable cause of the problem,
starting at the top with the simplest and easiest to repair,
and continuing downward to the most difficult.
The right column of boxes provides a brief description of
the corrective action with a reference number to the
correct procedure used to make the repair.
(Step 3) Locate the probable cause in the left column then turn to
the procedure referenced in the right column.
(Step 4) The Troubleshooting Symptom Charts are based on the
following assumptions:
The engine has been installed according to the
manufacturer's specifications.
The easiest repairs are done first.
"Generic" solutions to cover problems with the most
common applications and Original Equipment
Manufacturer (OEM).
The disassemble/assemble sections of this manual is divided into the same group system used for previous manuals
and the Cummins' filmcard system.
Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical
sequence. Refer to the Table of Contents at the front of the book to determine the section that details the desired
information.
Each section contains the following in sequence:
Table of Contents
Required Service Tool Listings
General Information containing the basic service, maintenance, design and revision information necessary to assist
in the rebuild of an engine or a component
Procedure instructions for the disassembly, inspection, maintenance, and assembly that can be required to rebuild
an engine; additional procedures that are not necessary during every rebuild, but can be necessary, are included.
These procedures depend on the length of time an engine has been in service and the conditions of the parts.
All the procedures are identified with a name and a number. Each digit in the procedure number has a specific
meaning.
The first three digits of the number refer to the specific section that the procedure can be found within the manual. In
this example, 001 represents Section 01 Cylinder Block. This number will range from 000 to 022.
Signature, ISX, and QSX15 Eng [...] How to Use the Manual
Section i - Introduction Page i-3

The second three digits of the number are unique and refer to a specific subject. In this example, 028 represents
Cylinder Liner. This number will range from 001 to 999.
Refer to Section V for specifications recommended by Cummins Engine Company, Inc. for your engine. Specifications
and torque values for each engine system are given in that section.
NOTE: Discharge of oil or oily water into or upon the water is a direct violation of today's laws. Violators are subject
to a penalty of various monetary charges. Dispose of these substances in accordance with standard set by the EPA.
Symbols Signature, ISX, and QSX15 Eng [...]
Page i-4 Section i - Introduction

Symbols
General Information
The following symbols have been used in this manual to help communicate the intent of the instructions. When one
of the symbols appears, it conveys the meaning defined below:
Signature, ISX, and QSX15 Eng [...] Illustrations
Section i - Introduction Page i-5

Illustrations
General Information
Some of the illustrations throughout this manual are
generic and will not look exactly like the engine or parts
used in your application. The illustrations can contain
symbols to indicate an action required and an acceptable
or not acceptable condition.

The illustrations are intended to show repair or


replacement procedures. The procedure will be the same
for all applications, although the illustration can differ.
General Safety Instructions Signature, ISX, and QSX15 Eng [...]
Page i-6 Section i - Introduction

General Safety Instructions


Important Safety Notice
WARNING
Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation
or other personal injury or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included
in the procedures when they apply.
Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition
sources and hazardous substances. Be aware of hazardous conditions that can exist.
Always wear protective glasses and protective shoes when working.
Rotating parts can cause cuts, mutilation or strangulation.
Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.
Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in
the operator's compartment or on the controls.
Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or
damage to the fan blade(s) causing premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler
cap to relieve the pressure from the cooling system.
Always use blocks or proper stands to support the product before performing any service work. Do not work on
anything that is supported ONLY by lifting jacks or a hoist.
Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure.
Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid
refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be
properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the
atmosphere. Federal law requires capturing and recycling refrigerant.
To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23
kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of
the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The
lifting hooks must not be side-loaded.
Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes.
Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash
skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum
of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas
flow, and hot fluids in lines, tubes, and compartments.
Always use tools that are in good condition. Make sure you understand how to use the tools before performing
any service work. Use ONLY genuine Cummins or Cummins ReCon replacement parts.
Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
lesser quality if replacements are necessary.
When necessary, the removal and replacement of any guards covering rotating components, drives, and/or belts
should only be carried out be a trained technician. Before removing any guards the engine must be turned off and
any starting mechanisms must be isolated. All fasteners must be replaced on re-fitting the guards.
Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
Signature, ISX, and QSX15 Eng [...] General Safety Instructions
Section i - Introduction Page i-7

Some state and federal agencies in the United States of America have determined that used engine oil can be
carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact
with used engine oil.
Do not connect the jumper starting or battery charging cables to any ignition or governor control wiring. This can
cause electrical damage to the ignition or governor.
Always torque fasteners and fuel connections to the required specifications. Overtightening or undertightening
can allow leakage. This is critical to the natural gas and liquefied petroleum gas fuel and air systems.
Always test for fuel leaks as instructed, as odorant can fade.
Close the manual fuel valves prior to performing maintenance and repairs, and when storing the vehicle inside.
Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.
The catalyst reagent contains urea. Do not get the substance in your eyes. In case of contact, immediately flood
eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of
contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent
is ingested, contact a physician immediately.
The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. Always wear protective gloves and eye protection when handling the catalyst assembly.
Do not get the catalyst material in your eyes. In Case of contact, immediately flood eyes with large amounts of
water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin
with soap and water.
The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local
regulations.
California Proposition 65 Warning - Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
General Repair Instructions Signature, ISX, and QSX15 Eng [...]
Page i-8 Section i - Introduction

General Repair Instructions


General Information
This engine incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using
normal repair practices performed to quality standards.

CAUTION
Cummins Inc. does not recommend or authorize any modifications or repairs to engines or components
except for those detailed in Cummins Service Information. In particular, unauthorized repair to safety-related
components can cause personal injury or death. Below is a partial listing of components classified as safety-
related:
1 Air Compressor
2 Air Controls
3 Air Shutoff Assemblies
4 Balance Weights
5 Cooling Fan
6 Fan Hub Assembly
7 Fan Mounting Bracket(s)
8 Fan Mounting Capscrews
9 Fan Hub Spindle
10 Flywheel
11 Flywheel Crankshaft Adapter
12 Flywheel Mounting Capscrews
13 Fuel Shutoff Assemblies
14 Fuel Supply Tubes
15 Lifting Brackets
16 Throttle Controls
17 Turbocharger Compressor Casing
18 Turbocharger Oil Drain Line(s)
19 Turbocharger Oil Supply Line(s)
20 Turbocharger Turbine Casing
21 Vibration Damper Mounting Capscrews

Follow all safety instructions noted in the procedures


- Follow the manufacturer's recommendations for cleaning solvents and other substances used during the repair of
the engine. Some solvents and used engine oil have been identified by government agencies as toxic or
carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety
practices with tools and equipment.
Provide a clean environment and follow the cleaning instructions specified in the procedures
- The engine and its components must be kept clean during any repair. Contamination of the engine or components
will cause premature wear.
Perform the inspections specified in the procedures
Replace all components or assemblies which are damaged or worn beyond the specifications
Use genuine Cummins new or ReCon service parts and assemblies
- The assembly instructions have been written to use again as many components and assemblies as possible. When
it is necessary to replace a component or assembly, the procedure is based on the use of new Cummins or
Cummins ReCon components. All of the repair services described in this manual are available from all Cummins
Distributors and most Dealer locations.
Follow the specified disassembly and assembly procedures to reduce the possibility of damage to the components
Signature, ISX, and QSX15 Eng [...] General Repair Instructions
Section i - Introduction Page i-9

Welding on a Vehicle with an Electronic Controlled Fuel System


CAUTION
Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the
vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not
connect the ground cable of the welder to the ECM cooling plate or ECM. Welding on the engine or engine
mounted components is not recommended or damage to the engine or components can result.
General Cleaning Instructions Signature, ISX, and QSX15 Eng [...]
Page i-10 Section i - Introduction

General Cleaning Instructions


Definition of Clean
Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to
appear as new.
Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forming
a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface. Gaskets are
designed to fill small voids in the specified surface finish.
Sanding gasket surfaces where edge-molded gaskets are used is most often unnecessary. Edge-molded gaskets are
those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal portion forms a
metal to metal joint for stability. Any of the small amounts of sealing material that can stick to the parts are better
removed with a blunt-edged scraper on the spots rather than spending time polishing the whole surface with an air
sander or disc.
For those gaskets that do not have the edge molding, nearly all have a material that contains release agents to prevent
sticking. Certainly this is not to say that some gaskets are not difficult to remove because the gasket has been in
place a long time, has been overheated or the purpose of the release agent has been defeated by the application of
some sealant. The object however is just to remove the gasket without damaging the surfaces of the mating parts
without contaminating the engine (don't let the little bits fall where they can not be removed).
Bead blasting piston crowns until the dark stain is removed is unnecessary. All that is required is to remove the carbon
build-up above the top ring and in the ring grooves. There is more information on bead blasting and piston cleaning
later in this document.
Cummins Inc. does not recommend sanding or grinding the carbon ring at the top of cylinder liners until clean metal
is visible. The liner will be ruined and any signs of a problem at the top ring reversal point (like a dust-out) will be
destroyed. It is necessary to remove the carbon ring to provide for easier removal of the piston assembly. A medium
bristle, high quality, steel wire wheel that is rated above the rpm of the power tool being used will be just as quick and
there will be less damage. Yes, one must look carefully for broken wires after the piston is removed but the wires are
more visible and can be attracted by a magnet.
Oil on parts that have been removed from the engine will attract dirt in the air. The dirt will adhere to the oil. If possible,
leave the old oil on the part until it is ready to be cleaned, inspected and installed, and then clean it off along with any
attracted dirt. If the part is cleaned then left exposed it can have to be cleaned again before installation. Make sure
parts are lubricated with clean oil before installation. They do not need to be oiled all over but do need oil between
moving parts (or a good lube system priming process conducted before cranking the engine).
Bead blasting parts to remove exterior paint is also usually unnecessary. The part will most likely be painted again
so all that needs happen is remove any loose paint.
Abrasive Pads and Abrasive Paper
The keyword here is "abrasive". There is no part of an engine designed to withstand abrasion. That is they are all
supposed to lock together or slide across each other. Abrasives and dirt particles will degrade both functions.

WARNING
Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive material
in oil passages can cause bearing and bushing failures that can progress to major component damage beyond
reuse. This is particularly true of main and rod bearings.
Cummins Inc. does not recommend the use of emery cloth or sand paper on any part of an assembled engine or
component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks or
counterbores.
Great care must be taken when using abrasive products to clean engine parts, particularly on partially assembled
engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum oxide particles,
silicon carbide, or sand or some other similar hard material. These particles are harder than most of the parts in the
engine. Since they are harder, if they are pressed against softer material they will either damage the material or
become embedded in it. These materials fall off the holding media as the product is used. If the products are used
with power equipment the particles are thrown about the engine. If the particles fall between two moving parts, damage
to the moving parts is likely.
If particles that are smaller than the clearance between the parts while they are at rest (engine stopped), but larger
than the running clearance then damage will occur when the parts move relative to each other (engine started). While
the engine is running and there is oil pressure, particles that are smaller than the bearing clearance are likely to pass
between the parts without damage and be trapped in the oil filter. However, particles larger than the bearing clearance
will remove material from one part and can become embedded in one of the parts. Once embedded in one part it will
Signature, ISX, and QSX15 Eng [...] General Cleaning Instructions
Section i - Introduction Page i-11

abrade the other part until contact is no longer being made between the two parts. If the damage sufficiently degrades
the oil film, the two parts will come into contact resulting in early wear-out or failure from lack of effective lubrication.
Abrasive particles can fly about during cleaning it is very important to block these particles from entering the engine
as much as possible. This is particularly true of lubricating oil ports and oil drilling holes, especially those located
downstream of the lubricating oil filters. Plug the holes instead of trying to blow the abrasive particles and debris with
compressed air because the debris is often simply blown further into the oil drilling.
All old gasket material must be removed from the parts gasket surfaces. However, it is not necessary to clean and
polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the gasket
surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member bonded to the steel).
What little sealing material that can adhere is best removed with a blunt-edged scraper or putty knife. Cleaning gasket
surfaces where an edge-molded gasket is used with abrasive pads or paper is usually a waste of time.

WARNING
Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner beyond
reuse. The surface finish will be damaged and abrasive particles can be forced into the liner material which
can cause early cylinder wear-out or piston ring failures.
Tape off or plug all openings to any component interior before using abrasive pads or wire brushes. If really necessary
because of time to use a power tool with abrasive pads, tape the oil drillings closed or use plug and clean as much
of the surface as possible with the tool but clean around the oil hole/opening by hand so as to prevent contamination
of the drilling. Then remove the tape or plug and clean the remaining area carefully and without the tool. DO NOT use
compressed air to blow the debris out of oil drilling on an assembled engine! More likely than not, the debris can be
blown further into the drilling. Using compressed air is fine if both ends of the drilling are open but that is rarely the
case when dealing with an assembled engine.
Gasket Surfaces
The object of cleaning gasket surfaces is to remove any gasket material, not refinish the gasket surface of the part.
Cummins Inc. does not recommend any specific brand of liquid gasket remover. If a liquid gasket remover is used,
check the directions to make sure the material being cleaned will not be harmed.
Air powered gasket scrapers can save time but care must be taken to not damage the surface. The angled part of
the scraper must be against the gasket surface to prevent the blade from digging into the surface. Using air powered
gasket scrapers on parts made of soft materials takes skill and care to prevent damage.
Do not scrape or brush across the gasket surface if at all possible.
Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons. See
Below). Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95
Celsius (180 to 200 Fahrenheit). Kerosene emulsion based cleaners have different temperature specifications, see
below. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results.
Cummins Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's instructions.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the
parts before putting them in the cleaning tank.

WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons. These cleaners
should not be heated to temperature in excess of 77C (170F). The solution begins to break down at temperatures
in excess of 82C (180F) and will be less effective.
Do not use solutions composed mainly of chlorinated hydrocarbons with cresols, phenols and/or cresylic components.
They often do not do a good job of removing deposits from the ring groove and are costly to dispose of properly.
Solutions with a pH above approximately 9.5 will cause aluminum to turn black; therefore do not use high alkaline
solutions.
Chemicals with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. As you move further away
from the neutral 7.0, the chemicals become highly alkaline or highly acidic.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use hot high
General Cleaning Instructions Signature, ISX, and QSX15 Eng [...]
Page i-12 Section i - Introduction

pressure water or steam clean the parts before putting them in the cleaning tank. Removing the heaviest dirt before
placing in the tank will allow the cleaner to work more effectively and the cleaning agent will last longer.
Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all the
capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rust proofing compound. The rust
proofing compound must be removed from the parts before assembly or installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good method
for cleaning the oil drillings and coolant passages

WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Do not steam clean the following components:
Electrical Components
Wiring Harnesses
Injectors
Fuel Pump
Belts and Hoses
Bearings (ball or taper roller)
Electronic Control Module (ECM)
ECM Connectors
Dosing Control Unit
NOx Sensor.
Plastic Bead Cleaning
Cummins Inc. does not recommend the use of glass bead blast or walnut shell media on any engine part. Cummins
Inc. recommends using only plastic bead media, Part Number 3822735 or equivalent on any engine part. Never use
sand as a blast media to clean engine parts. Glass and walnut shell media when not used to the media manufacturer's
recommendations can cause excess dust and can embed in engine parts that can result in premature failure of
components through abrasive wear.
Plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is
controlled by the use of plastic beads, the operating pressure and cleaning time.

CAUTION
Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston, piston
skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal and result
in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shafts, etc.,
can also be damaged. Follow the cleaning directions listed in the procedures.

CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic beads.
Remove the foreign material and plastic beads with compressed air, hot high pressure water or steam before
placing them in tanks or cleaners. The foreign material and plastic beads can contaminate the tank and any
other engine parts cleaned in the tank. Contaminated parts may cause failures from abrasive wear.
Plastic bead blasting media, Part Number 3822735, can be used to clean all piston ring grooves. Do not sure any
bead blasting media on piston pin bores or aluminum skirts.
Follow the equipment manufacturer's cleaning instructions. Make sure to adjust the air pressure in the blasting
machine to the bead manufacturer's recommendations. Turning up the pressure can move material on the part and
cause the plastic bead media to wear out more quickly. The following guidelines can be used to adapt to
manufacturer's instructions:
1. Bead size: U.S. size Number 16 20 for piston cleaning with plastic bead media, Part Number 3822735
2. Operating Pressure 270 kPa (40 psi) for piston cleaning. Pressure should not cause beads to break.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning.
Rinse with hot water. Dry with compressed air.
Signature, ISX, and QSX15 Eng [...] General Cleaning Instructions
Section i - Introduction Page i-13

CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the engine
can be damaged due to increased parts clearance or inadequate surface finish on parts that move against
other parts.
When cleaning pistons, it is not necessary to remove all the dark stain from the piston. All that is necessary is to
remove the carbon on the rim and in the ring grooves. This is best done by directing the blast across the part as
opposed to straight at the part. If the machining marks are disturbed by the blasting process, then the pressure is too
high or the blast is being held on one spot too long. The blast operation must not disturb the metal surface.
Walnut shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell blasting
produces a great amount of dust particularly when the pressure if the air pressure on the blasting machine is increased
above media manufacturer's recommendation. Cummins Inc. recommends not using walnut shell media to clean
engine parts due to the risk media embedment and subsequent contamination of the engine.
Cummins Inc. now recommends glass bead media NOT used to clean any engine parts. Glass media is too easily
embedded into the material particularly in soft materials and when air pressures greater than media manufacturer's
recommend are used. The glass is an abrasive so when it is in a moving part, that part is abrading all the parts in
contact with it. When higher pressures are used the media is broken and forms a dust of a very small size that floats
easily in the air. This dust is very hard to control in the shop, particularly if only compressed air (and not hot water)
is used to blow the media after it is removed from the blasting cabinet (blowing the part off inside the cabinet may
remove large accumulations but never removes all the media).
Bead blasting is best used on stubborn dirt/carbon build-up that has not been removed by first steam/higher pressure
washing then washing in a heated wash tank. This is particularly true of pistons. Steam and soak the pistons first then
use the plastic bead method to safely remove the carbon remaining in the grooves (instead of running the risk of
damaging the surface finish of the groove with a wire wheel or end of a broken piston ring. Make sure the parts are
dry and oil free before bead blasting to prevent clogging the return on the blasting machine.
Always direct the bead blaster nozzle "across" rather than directly at the part. This allows the bead to get under the
unwanted material. Keep the nozzle moving rather than hold on one place. Keeping the nozzle directed at one-place
too long causes the metal to heat up and be moved around. Remember that the spray is not just hitting the dirt or
carbon. If the machining marks on the piston groove or rim have been disturbed then there has not been enough
movement of the nozzle and/or the air pressure is too high.
Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle across
the seat surface and radius rather than straight at them. The object is to remove any carbon build up and continuing
to blast to remove the stain is a waste of time.
Fuel System
When servicing any fuel system components, which can be exposed to potential contaminants, prior to disassembly,
clean the fittings, mounting hardware, and the area around the component to be removed. If the surrounding areas
are not cleaned, dirt or contaminants can be introduced into the fuel system.
The internal drillings of some injectors are extremely small and susceptible to plugging from contamination. Some
fuel injection systems can operate at very high pressures. High pressure fuel can convert simple particles of dirt and
rust into a highly abrasive contaminant that can damage the high pressure pumping components and fuel injectors.
Electrical contact cleaner can be used if steam cleaning tools are not available. Use electrical contact cleaner rather
than compressed air, to wash dirt and debris away from fuel system fittings. Diesel fuel on exposed fuel system parts
attracts airborne contaminants.
Choose lint free towels for fuel system work.
Cap and plug fuel lines, fittings, and ports whenever the fuel system is opened. Rust, dirt, and paint can enter the
fuel system whenever a fuel line or other component is loosened or removed from the engine. In many instances, a
good practice is to loosen a line or fitting to break the rust and paint loose, and then clean off the loosened material.
When removing fuel lines or fittings from a new or newly-painted engine, make sure to remove loose paint flakes/
chips that can be created when a wrench contacts painted line nuts or fittings, or when quick disconnect fittings are
removed.
Fuel filters are rated in microns. The word micron is the abbreviation for a micrometer, or one millionth of a meter.
The micron rating is the size of the smallest particles that will be captured by the filter media. As a reference, a human
hair is 0.003 mm [3/1000 in] in diameter. One micron measures 0.00004 mm [4/100,000 in]. The contaminants being
filtered out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope.
The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination. Like fuel
system parts, tools that are coated with oil or fuel attract airborne contaminants. Remember the following points
regarding your fuel system tools:
General Cleaning Instructions Signature, ISX, and QSX15 Eng [...]
Page i-14 Section i - Introduction

Fuel system tools are to be kept as clean as possible.


Clean and dry the tools before returning them to the tool box.
If possible, store fuel system tools in sealed containers.
Make sure fuel system tools are clean before use.
Signature, ISX, and QSX15 Eng [...] Acronyms and Abbreviations
Section i - Introduction Page i-15

Acronyms and Abbreviations


General Information
The following list contains some of the acronyms and abbreviations used in this manual.
API American Petroleum Institute
ASTM American Society of Testing and Materials
BTU British Thermal Unit
BTDC Before Top Dead Center
C Celsius
CO Carbon Monoxide
CCA Cold Cranking Amperes
CARB California Air Resources Board
C.I.B. Customer Interface Box
C.I.D. Cubic Inch Displacement
CNG Compressed Natural Gas
CPL Control Parts List
cSt Centistokes
DEF Diesel Exhaust Fluid
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
ECM Electronic Control Module
EGR Exhaust Gas Recirculation
EPA Environmental Protection Agency
F Fahrenheit
ft-lb Foot-Pound Force
FMI Failure Mode Indentifier
GVW Gross Vehicle Weight
Hg Mercury
hp Horsepower
H2O Water
inHg Inches of Mercury
in H20 Inches of Water
ICM Ignition Control Module
km/l Kilometers per Liter
kPa Kilopascal
LNG Liquid Natural Gas
LPG Liquified Petroleum Gas
LTA Low Temperature Aftercooling
MIL Malfunction Indicator Lamp
MPa Megapascal
mph Miles Per Hour
mpq Miles Per Quart
Nm Newton-meter
NOx Mono-Nitrogen Oxides
NG Natural Gas
OBD On-Board Diagnostics
OEM Original Equipment Manufacturer
PID Parameter Identification Descriptions
ppm Parts Per Million
Acronyms and Abbreviations Signature, ISX, and QSX15 Eng [...]
Page i-16 Section i - Introduction

psi Pounds Per Square Inch


PTO Power Takeoff
RGT Rear Gear Train
rpm Revolutions Per Minute
SAE Society of Automotive Engineers
SCA Supplemental Coolant Additive
SCR Selective Catalytic Reduction
STC Step Timing Control
SID Subsystem Identification Descriptions
VDC Volts of Direct Current
VS Variable Speed
VSS Vehicle Speed Sensor
Signature, ISX, and QSX15 Eng [...]
Section 2 - Cylinder Head - Group 02 Page 2-a

Section 2 - Cylinder Head - Group 02


Section Contents
Page
Cylinder Head ....................................................................................................................................................2-5
Assemble........................................................................................................................................................2-32
Clean..............................................................................................................................................................2-10
Clean and Inspect for Reuse...........................................................................................................................2-21
Disassemble................................................................................................................................................... 2-17
Finishing Steps...............................................................................................................................................2-38
General Information..........................................................................................................................................2-5
Initial Check......................................................................................................................................................2-6
Inspect for Reuse..............................................................................................................................................2-9
Install..............................................................................................................................................................2-37
Leak Test........................................................................................................................................................2-11
Magnetic Crack Inspect...................................................................................................................................2-30
Measure..........................................................................................................................................................2-27
Preparatory Steps.............................................................................................................................................2-7
Remove............................................................................................................................................................2-8
Vacuum Test...................................................................................................................................................2-15
Injector Camshaft Scissor Gear ......................................................................................................................2-86
Install..............................................................................................................................................................2-87
Remove.......................................................................................................................................................... 2-86
Overhead Camshaft End Clearance, Valve .....................................................................................................2-81
Measure..........................................................................................................................................................2-81
Overhead Camshaft Bushings, Injector ..........................................................................................................2-69
Initial Check....................................................................................................................................................2-69
Inspect for Reuse............................................................................................................................................2-74
Install..............................................................................................................................................................2-74
Remove.......................................................................................................................................................... 2-69
Overhead Camshaft Bushings, Valve .............................................................................................................2-57
Initial Check....................................................................................................................................................2-57
Inspect for Reuse............................................................................................................................................2-62
Install..............................................................................................................................................................2-62
Remove.......................................................................................................................................................... 2-57
Overhead Camshaft End Clearance, Injector .................................................................................................2-83
Measure..........................................................................................................................................................2-83
Overhead Camshaft Gear, Valve .....................................................................................................................2-86
Install..............................................................................................................................................................2-86
Remove.......................................................................................................................................................... 2-86
Overhead Camshaft, Injector ..........................................................................................................................2-51
Clean and Inspect for Reuse...........................................................................................................................2-54
Finishing Steps...............................................................................................................................................2-55
Install..............................................................................................................................................................2-55
Preparatory Steps...........................................................................................................................................2-51
Remove.......................................................................................................................................................... 2-53
Overhead Camshaft, Valve ..............................................................................................................................2-47
Clean and Inspect for Reuse...........................................................................................................................2-49
Finishing Steps...............................................................................................................................................2-50
Install..............................................................................................................................................................2-50
Preparatory Steps...........................................................................................................................................2-47
Remove.......................................................................................................................................................... 2-48
Service Tools ....................................................................................................................................................2-1
.........................................................................................................................................................................2-1
Valve Guide Seal, Cylinder Head ....................................................................................................................2-39
Finishing Steps...............................................................................................................................................2-47
On-Engine Repair.........................................................................................................................................2-47
Off-Engine Repair.........................................................................................................................................2-47
General Information.........................................................................................................................................2-39
Install..............................................................................................................................................................2-43
Preparatory Steps...........................................................................................................................................2-39
Signature, ISX, and QSX15 Eng [...]
Page 2-b Section 2 - Cylinder Head - Group 02

On-Engine Repair.........................................................................................................................................2-39
Off-Engine Repair.........................................................................................................................................2-40
Remove.......................................................................................................................................................... 2-40
Signature, ISX, and QSX15 Eng [...] Service Tools
Section 2 - Cylinder Head - Group 02 Page 2-1

Service Tools
Cylinder Head

The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.

Tool No. Tool Description Tool Illustration


Protective Plug Kit
Used to plug oil passages and drillings during a repair process.
4918319

Four-Valve Spring Compressor


Use to remove or install valve spring retainers, valve springs, and
4919358 valve seals.

Head Bolt Stretch Gauge


Use to measure head bolts.
3163162

Hydraulic Camshaft Bushing Installation and Removal Tool


Use to remove and install camshaft bushings.
3823621

Valve Camshaft Bushing Installation and Removal Tool


Use with the hydraulic camshaft bushing installation and removal
3164088 tool, Part Number 3823621.

Injector Camshaft Bushing Installation and Removal Tool


Use with the hydraulic camshaft bushing installation and removal
3164089 tool, Part Number 3823621.
Service Tools Signature, ISX, and QSX15 Eng [...]
Page 2-2 Section 2 - Cylinder Head - Group 02

Tool No. Tool Description Tool Illustration


Cylinder Head Lifting Fixture
Use to remove the cylinder head from the cylinder block.
3400329

Scotch-Brite 7448
Use to clean carbon, rust, and corrosion from the engine block and
3823258 parts.

Air Impact Wrench


A tool which produces the amount of torque required to rotate
3163059 Signature 600 capscrews. It has a square drive size of 3/4-inch, an
output of 75 to 900 ft-lbs and a continuous working torque of 500 ft-
lb when using a 3/8-inch unrestricted hose and a 90 psi pressure
source.
24-mm Impact Socket
Use to tighten both the cylinder head bolts and the main bearing cap
3163484 bolts. The socket has sufficient length for Signature 600 and is laser
marked at 90-degree increments.

Depth Gauge Assembly


Use to measure liner protrusion, injector protrusion, cylinder block
3164438 counterbore depths, and valve intrusion and/or protrusion.

Valve Seal Installation Tool


Use to push the valve guide seals onto the valve and valve guide
3163294 when assembled in the head.

Valve Seal Puller


Use to remove the valve seal.
3163293

Valve Guide Installer


Use to press the valve guides into the cylinder head to the proper
3162892 assembled height.
Signature, ISX, and QSX15 Eng [...] Service Tools
Section 2 - Cylinder Head - Group 02 Page 2-3

Tool No. Tool Description Tool Illustration


Intake Seat Installer
Use to install the intake valve seat into the cylinder head.
3163318

Exhaust Seat Installer


Use to install the exhaust valve seat into the cylinder head.
3163319

Exhaust Seat Puller


Use to remove the exhaust valve seat from the cylinder head.
ST1276-1

Intake Seat Puller


Use to remove the intake valve seat from the cylinder head.
ST1279-1

Valve Guide Removal Tool


Use to remove the valve guides from the cylinder head.
3163321

Valve Vacuum Tester


Use to determine if the valves are correctly seated in the cylinder
ST1257-1 head. The seal ring, Part Number ST1257-3, and vacuum cup, Part
Number ST1257-6, are purchased separately.

Slide Hammer Assembly


Use with the valve seat puller to remove the valve seat insert from
3376617 the cylinder head.

Magnetic Crack Detector


Use to inspect cylinder heads and other ferrous castings that can
ST1166-1 not be magnafluxed for crack detection.
Service Tools Signature, ISX, and QSX15 Eng [...]
Page 2-4 Section 2 - Cylinder Head - Group 02

Tool No. Tool Description Tool Illustration


Valve Seat Grooving Tool
Use to cut a groove circumferentially in the inside diameter of a valve
3376405 seat to allow the seat extractor a suitable grip area.

Cylinder Head Fuel Passage Leak Test Kit


Use to test the fuel passages in the cylinder head. Use with leak test
3164943 kit, Part Number 3164231, purchased separately.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-5

Cylinder Head (002-004)


General Information
The cylinder head group consists of the cylinder head,
valves, valve guides, valve springs, valve seat inserts,
crossheads, and injector sleeves. The exhaust valves are
manufactured from a material capable of operating at a
higher temperature than the intake valves. In addition to
being made from different materials, the intake and
exhaust valves are different sizes.
Mark, label, or tag the cylinder head parts such as
crossheads, valves, and valve springs with the cylinder
number and location from which they were removed. It is
also recommended that the intake and exhaust valve
positions be marked on the combustion face of the
cylinder head. Use a paint pen to facilitate installing the
correct parts in the correct locations.

There are two different designs of cylinder liners used in


Signature, ISX, and QSX15 engines. The design used in
a particular engine is dependent on the engine's
production vintage.
Engines assembled prior to engine serial number
14022615 have groove-top liners. They are characterized
by a groove machined into the top surface of the liner
flange.
Engines assembled with engine serial number 14022615
and higher have flat-top liners. They are characterized by
a cylinder liner flange that is flat, except for the fire dam.

CAUTION
Cylinder head gaskets are different depending on the
liner design. The cylinder head gasket designed to be
used with groove-top liners can not be used with flat-
top liners, and the head gasket designed to be used
with the flat-top liners can not be used with groove-
top liners.
Engines built with groove-top liners must use a cylinder
head gasket and fire rings.
Engines built with flat-top liners must use a one-piece
cylinder head gasket without the fire rings.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-6 Section 2 - Cylinder Head - Group 02

Initial Check

WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Use steam or high-pressure water to clean the exterior of
the engine.

Operate the engine at low idle.


Check for oil or coolant leaks between the cylinder head
and the engine block.

Listen for a chirping sound between the cylinder head and


engine block.
A chirping sound, usually during acceleration, indicates a
combustion leak.
Confirm leaks with a transparent bottle half filled with
water. Immerse the overflow tube from the coolant tank
and run the engine at high idle until the thermostat opens
and watch for a stream of bubbles in the water. This
confirms a combustion leak.

If a leak is found, remove and inspect the cylinder head


and all related components.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-7

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
Do not remove the pressure cap from a hot engine. Wait until the
coolant temperature is below 50C [120F] before removing the
pressure cap. Heated coolant spray or steam can cause personal
injury.

WARNING
Coolant is toxic. Keep away from children and pets. If not reused,
dispose of in accordance with local environmental regulations.
Disconnect the batteries or air supply to the air starter to prevent
accidental engine starting. Refer to the OEM service manual.
Drain the cooling system. Refer to Procedure 008-018 in Section
8.
Remove the turbocharger. Refer to Procedure 010-033 in Section
10.
Remove the exhaust manifold. Refer to Procedure 011-007 in
Section 11.
Remove the thermostat housing. Refer to Procedure 008-014 in
Section 8.
Remove the air intake connection.Refer to Procedure 010-080 in
Section 10.
Remove the integrated fuel system module. Refer to Procedure
005-073 in Section 5.
Remove the ECM. Use the following procedure for CM570
engines, in the Signature, ISX and QSX15 Electronic Control
System, Troubleshooting and Repair Manual, Bulletin 3666259.
Refer to Procedure 019-031 in Section 19.
Remove the ECM. Use the following procedure for CM870
engines, in the Signature and ISX CM870 Electronic Control
System, Troubleshooting and Repair Manual, Bulletin 4021334.
Refer to Procedure 019-031 in Section 19.
Remove the ECM. Use the following procedure for CM871
engines, in the ISX CM871 and ISM CM876 5 Electronic Control
System, Troubleshooting and Repair Manual, Bulletin 4021560.
Refer to Procedure 019-031 in Section 19.
Remove the air compressor air inlet hose.Refer to Procedure
012-014 in Section 12.
Remove the rocker lever cover.Refer to Procedure 003-011 in
Section 3.
Remove the rocker lever shaft assemblies. Refer to Procedure
003-009 in Section 3.
Remove the injectors. Refer to ProcedureRefer to Procedure
006-026 in Section 6.
Remove the upper front gear cover. Refer to Procedure 001-079
in Section 1.
Remove the valve and injector camshaft gears.Refer to Procedure
001-088 in Section 1.
Remove the retaining brace bracket. Refer to Procedure 001-081
in Section 1.
Remove the accessory bracket. Refer to Procedure 001-082 in
Section 1.
Remove the overhead valve camshaft. Refer to Procedure 002-024
in Section 2.
Remove the overhead injector camshaft. Refer to Procedure
002-025 in Section 2.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-8 Section 2 - Cylinder Head - Group 02

Remove

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Use a chip vacuum to remove the excess oil from the top
of the cylinder head.
Remove the cylinder head capscrews.
Use engine lifting fixture, Part Number 4919360 or
equivalent, to lift the cylinder head.
Remove the cylinder head. Remove and discard the
gasket.
Remove the fire rings from the cylinder liners, if equipped.

CAUTION
Immediately upon removal of the cylinder head, plugs
must be installed into the oil passage drillings in both
the cylinder head and the block. The plugs are
necessary to prevent debris from entering the
lubrication system during the repair. Failure to insert
the oil passage plugs can result in a connecting rod
bearing failure, crankshaft failure or both.
Reusable plugs, Part Number 4089255, are included in
the master plug kit, Part Number 4918319.
Install the plugs in the cylinder block and cylinder head oil
drillings.

NOTE: This step is not applicable if the engine has flat-


top liners and a single-piece head gasket, or when
upgrading from grooved-top liners and a 13-piece gasket
to flat-top liners and a single-piece gasket.
Prior to removing the cylinder head gasket and sealing
rings (if installed), examine the gasket for carbon tracks
across the sealing ring.
The pressure of carbon indicates a combustion leak.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-9

Remove the cylinder head gasket.


Make sure the cylinder liner recession or protrusion
(based on liner style) is within specification.
Refer to Procedure 001-028 in Section 1.

Inspect for Reuse


Use depth gauge, Part Number 3164438, to measure the
valve recess in the cylinder head.

Service Valve Recession Specification (NEW)


mm in
Intake 0.88 MIN 0.035
1.21 MAX 0.048
Exhaust 0.43 MIN 0.017
0.77 MAX 0.030

Service Valve Recession Specification (USED)


mm in
Intake 1.35 MAX 0.053
Exhaust 0.91 MAX 0.036
If the valve recess is not within specifications, the cylinder
head must be reconditioned.

Prior to cleaning the cylinder head combustion surface,


inspect for a leak path between the cylinder and cylinder
head capscrew holes.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-10 Section 2 - Cylinder Head - Group 02

NOTE: This step is not applicable if the engine has flat-


top liners and a single-piece head gasket, or when
upgrading from grooved-top liners and a 13-piece gasket
to flat-top liners and a single-piece gasket.
Inspect the cylinder head combustion surface for pitting
or erosion.
Pitting or erosion on the cylinder head combustion surface
located in the area where the cylinder liner fire dam
contacts the head is not acceptable.
Pitting or erosion on the cylinder head combustion surface
located inside the fire ring area is acceptable.

Clean
Prior to cleaning the combustion face of the cylinder head,
small rubber plugs, Part Number 4089255, and tape
must be used to plug or cover the oil supply holes at the
ends of the cylinder head to prevent debris from entering
the oil passages.
Use Scotch-Brite 7448, Part Number 3823258, or
equivalent, to clean the cylinder head combustion face.
Also make sure there is no loose debris sitting in the valve
pockets around the head of the valve.
Do not use power tools to clean the combustion face of
the cylinder head.

Prior to cleaning the combustion face of the cylinder head,


small rubber plugs, Part Number 4089255, and tape
must be used to plug or cover the oil supply holes at the
ends of the cylinder head to prevent debris from entering
the oil passages.
Use Scotch-Brite 7448, Part Number 3823258, or
equivalent, to clean the cylinder head combustion face.
Also make sure there is no loose debris sitting in the valve
pockets around the head of the valve.
See the Leak Test section of this procedure for more
cleaning details.

CAUTION
If the oil passages are not plugged or covered before
cleaning, a crankshaft failure can occur.
Make sure the plugs are installed in the oil passages of
the cylinder block deck.
Plug or cover the coolant passages in the cylinder block
deck.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-11

WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
Use a gasket scraper to clean the cylinder block deck
surface.
Use Scotch-Brite 7448, Part Number 3823258, or
equivalent, and solvent to remove any residual gasket
material from the cylinder block deck surface.
Use a chip vacuum to remove the excess oil and coolant
from the capscrew holes.
Make sure the cylinder head capscrew holes are clean
and free of debris, oil, and coolant.
Do not use power tools to clean the combustion face.

Leak Test
Fuel Passage
NOTE: This task can be preformed either on or off-engine.
The fuel system is split into two banks.
The front bank is for cylinders one through three, and the
rear bank is for cylinders four through six.
The banks are tested independently of each other. Use
test kit, Part Number 3164943.
The left three male connectors on the plate are for the front
bank and the right three male connectors are for the rear
bank.
The three male connectors on the plate are:
Metering
Timing
Return.

Apply thread sealant to the male connectors and install


them into the plate, if they are not installed.
Install the gasket, plate, two short capscrews (5), and two
long capscrews (4).
Tighten the capscrews.
Torque Value: 27 Nm [ 239 in-lb ]
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-12 Section 2 - Cylinder Head - Group 02

Install the injector cavity plug (3) into the appropriate


injector bores.
Center the injector cavity plugs in the injector bores.
Install the injector hold-down clamps and capscrews.
Tighten the capscrews.
Torque Value: 41 Nm [ 30 ft-lb ]

Attach leak test kit, Part Number 3164231 or equivalent,


to one of the male connectors on the plate.
Apply 207 kPa [30 psi] of air pressure.
Verify the test hardware is not leaking.
Shut off the air pressure supply.
The air pressure must not drop below 193 kPa [28 psi] in
30 seconds.
If the fuel passages are leaking, the cylinder head must
be replaced.
Remove the test kit.

Coolant Passage

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
NOTE: This task is preformed off-engine.
Place the cylinder head on a work bench with the intake
side down.
Install the gasket (2) onto the combustion face of the
cylinder head.
Install the plate (1), with the marking exhaust toward the
exhaust side of the cylinder head.

Install the cylinder head capscrews and nuts (5).


Tighten the capscrews.
Torque Value: 68 Nm [ 50 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-13

Apply thread sealant and install the male connector (7)


into the plate (3) if it is not installed.
Install the gasket (4) and plate (3) onto the cylinder head
at the thermostat location.
Install the capscrews (8) and washers (9).
Tighten the capscrews.
Torque Value: 27 Nm [ 239 in-lb ]
Attach leak test kit, Part Number 3164231 or equivalent,
to the male connector.

Install the injector cavity plugs (6) into the injector bores.
Center the injector cavity plugs in the injector bores.
Install the injector hold-down clamps and capscrews.
Tighten the capscrews.
Torque Value: 41 Nm [ 30 ft-lb ]

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Place the cylinder head into a tank of water.
Apply 207 kPa [30 psi] of air pressure to the cylinder head.
Inspect for bubbles.
Make sure the test assembly is not leaking.
If bubbles are present, the cylinder head must be
replaced.

An alternate method to placing the cylinder head into a


tank of water is to use a water and soap solution.
Apply 207 kPa [30 psi] of air pressure to the cylinder head.
Spray the cylinder head with a mild water and soap
solution.
Inspect for bubbles.
Make sure the test assembly is not leaking.
If bubbles are present, the cylinder head must be
replaced.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-14 Section 2 - Cylinder Head - Group 02

Remove the test kit.

Valve Seat
NOTE: This task is performed off-engine.
Set the head down with the intake ports on the bottom.
Pour fuel into the exhaust port until it is full.
Start the timer.

If a drop of fuel drips or runs down the face of the head


within 30 seconds, inspect the valves and seats to
determine the necessity of parts replacement. The valve
and valve seat must be checked using the vacuum test
procedure.
If a drop of fuel has not run down the face of the head in
30 seconds, it indicates that the valves and seats are
sealing properly.

Drain the fuel from the exhaust side of the head.


Turn the head over so the exhaust port is on the bottom.
Pour fuel into the intake ports until full.
Start the timer.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-15

If a drop of fuel drips or runs down the face of the head


within 30 seconds, the valve and valve seat interface
must be checked using the vacuum test procedure.
If a drop of fuel has not run down the face of the head in
30 seconds, it indicates that the valves and seats are
sealing properly.

Vacuum Test
NOTE: This task is preformed off-engine.
Use valve vacuum tester, Part Number ST-1257, to
inspect the seal between the valve and the valve seat. To
perform this test, the cylinder head must either be sitting
on its side or turned upside down so that the combustion
face can be accessed.
The valve vacuum tester can be used to test all Cummins
engine models. The seal ring, Part Number ST-1257-35,
and vacuum cup, Part Number ST-1251-6, are used to
seal the cylinder head inserts.

Install the seal ring and vacuum cup to the vacuum line
(hose).

The valves and valve seats must be clean and dry when
vacuum testing.
Make sure the combustion face of the cylinder head is
clean and dry and there is no loose debris in the valve
recess.
This will help to provide a good vacuum cup to cylinder
head sealing surface.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-16 Section 2 - Cylinder Head - Group 02

Move the toggle switch (1) to the ON position.


Turn the vacuum control valve (2) to the OPEN position.
The vacuum control valve is in the OPEN position if the
vacuum gauge needle moves clockwise.

Operate the vacuum pump until the gauge indicates the


specified vacuum.

Valve to Valve Seat Vacuum


mm Hg in Hg
508 MIN 20
685 MAX 25
Turn the vacuum control valve to the closed position.
Turn the toggle switch (1) to the OFF position.

Use a stopwatch and start timing when the needle on the


gauge indicates 457 mm Hg [18 in Hg].
Stop timing when the needle on the gauge indicates 203
mm Hg [8 in Hg].
The elapsed time for the needle to move between the
specified gauge readings must be 10 seconds or more.

If the elapsed time is less than 10 seconds, perform the


following checks:
Repeat the test to be sure the equipment is operating
properly.
Use a mallet to hit the valve stem lightly to make sure
the valve is seated. Repeat the test.
Apply a thin layer of grease on the outside diameters
of the insert and the valve head. Repeat the test. The
grease pattern will show the point of leakage.
A break in the grease seal pattern will indicate leakage
between the valves and valve seat or the valve seat insert
and the cylinder head.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-17

Disassemble
NOTE: This task is performed off-engine.
Prior to disassembly, make sure the valve recess has been
measured and recorded.

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Place the cylinder head combustion face down on a clean,
smooth and level work surface that is sturdy enough to
support the weight of the cylinder head.

WARNING
Valve springs are under tension and can act as
projectiles if improperly released. To reduce the
possibility of eye injury, wear safety glasses with side
shields. Before releasing the valve spring tension,
check that the collets are properly seated.

CAUTION
Do not use an impact tool for any part of this
procedure. Doing so can damage the tool and/or the
engine.
Use the four valve spring compressor, Part Number
4919358, to compress the valve springs.
The replacer screw pilots in the injector bore and is
secured using the injector hold-down clamp.

Position the replacer screw (1) in the injector hole with the
threaded end pointing up.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-18 Section 2 - Cylinder Head - Group 02

Secure the replacer screw (1) in the injector hole with the
injector clamp and capscrew.
Tighten the capscrew.
Torque Value: 54 Nm [ 40 ft-lb ]

CAUTION
The side of the retainer plate with the larger diameter
chamfers faces down to accommodate the valve
springs. Failure to position the retainer plate properly
can result in damage to the engine and/or tool.
Position the compressor plate (2) over the replacer screw
(1) and onto the valve springs.

Install the washer (4) and forcing nut (3) on the replacer
screw (1).
Tighten hand-tight.

WARNING
Wear eye protection during this procedure. Springs
are under tension and can act as a projectile if
released, causing serious injury.
Turn the forcing nut (3) clockwise until the valve springs
start to compress.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-19

CAUTION
Do not overtighten the forcing nut. Doing so can
damage the tool and/or springs.
Continue turning the forcing nut (3) clockwise until the
valve collets can be removed with a magnetic tool.
Discard the valve collets.

WARNING
Wear eye protection during this procedure. Springs
are under tension and can act as a projectile if
released, causing serious injury.
Carefully turn the forcing nut (3) counterclockwise until
the tension is released from the valve springs.
Remove the forcing nut (3) and compressor plate (2) from
the replacer screw (1).

Remove the replacer screw (1) by removing the injector


hold-down bolt and injector hold-down clamp.

Remove the valve spring retainer.


Remove the valve spring.
Remove the valve spring guide.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-20 Section 2 - Cylinder Head - Group 02

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
With the use of a lifting device, roll the head up on its side
to gain access to the valves.
Remove the valves.
Mark the valves with an electric pencil (engraving tool) for
location as they are removed.
The intake and exhaust valves are manufactured from
different materials and are not interchangeable.

Remove the valve seals from the valve guides.Refer to


Procedure 002-016 in Section 2.

NOTE: Only remove the valve guides if they were not


within specification criteria in the Clean and Inspect for
Reuse section.
Use valve guide removal tool, Part Number 3163321, to
remove the old valve guides.
It is preferable to drive the guides out with an air hammer,
but the use of a dead blow hammer is acceptable.

NOTE: Only remove the valve seats if they were not


within specification criteria in the Clean and Inspect for
Reuse section.
Use slide hammer assembly, Part Number 3376617, and
valve seat extractor, Part Number ST-1279-1, to remove
the intake valve seat inserts from the cylinder head.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-21

The exhaust valve seat insert does not have a lower inside
diameter chamfer for the exhaust seat puller to grip. It will
be necessary to use the valve seat grooving tool to cut a
groove in the inside diameter of the exhaust valve seat
inserts.
Set up the cutting tool with the cutting edge 7.75 mm [0.3
in] from the base of the grooving tool motor.
When cutting the groove, make sure the base of the tool
remains flat on the cylinder head combustion face during
the entire cutting operation.
To cut, set the tool on the head surface with the cutter in
the valve bore.
Contact the valve seat insert inside diameter with the
grooving tool on.
Apply enough pressure to prevent tool chatter, but not so
much pressure that the tool or seat insert is overheated.
Follow the inside circumference in a clockwise direction
for three complete rotations.

Remove the tool and inspect the groove for uniformity of


depth. Recut any areas that are shallow.
Use seat extractor, Part Number ST-1276-1 or equivalent,
to remove the exhaust valve seat inserts from the cylinder
head.

Clean and Inspect for Reuse


Inspect the injector bores for wear, cracks, other damage,
or mis-drilled passages.
The cylinder head can not be used if wear, cracks, other
damage, or mis-drilled passages are detected in the
injector bores.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-22 Section 2 - Cylinder Head - Group 02

Inspect the insert bore for cracks or other damage, if the


valve seat insert was removed during disassembly.
The cylinder head can not be used if cracks or other
damage is detected in the insert bore.

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

CAUTION
Do not use caustic or acid solutions to clean the
cylinder head capscrews. Damage to the capscrews
can occur.
Clean the cylinder head capscrews with a petroleum-
based solvent.
Clean the capscrews thoroughly with a wire brush, wire
wheel (soft), or nonabrasive bead blast to remove deposits
from the shank and threads.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.

WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Steam clean the cylinder head and dry with compressed
air.
Use a chip vacuum to clean out all capscrew holes.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-23

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

CAUTION
If the oil passages are not plugged or covered before
cleaning, a crankshaft failure can occur.
Do not use power tools to clean the combustion face of
the cylinder head.
Prior to cleaning the combustion face of the cylinder head,
small rubber plugs, Part Number 4089255, must be
inserted in the oil supply holes at the ends to prevent
debris from entering the oil passages.
Use Scotch-Brite 7448, Part Number 3823258 or
equivalent, and solvent to clean the cylinder head
combustion face.
Clean the exhaust manifold gasket surface.
Clean the air intake gasket surface.

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a flexible brush and solvent to clean the valve guide
bores in the cylinder head.
Dry with compressed air.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a wire brush and solvent to clean the deposits from
the valve seat insert bores.
Dry with compressed air.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-24 Section 2 - Cylinder Head - Group 02

Inspect the fuel drillings and water passages for


restrictions or foreign material.
Remove any obstructions.

Inspect the valves and valve springs for cracks, bent or


broken valve stems, broken valve spring collets, or other
damage.
Inspect the valves for indications of leakage or burning.
If any of the following damage is found, the cylinder head
must be rebuilt or replaced.
Cracks
Leaks
Burnt valves
Other damage.

Inspect the cylinder head for cracks or damage.


Inspect the combustion face for ring-shaped wear or
erosion that encircles the valves.

NOTE: This step is not applicable if the engine has flat-


top liners and a single-piece head gasket, or when
upgrading from grooved-top liners and a 13-piece gasket
to flat-top liners and a single-piece gasket.
Wear in the area where the cylinder liner fire dam contacts
the head is acceptable.
Wear in the area where the fire ring combustion seal
contacts the head is not acceptable.
To distinguish the difference, use one of the inspection
gauges detailed below.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-25

NOTE: This step is not applicable if the engine has flat-


top liners and a single-piece head gasket or, when
upgrading from grooved-top liners and a 13-piece gasket
to flat-top liners and a single-piece gasket.
Install the inspection gauge, Part Number 3164442, on the
cylinder head combustion face with the dowel pin in the
injector bore for the cylinder being evaluated.
Inspect the area within 1/8-inch of the outside diameter of
the tool all the way around its perimeter. Any wear that can
be felt with a fingernail within the 1/8-inch area is
unacceptable, making the cylinder head not reusable.
Wear beyond this 1/8-inch area will have no effect on
future combustion sealing and the usability of the cylinder
head.

NOTE: This step is not applicable if the engine has flat-


top liners and a single-piece head gasket, or when
upgrading from grooved-top liners and a 13-piece gasket
to flat-top liners and a single-piece gasket.
Install the inspection gauge, Part Number 3165071, on the
cylinder head combustion face with the dowel pin in the
injector bore for the cylinder being evaluated.
Inspect the area within the narrow slots cut into the tool.
Rotate the tool to view the entire wire ring area on the
cylinder head combustion face.
Any wear that can be felt by fingernail within these slots
is unacceptable, making the cylinder head not reusable.
Wear outside the slots will have not have an effect on
future combustion sealing and the usability of the cylinder
head.

Inspect the valve spring retainers and valve spring guides


for damaged or worn areas.
Discard damaged and worn parts.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-26 Section 2 - Cylinder Head - Group 02

The use of flange-head capscrews with the torque-plus-


angle method of installation places the capscrew beyond
the yield point and permanently stretches the capscrew.
These capscrews can be reused throughout the life of the
engine, unless the capscrew exceeds the specified free
length.
The free length must be checked to reduce the possibility
of bottoming in the block during installation.

Use the head bolt stretch gauge, Part Number 3163162,


to measure the capscrew free length.
To check the capscrew free length, place the head of the
capscrew in the appropriate slot, long or short, with the
flange against the base of the slot.

If the end of the capscrew touches the foot of the gauge,


the capscrew is too long and must be discarded.

If there is clearance between the end of the capscrew and


the bottom base of the tool, the capscrew can be used.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-27

Measure
The capscrew can also be checked using a set of calipers.
The maximum allowable free length is measured from the
bottom of the flange to the end of the capscrew
(Dimension X).
Cylinder Head Capscrew Free Length
Short Capscrews 176 mm [ 6.93 in ]
Long Capscrews 231 mm [ 9.09 in ]

Measure the flatness of the cylinder head combustion face


surface as follows:
A to A and B to B (corner to corner)
C to C (across combustion face).
Dimensions for C to C must be checked at multiple
locations from front to rear of the cylinder head.

Cylinder Head Flatness


mm in
A to A 0.15 MAX 0.006
B to B 0.15 MAX 0.006
C to C 0.15 MAX 0.006
If the cylinder head is pitted, grooved, or is not within
specifications, the cylinder head must be replaced.

Use valve spring tester, Part Number 3375182, to


measure the valve spring load at the valve spring working
height.

Valve Spring Load at 61.75 mm [2.431 in]


N lbf
1511 MIN 339.5
1604 MAX 360.5
If the valve spring load for the working height is less than
the minimum specified, the valve spring must be
replaced.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-28 Section 2 - Cylinder Head - Group 02

Inspect the valves for damage and the collet grooves for
wear.
Measure the outside diameter of the valve stem.
Three measurements must be taken of each valve stem
at 40 mm [1.57 in], 90 mm [3.54 in], and 140 mm [5.51 in]
from the tip end.

Valve Stem Outside Diameter


mm in
9.593 MIN 0.378
9.627 MAX 0.379
If the valves are damaged or are not within specifications,
the valves must be replaced.

Inspect the valve guides for chips or cracks.


Measure the inside diameter of the valve guides in
locations 13 mm [ in] from each end and at the center
as shown.

Used Valve Guide Inside Diameter (Installed)


mm in
9.663 MIN 0.380
9.713 MAX 0.382
If the valve guide inside diameter is not within
specifications, it must be replaced.

Measure the valve guide installed height.

Valve Guide Height (Installed)


mm in
44.77 MIN 1.763
45.77 MAX 1.802
If damage is found or the valve guide is not within
specifications, it must be replaced.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-29

Use depth gauge, Part Number 3164438, to measure the


valve recess in the cylinder head.

Service Valve Recession Specification (NEW)


mm in
Intake 0.88 MIN 0.035
1.21 MAX 0.048
Exhaust 0.43 MIN 0.017
0.77 MAX 0.030

Service Valve Recession Specification (USED)


mm in
Intake 1.35 MAX 0.053
Exhaust 0.91 MAX 0.036
If the valve recess is not within specifications, the valve
seat and the valve must be replaced.

Measure the inside diameter of the valve guide bore.

Valve Guide Bore Inside Diameter


mm in
16.48 MIN 0.649
16.50 MAX 0.650
If the valve guide bore is not within specifications, the
cylinder head must be replaced.

Measure the valve seat insert bore depth in the cylinder


head.

Insert Bore Depth


mm in
Intake 9.32 MIN 0.367
9.48 MAX 0.373
Exhaust 10.32 MIN 0.406
10.48 MAX 0.413
If the valve seat insert bore is not within specifications, the
cylinder head must be replaced.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-30 Section 2 - Cylinder Head - Group 02

Measure the inside diameter of the valve seat insert bore.

Insert Bore Inside Diameter


mm in
Intake 49.51 MIN 1.949
49.54 MAX 1.950
Exhaust 47.51 MIN 1.870
47.54 MAX 1.872
If the valve seat insert bore inside diameter is not within
specifications, the cylinder head must be replaced.

Magnetic Crack Inspect


CAUTION
Prior to magnetic crack inspection of the combustion
face of the cylinder head, small plugs, Part Number
4089255, must be used to cover the oil supply holes
at the ends of the cylinder head to prevent debris and
magnetic powder from entering the lubrication system
during magnetic crack inspection. Failure to insert the
oil passage plugs can result in a connecting rod
bearing failure, crankshaft failure, or both.
Use magnetic crack detector, Part Number ST-1166, to
find cracks in the combustion face, in areas around the
valve ports, and the injector bores.
Place the magnetizing head on the combustion face, as
illustrated, to check for cracks that run across the cylinder
head.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Fill the powder spray bulb one-third (1/3) full with metal
powder.
Spray the powder lightly onto the combustion face.
Use compressed air to remove the excess metal powder.
Air Pressure 276 kPa [ 40 psi ]
The powder will remain in the cracks, if present, and show
as a white line.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-31

Cracks are not allowable on the combustion face of the


cylinder head.

Place the magnetizing head on the combustion face, as


shown, to check for cracks that run lengthwise.
Repeat the procedure as outlined above.

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.

CAUTION
Failure to insert the oil passage plugs can result in a
connecting rod bearing failure, crankshaft failure, or
both.
Remove the magnetizing head and use solvent to clean
the cylinder head. Dry with compressed air.
The cylinder head must be thoroughly cleaned after using
the magnetic crack detector to remove all of the iron
fragments.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-32 Section 2 - Cylinder Head - Group 02

Use the magnetic particle residual method to inspect the


valve for cracks.
The exhaust valves contain two types of metal, and
must be inspected by the coil shot method.
There will be a magnetic leakage apparent at the point
where the two metals are welded together.
The leakage will appear as a wide pattern of magnetic
particles.
Magnetize the valves in a coil of 100 to 200 amperes.

Inspect the valves with residual Magnaglo.


A broad fuzzy pattern will appear at the welded joint on
the exhaust valves. If there is a distinct line in the pattern,
the valve must be replaced.

The intake valves contain only one type of metal, and


must be magnetized and inspected in two directions.
Use the magnetic coil method and inspect with residual
Magnaglo, the same as the exhaust valves.
Magnetize the intake valves again with a headshot at 500
to 700 amperes.
Inspect the valves with residual Magnaglo.

Assemble
Use valve guide installer (1), Part Number 3163294, to
install the new valve guides.
The valve guides can be driven in using a dead blow
hammer.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-33

Measure the valve guide installed height above the


cylinder head top deck surface.

Valve Guide Height (Installed)


mm in
44.77 MIN 1.763
45.77 MAX 1.802

Measure the valve guide inside diameter.

New Valve Guide Inside Diameter (Installed)


mm in
9.66 MIN 0.380
9.71 MAX 0.382
If the valve guide is not within specifications, it must be
replaced.

The insert chamfer (1) must be installed toward the bottom


of the counterbore.
Use intake valve seat installer, Part Number 3163318, to
drive the intake seat insert into the counterbore.
Use exhaust valve seat installer, Part Number 3163319,
to drive the exhaust valve seat insert into the counterbore.
These two service tools pilot in the valve guide. Use a
dead blow hammer with the seat drivers to install the new
seat inserts.

Install new valve stem seals onto the valve guides. Refer
to Procedure 002-016 in Section 2.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-34 Section 2 - Cylinder Head - Group 02

Use clean 80W, or higher, gear lube with EP additives to


lubricate the valve stems.
Install the valves in the valve guides.
After the valves are installed, place the cylinder head on
a flat surface that will not damage the cylinder head
surface.

Install the valve spring guides.


Install the valve springs.
Install the valve spring retainers.

CAUTION
Do not use an impact tool for any part of this
procedure. Doing so can damage the service tool and/
or the engine.
Use the four valve spring compressor, Part Number
4919358, to compress the valve springs.
The replacer screw pilots into the injector bore and is
secured with the injector hold-down clamp.

Position the replacer screw (1) in the injector hole with the
threaded end pointing up.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-35

Secure the replacer screw (1) in the injector hole with the
injector clamp and capscrew.
Tighten the capscrew.
Torque Value: 54 Nm [ 40 ft-lb ]

CAUTION
The side of the retainer plate with the larger diameter
chamfers faces down to accommodate the valve
springs. Failure to position the retainer plate properly
can result in damage to the engine and/or tool.
Position the compressor plate (2) over the replacer screw
(1) and onto the valve springs.

Install the washer (4) and forcing nut (3) on the replacer
screw (1).
Tighten the nut hand-tight.

WARNING
Wear eye protection during this procedure. Springs
are under tension and can act as a projectile if
released, causing serious injury.
Turn the forcing nut (3) clockwise until the valve springs
start to compress.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-36 Section 2 - Cylinder Head - Group 02

CAUTION
Do not overtighten the forcing nut. Doing so can
damage the tool and/or springs.
Always use new collets when rebuilding the cylinder
head.
Install the new valve spring retainer collets.
Inspect the collets for proper seating and installation.
Once the cylinder head is assembled, it will be necessary
to run the vacuum test to make sure of a good valve to
seat sealing.
See the Vacuum Test section of this procedure.

WARNING
Wear eye protection during this procedure. Springs
are under tension and can act as a projectile if
released, causing serious injury.
Carefully turn the forcing nut (3) counterclockwise until
the tension is released from the valve springs.
Remove the forcing nut (3) and compressor plate (2) from
the replacer screw (1).

Remove the replacer screw (1) by removing the injector


hold-down bolt and injector hold-down clamp.
Repeat the above steps for each cylinder as needed.

CAUTION
Before the cylinder head is assembled onto the block,
all oil passage plugs must be removed. Failure to
remove the oil plugs will result in extensive engine
damage.
Remove the oil plugs from the cylinder head and the
cylinder block.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-37

Install
Two different styles of head gaskets are used on
Signature, ISX, and QSX15 engines, based on the style
of liner used in the engine. Correctly identify which style
of liner is used before installing the head gasket. Refer to
Procedure 001-028 in Section 1.
Install the cylinder head gasket.

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Use engine lifting fixture, Part Number 4919360 or
equivalent, to lift the cylinder head.
Two long cylinder head capscrews placed toward each
end of the cylinder head serve as convenient guides when
lowering the cylinder head into place.
Align the cylinder head over the dowel pins and lower into
position.

Use clean 15W-40 oil to lubricate the cylinder head


capscrews.
Allow the excess oil to drain from the threads.
Install the 26 capscrews into the cylinder head.

CAUTION
Make sure the four longer capscrews placed in the
correct location. Engine damage can occur if these
capscrews are not placed in the correct locations.
Tighten capscrews in sequence.
It is recommended to use an air impact wrench and
socket, Tool Number 3163059 and 3163484, to rotate the
capscrew 90 degrees.
Torque Value:
Step 1 203 Nm [ 150 ft-lb ]
Step 2 407 Nm [ 300 ft-lb ]
Step 3 Rotate 90 degrees.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-38 Section 2 - Cylinder Head - Group 02

Finishing Steps
NOTE: If the cylinder head or the cylinder head gasket is being replaced
due to a malfunction that caused an internal coolant leak, the external
crankcase breather element must be replaced, if the unit is equipped with
an external crankcase breather element.

WARNING
Coolant is toxic. Keep away from children and pets. If not reused,
dispose of in accordance with local environmental regulations.

WARNING
Batteries can emit explosive gases. To reduce the possibility of
personal injury, always ventilate the compartment before servicing
the batteries. To reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the negative (-) battery
cable last.
Install the overhead injector camshaft. Refer to Procedure 002-025 in
Section 2.
Install the overhead valve camshaft. Refer to Procedure 002-024 in
Section 2.
Install the accessory bracket. Refer to Procedure 001-082 in Section
1.
Install the retaining brace bracket. Refer to Procedure 001-081 in
Section 1.
Install the valve and injector camshaft gears. Refer to Procedure
001-088 in Section 1.
Install the upper front gear cover. Refer to Procedure 001-079 in
Section 1.
Install the injectors. Refer to Procedure 006-026 in Section 6.
Install the rocker lever shaft assemblies.Refer to Procedure 003-009
in Section 3.
Adjust the overhead settings. Refer to Procedure 003-004 in Section
3.
Install the rocker lever cover. Refer to Procedure 003-011 in Section
3.
Install the air compressor air inlet hose. Refer to Procedure 012-014
in Section 12.
Install the ECM. Use the following procedure for CM570 engines, in
the Signature, ISX and QSX15 Electronic Control System,
Troubleshooting and Repair Manual, Bulletin 3666259. Refer to
Procedure 019-031 in Section 19.
Install the ECM. Use the following procedure for CM870 engines, in
the Signature and ISX CM870 Electronic Control System,
Troubleshooting and Repair Manual, Bulletin 4021334. Refer to
Procedure 019-031 in Section 19
Install the ECM. Use the following procedure for CM871 engines, in
the ISX CM871 and ISM CM876 5 Electronic Control System,
Troubleshooting and Repair Manual, Bulletin 4021560. Refer to
Procedure 019-031 in Section 19.
Install the integrated fuel system module.Refer to Procedure 005-073
in Section 5.
Install the air intake connection. Refer to Procedure 010-080 in
Section 10.
Install the thermostat housing. Refer to Procedure 008-014 in Section
8.
Install the exhaust manifold. Refer to Procedure 011-007 in Section
11.
Install the turbocharger. Refer to Procedure 010-033 in Section 10.
Fill the cooling system. Refer to Procedure 008-018 in Section 8.
Install the batteries or air supply to the air starter. Refer to the OEM
service manual.
If a malfunction resulted in coolant, oil, excessive fuel or excessive
black smoke entering the exhaust system, the aftertreatment system
must be inspected.Refer to Procedure 014-013 in Section 14.
Operate the engine and check for leaks.
Signature, ISX, and QSX15 Eng [...] Valve Guide Seal, Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-39

Valve Guide Seal, Cylinder Head


(002-016)
General Information
Two different valve guides and valve guide seals are used
on Signature, ISX, and QSX15 engines.
Engines built prior to engine serial number 14010274 use
non-grooved valve guides and small valve guide seals.
These engines require the valve stem seal installer, Part
Number 3163294, to be used when installing the valve
guide seals.

Engine serial number (ESN) 14010274 and all engines


built after, use a larger valve guide seal. These seals are
designed to be installed by hand without the seal driver.
The new seals snap into a groove machined on the valve
guide. The seals introduced into engines built after ESN
14010274 with the grooved valve guides are not
compatible with engines built with the non-grooved valve
guides and vice versa.
NOTE: The seals that mate with the grooved valve guides
had two iterations.
1. Engines built from May 15, 2000 to the end of
February, 2002 had separate intake and exhaust
valve guide seals which were color coded. Intake
valve guide seals had a brass-colored garter spring
and three raised dots molded into the rubber; the
exhaust valve guide seals had a silver-colored garter
spring and no raised dots.
2. Engines built after March, 2002 had only one valve
guide seal for both intake and exhaust valve guides.
These seals can be used on any engines built after
ESN 14010274.

Preparatory Steps
On-Engine Repair

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the coolant to below the cylinder head level.
Refer to Procedure 008-018 in Section 8.
Remove the rocker lever cover. Refer to Procedure
003-011 in Section 3.
Disconnect the engine brake solenoid wiring
harness. Refer to Procedure 020-015 in Section 20.
Remove the injector for the cylinder to be repaired.
Refer to Procedure 006-026 in Section 6.
Valve Guide Seal, Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-40 Section 2 - Cylinder Head - Group 02

Bar the engine over so the cylinder you are working on is


at top-dead-center (TDC). Refer to Procedure 003-004 in
Section 3.
Repeat this step as needed for each cylinder.

Off-Engine Repair

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To reduce the possibility of serious
personal injury, be sure to have assistance or use
appropriate lifting equipment to lift this component or
assembly.
Remove the cylinder head and set it on a bench or
table. Refer to Procedure 002-004 in Section 2.

Remove

WARNING
Valve springs are under tension and can act as
projectiles if improperly released. To reduce the
possibility of eye injury, wear safety glasses with side
shields. Before releasing the valve spring tension,
check that the collets are properly seated.

CAUTION
Do not use an impact tool for any part of this
procedure. Doing so can damage the tool and/or the
engine.
NOTE: This step can be preformed either on or off-engine.
Use valve spring compressor, Part Number 4919358, to
compress the valve springs.
Remove the spring retainer collets.
Signature, ISX, and QSX15 Eng [...] Valve Guide Seal, Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-41

Position the replacer screw (1) in the injector hole with the
threaded end pointing up.

Secure the replacer screw (1) in the injector hole with the
injector clamp and capscrew.
Tighten the capscrew.
Torque Value: 54 Nm [ 40 ft-lb ]

CAUTION
The side of the retainer plate with the larger diameter
chamfers faces down to accommodate the valve
springs. Failure to position the retainer plate properly
can result in damage to the engine and/or tool.
Position the compressor plate (2) over the replacer screw
(1) and onto the valve springs.

Install the washer (4) and forcing nut (3) on the replacer
screw (1).
Tighten finger tight.
Valve Guide Seal, Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-42 Section 2 - Cylinder Head - Group 02

WARNING
Eye protection should be worn during this procedure.
Springs are under tension and can act as a projectile
if released, causing serious injury.
Turn the forcing nut (3) clockwise until the valve springs
start to compress.

CAUTION
Do not overtighten the forcing nut. Doing so can
damage the tool and/or springs.
Continue turning the forcing nut (3) clockwise until the
valve collets can be removed with a magnetic tool.
Discard the valve collets.

WARNING
Wear eye protection during this procedure. Springs
are under tension and can act as a projectile if
released, causing serious injury.
Carefully turn the forcing nut (3) counterclockwise until
the tension is released from the valve springs.
Remove the forcing nut (3) and compressor plate (2) from
the replacer screw (1).

Remove the replacer screw (1) by removing he injector


hold down bolt and injector hold down clamp.
Signature, ISX, and QSX15 Eng [...] Valve Guide Seal, Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-43

Remove the valve spring retainer.


Remove the valve spring.
Remove the valve spring guide.
Repeat the above steps for each cylinder as needed.
NOTE: It is not necessary to remove the valve spring
guides on cylinder heads that have the grooved style valve
guides. Valve guides that do not have the groove must
have the valve spring guides removed for use of the
installation tool.

Use the valve guide seal remover, Part Number 3163293,


to remove the valve guide seals.

Install
Grooved Valve Guide Seals:
NOTE: The seals that mate with the grooved valve guides
had two iterations.
1. Engines built from May 15, 2000 to the end of
February, 2002 had separate intake and exhaust
valve guide seals which were color coded. Intake
valve guide seals had a brass-colored garter spring
and three raised dots molded into the rubber; the
exhaust valve guide seals had a silver-colored garter
spring and no raised dots.
2. Engines built after March, 2002 had only one valve
guide seal for both intake and exhaust valve guides.
These seals can be used on any engines built after
ESN 14010274.
Install the intake and exhaust valve guide seals by
snapping the seal by hand into the groove on the valve
guide.
Valve Guide Seal, Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-44 Section 2 - Cylinder Head - Group 02

Non-Grooved Valve Guide Seals:


NOTE: Make certain the valve spring guides are removed
before installing the non-grooved valve guide seals.
Use an unmodified valve seal installer, Part Number
3163294, to install the valve guide seals. The seal installer
must make contact with the cylinder head when installed.
This correctly locates the valve guide seal.

Install the valve spring retainer.


Install the valve spring.
Install the valve spring guide.
Repeat the above steps for each cylinder as needed.

WARNING
Valve springs are under tension and can act as
projectiles if improperly released. To reduce the
possibility of eye injury, wear safety glasses with side
shields. Before releasing the valve spring tension,
check that the collets are properly seated.

CAUTION
Do not use an impact tool for any part of this
procedure. Doing so can damage the tool and/or the
engine.
Use the four valve spring compressor, Part Number
4919358, to compress the valve springs.

Position the replacer screw (1) in the injector hole with the
threaded end pointing up.
Signature, ISX, and QSX15 Eng [...] Valve Guide Seal, Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-45

Secure the replacer screw (1) in the injector hole with the
injector clamp and capscrew.
Tighten the capscrew.
Torque Value: 54 Nm [ 40 ft-lb ]

CAUTION
The side of the retainer plate with the larger diameter
chamfers faces down to accommodate the valve
springs. Failure to position the retainer plate properly
can result in damage to the engine and/or tool.
Position the compressor plate (2) over the replacer screw
(1) and onto the valve springs.

Install the washer (4) and forcing nut (3) on the replacer
screw (1).
Tighten the nut finger tight.

WARNING
Eye protection should be worn during this procedure.
Springs are under tension and can act as a projectile
if released, causing serious injury.
Turn the forcing nut (3) clockwise until the valve springs
start to compress.
Valve Guide Seal, Cylinder Head Signature, ISX, and QSX15 Eng [...]
Page 2-46 Section 2 - Cylinder Head - Group 02

CAUTION
Do not overtighten the forcing nut. Doing so can
damage the tool and/or springs.
Continue turning the forcing nut (3) clockwise until the
valve collets can be installed.
Always use new collets when rebuilding the cylinder
head.
Install the new valve spring retainer collets.
Inspect the collets for proper seating and installation.

WARNING
Eye protection should be worn during this procedure.
Springs are under tension and can act as a projectile
if released, causing serious injury.
Carefully turn the forcing nut (3) counterclockwise until
the tension is released from the valve springs.
Remove the forcing nut (3) and compressor plate (2) from
the replacer screw (1).

Remove the replacer screw (1) by removing the injector


hold down bolt and injector hold down clamp.
Repeat the above steps for each cylinder as needed.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Valve
Section 2 - Cylinder Head - Group 02 Page 2-47

Finishing Steps
On-Engine Repair

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Install the injectors. Refer to Procedure 006-026 in
Section 6.
Connect the engine brake solenoid wiring harness.
Refer to Procedure 020-015 in Section 20.
Install the rocker lever cover. Refer to Procedure
003-011 in Section 3.
Fill the cooling system. Refer to Procedure 008-018
in Section 8.
If failure resulted in coolant, oil, excessive fuel or
excessive black smoke entering the exhaust system,
the aftertreatment system must be inspected. Refer
to Procedure 014-013 in Section 14.
Operate the engine and check for leaks and proper
operation.

Off-Engine Repair

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To reduce the possibility of serious
personal injury, be sure to have assistance or use
appropriate lifting equipment to lift this component or
assembly.
Install the cylinder head. Refer to Procedure 002-004
in Section 2.
If failure resulted in coolant, oil, excessive fuel or
excessive black smoke entering the exhaust system,
the aftertreatment system must be inspected. Refer
to Procedure 014-013 in Section 14.
Operate the engine and check for leaks and proper
operation.

Overhead Camshaft, Valve (002-024)


Preparatory Steps
Remove the upper gear cover. Refer to Procedure
001-079.
Overhead Camshaft, Valve Signature, ISX, and QSX15 Eng [...]
Page 2-48 Section 2 - Cylinder Head - Group 02

Remove the rocker lever cover. Refer to Procedure


003-011.

Disconnect the engine brake wiring harness. Refer to


Procedure 020-015.
Remove the rocker lever shafts. Refer to Procedure
003-009.

Remove the valve camshaft gear. Refer to Procedure


001-088.

Remove
Remove the retainer capscrews, retainer, seal, and o-ring.
Discard the seal and o-ring.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Valve
Section 2 - Cylinder Head - Group 02 Page 2-49

CAUTION
Use caution when removing the camshaft to avoid
damaging the camshaft bushings.
Remove the valve camshaft.

Clean and Inspect for Reuse

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the valve camshaft and the bore of the valve
camshaft gear with Envirosol 655 solvent, or equivalent,
and a lint-free cloth.

Check the valve camshaft and valve camshaft gear for


fretting damage.
The valve camshaft and valve camshaft gear must be
replaced if damaged.

Measure the outside diameter of the seven valve camshaft


bearing journals.

Valve Camshaft Bearing Journal Outside Diameter


mm in
64.987 MIN 2.5585
65.013 MAX 2.5596
If the camshaft journals are not within specifications, the
camshaft must be replaced.
Overhead Camshaft, Valve Signature, ISX, and QSX15 Eng [...]
Page 2-50 Section 2 - Cylinder Head - Group 02

Inspect the camshaft lobes for cracks, scratches, and


other damage. Refer to Camshaft Reuse Guidelines for
Cummins Engines with Roller Followers or Roller
Tappets, Bulletin 3666052, for further reuse guidelines.

Install
CAUTION
Use caution when installing the camshaft to avoid
damaging the camshaft bushings.
Coat the inside of the valve camshaft bushings with
Lubriplate prior to installing camshaft.
Install the valve camshaft.

Install new o-rings onto the retainer plate.


Install the retainer plate and capscrews.
Tighten the capscrews.
Torque Value: 40 Nm [ 30 ft-lb ]

Finishing Steps
Install the valve camshaft gear. Refer to Procedure
001-088.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Injector
Section 2 - Cylinder Head - Group 02 Page 2-51

Install the rocker lever shafts. Refer to Procedure 003-009.


Connect the engine brake wiring harness. Refer to
Procedure 020-015.
Install the rocker lever cover. Refer to Procedure 003-011.

Install the upper gear cover. Refer to Procedure 001-079.

Operate the engine until it reaches normal operating


temperature and check for leaks.

Overhead Camshaft, Injector (002-025)


Preparatory Steps
Remove the upper gear cover. Refer to Procedure
001-079.
Overhead Camshaft, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-52 Section 2 - Cylinder Head - Group 02

Remove the rocker lever cover. Refer to Procedure


003-011.

Remove the rocker lever shafts. Refer to Procedure


003-009.

Remove the injector camshaft scissor gear. Refer to


Procedure 001-088.

Remove the integrated fuel system module. Refer to


Procedure 005-073.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Injector
Section 2 - Cylinder Head - Group 02 Page 2-53

Remove the camshaft sensor. Refer to Procedure 019-038


in the Troubleshooting and Repair Manual Electronic
Control System Signature, ISX and QSX15 Engines.

Remove
Remove the injector camshaft cover plate capscrews.
Remove the injector cover plate and gasket.
Discard the gasket.

Remove the two capscrews and the injector camshaft


retainer plate and o-rings.
Discard the o-rings.

CAUTION
Use caution when removing the camshaft to avoid
damaging the camshaft bushings.
Remove the injector camshaft.
Overhead Camshaft, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-54 Section 2 - Cylinder Head - Group 02

Clean and Inspect for Reuse

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

WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
Clean the injector camshaft and the bore of the injector
camshaft scissor gear with Envirosol 655 solvent, or
equivalent and a lint-free cloth.

Check the injector camshaft and injector camshaft scissor


gear for fretting damage.
The camshaft and gear must be replaced if damaged.

Measure the seven injector camshaft bearing journals.

Injector Camshaft Bearing Journal Outside Diameter


mm in
84.987 MIN 3.3459
85.013 MAX 3.3469
If the camshaft bearing journals are not within
specifications, the camshaft must be replaced.

Inspect the camshaft lobes for cracks, scratches, or other


damage.
Refer to the Camshaft Reuse Guidelines for Cummins
Engines with Roller Tappets, Bulletin 3666052, for further
reuse guidelines.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Injector
Section 2 - Cylinder Head - Group 02 Page 2-55

Install
CAUTION
Use caution when installing the camshaft to avoid
damaging the camshaft bushings.
Coat the inside of the injector camshaft bearings with
Lubriplate prior to installing camshaft.
Install the injector camshaft.

Install new o-rings on the retainer plate.


Install the retainer plate and capscrews.
Tighten the capscrews.
Torque Value: 40 Nm [ 30 ft-lb ]

Install the injector camshaft cover plate with new gasket.


Install the capscrews.
Tighten the capscrews.
Torque Value: 40 Nm [ 30 ft-lb ]

Finishing Steps
Install the integrated fuel system module. Refer to
Procedure 005-073.
Overhead Camshaft, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-56 Section 2 - Cylinder Head - Group 02

Install the camshaft sensor. Refer to Procedure 019-038


in Troubleshooting and Repair Manual Electronic Control
System Signature, ISX and QSX15 Engines.

Install the injector camshaft scissor gear. Refer to


Procedure 001-088.

Install the rocker lever shafts. Refer to Procedure 003-009.


Install the rocker lever cover. Refer to Procedure 003-011.

Install the upper gear cover. Refer to Procedure 001-079.


Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Valve
Section 2 - Cylinder Head - Group 02 Page 2-57

Operate the engine to normal operating temperature and


check for leaks.

Overhead Camshaft Bushings, Valve


(002-026)
Initial Check
Remove the valve camshaft. Refer to Procedure 002-024.

Inspect the amount of copper exposure on the camshaft


bushing. If it extends more than 180 degrees around the
bushing, the bushing must be replaced.

Remove
Use service tool, Part Number 3164088, for valve
camshaft bushing removal.
The hydraulic camshaft bushing tool kit, Part Number
3823621, consists of:

Item Part Number Description Qty.


1 3823622 Pump, air hydraulic 1
2 3823623 Center hole ram 1
3 3823624 Hydraulic hose 1
4 3823625 Puller shaft 1
5 3823626 Stop collar 2
Overhead Camshaft Bushings, Valve Signature, ISX, and QSX15 Eng [...]
Page 2-58 Section 2 - Cylinder Head - Group 02

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

Step 1
CAUTION
Make sure to select the proper-size centering guides.
This kit contains different-size centering guides for
journals both with and without bushings installed.
Selection of incorrect centering guides can result in
damage to the journal and/or guides.
Install the centering guides in two of the camshaft bore
ends.
NOTE: The centering guide can be installed in any of the
holes, but keeping the wider distance is preferred.

Step 2
Install the puller shaft through both of the installed
centering guides.

Step 3
Position the receiver spacer on the puller shaft with the
open end facing the cylinder head.
NOTE: A receiver spacer has not been included in the
valve camshaft bushing replacer kit, Part Number
3164088. Use receiver spacer, Part Number 3824864, or
an appropriate-size spacer from another kit.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Valve
Section 2 - Cylinder Head - Group 02 Page 2-59

Step 4
Slide the center hole ram onto the puller shaft until it
touches the receiver spacer.

Step 5
Install the stop collar in the groove of the puller shaft
closest to the center hole ram.

Step 6
CAUTION
Make sure to install the proper-size bushing driver.
Selection of incorrect bushing driver can result in
damage to the camshaft bushing, journal cylinder
head bore, and tool equipment.
Position the bushing driver on the puller shaft next to the
bushing that is being removed.
Slide the bushing driver into the camshaft bushing until it
stops against the flange of the bushing driver.

Step 7 (for inner bushings only)


Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Overhead Camshaft Bushings, Valve Signature, ISX, and QSX15 Eng [...]
Page 2-60 Section 2 - Cylinder Head - Group 02

Step 8 (for inner bushings only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
Push down on the PRESS side of the air/hydraulic pump
pedal and hold until the cam bushing is out of the bore.

Step 9 (for inner bushings only)


Remove the camshaft bushing from the bushing driver.
Remove the bushing driver and stop collar from the puller
shaft.

Step 10 (for inner bushings only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Step 11 (for rear bushing only)


Install the bushing driver onto the puller shaft behind the
outer camshaft bushing.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Valve
Section 2 - Cylinder Head - Group 02 Page 2-61

Step 12 (for rear bushing only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
Push down on the PRESS side of the air/hydraulic pump
pedal and hold until the rear camshaft bushing and
centering guide are out of the bore.

Step 13 (for rear bushing only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Step 14 (for front bushing only)


Install the bushing driver on the puller shaft so that the
larger end of the bushing driver is facing the front
camshaft bushing.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.

Step 15 (for front bushing only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
Push down on the PRESS side of the air/hydraulic pump
pedal and hold until the camshaft bushing and centering
guide are out of the bore.
Overhead Camshaft Bushings, Valve Signature, ISX, and QSX15 Eng [...]
Page 2-62 Section 2 - Cylinder Head - Group 02

Step 16 (for front bushing only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Inspect for Reuse


Clean and inspect the camshaft bores in the cylinder head
for reuse. Use an emery cloth to remove any burrs and
sharp edges from the bore.

Install
Use service tool, Part Number 3164088, for valve
camshaft bushing removal.
The hydraulic camshaft bushing tool Kit, Part Number
3823621, consists of:

Item Part Number Description Qty.


1 3823622 Pump, air hydraulic 1
2 3823623 Center hole ram 1
3 3823624 Hydraulic hose 1
4 3823625 Puller shaft 1
5 3823626 Stop collar 2

NOTE:
For inner camshaft bushing installation, follow Steps
1, 2, 5, 6, 7, 8, 9, 10, and 11.
For rear camshaft bushing installation, follow Steps
1, 3, 5, 6, 7, 12, 13, 14, and 15.
For front camshaft bushing installation, follow Steps
1, 4, 5, 6, 7, 16, 17, 18, and 19.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Valve
Section 2 - Cylinder Head - Group 02 Page 2-63

Step 1
CAUTION
Make sure to select the proper-size centering guides.
This kit contains different-size centering guides for
journals both with and without bushings installed.
Selection of incorrect centering guides can result in
damage to the journal and/or guides.
Install the centering guides into both camshaft bore ends.

Step 2 (for inner bushing only)


Slide the puller shaft through the centering guide and into
the number 2 journal. Place a camshaft bushing, if
desired, over the end of the puller shaft.
Move the puller shaft through the number 3 journal and do
the same as above.
Continue through each inner journal until the puller shaft
is completely through the opposite-end centering guide.

Step 3 (for rear bushing only)


Install the puller shaft through the two installed centering
guides.

Step 4 (for front bushing only)


Slide the puller shaft through the centering guide and into
the number 1 journal.
Place a camshaft bushing over the end of the puller shaft.
Continue to slide the puller shaft through the block and
opposite-end centering guide.
Overhead Camshaft Bushings, Valve Signature, ISX, and QSX15 Eng [...]
Page 2-64 Section 2 - Cylinder Head - Group 02

Step 5
Position the receiver spacer on the puller shaft with the
open end facing the cylinder head.

Step 6
Slide the center hole ram onto the puller shaft until it
touches the receiver spacer.

Step 7
Install the stop collar in the groove of the puller shaft
closest to the center hole ram.

Step 8 (for inner bushings only)


CAUTION
Make sure to install the proper-size bushing driver.
Selection of incorrect bushing driver can result in
damage to the camshaft bushing, journal, and tool
equipment.
Position the proper bushing driver on the puller shaft next
to the bushing being installed.
Slide the camshaft bushing over the bushing driver.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Valve
Section 2 - Cylinder Head - Group 02 Page 2-65

Step 9 (for inner bushings only)


CAUTION
It is very important that the oil ports on the camshaft
bushings being installed be aligned with the oil ports
in the journal. Misalignment of cam bushing oil port to
journal oil port can result in damage to the engine.
Push the bushing driver over until the cam bushing just
touches the cylinder head.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Rotate the camshaft bushing until the oil port is aligned
with the oil port of the bore.

Step 10 (for inner bushings only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
Push down on the PRESS side of the air/hydraulic pump
pedal to pull the cam bushing into the cylinder head. As
the camshaft bushing oil port comes close to the bore oil
port, let up on the pedal.
Lightly tapping the PRESS side of the air/hydraulic pump
pedal will provide control to stop the camshaft bushing in
the desired position.

Step 11 (for inner bushings only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.
Overhead Camshaft Bushings, Valve Signature, ISX, and QSX15 Eng [...]
Page 2-66 Section 2 - Cylinder Head - Group 02

Step 12 (for rear bushings only)


CAUTION
Make sure to install the proper-size bushing driver.
Selection of incorrect bushing driver can result in
damage to the cam bushing, journal, and tool
equipment.
Place the camshaft bushing over the end of the puller
shaft.
Position the bushing driver on the puller shaft and slide
the camshaft bushing onto the bushing driver.

Step 13 (for rear bushings only)


CAUTION
It is very important that the oil ports on the camshaft
bushings being installed be aligned with the oil ports
in the journal. Misalignment of camshaft bushing oil
port to journal oil port can result in damage to the
engine.
Push the bushing driver over until the camshaft bushing
just touches the cylinder head.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Rotate the camshaft bushing until the oil port is aligned
with the oil port of the bore.

Step 14 (for rear bushings only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
For front and rear bushing installation, move the centering
guides to journals 2 and 6.
Push down on the PRESS side of the air/hydraulic pump
pedal to pull the camshaft bushing into the cylinder head.
As the camshaft bushing oil port comes close to the bore
oil port, let up on the pedal.
Lightly tapping the PRESS side of the air/hydraulic pump
pedal will provide control to stop the camshaft bushing in
the desired position.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Valve
Section 2 - Cylinder Head - Group 02 Page 2-67

Step 15 (for rear bushings only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Step 16 (for front bushings only)


CAUTION
Make sure to install the proper-size bushing driver.
Selection of incorrect bushing driver can result in
damage to the camshaft bushing, journal, and tool
equipment.
Position the proper bushing driver on the puller shaft.
Slide the camshaft bushing over the bushing driver.

Step 17 (for front bushings only)


CAUTION
It is very important that the oil ports on the camshaft
bushings being installed be aligned with the oil ports
in the journal. Misalignment of camshaft bushing oil
port to journal oil port can result in damage to the
engine.
Push the bushing driver over until the camshaft bushing
just touches the cylinder head.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Rotate the camshaft bushing until the oil port is aligned
with the oil port of the bore.
Overhead Camshaft Bushings, Valve Signature, ISX, and QSX15 Eng [...]
Page 2-68 Section 2 - Cylinder Head - Group 02

Step 18 (for front bushings only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
NOTE: The centering guide will be forced into the receiver
spacer when the bushing and driver are pulled into the
bore.
Push down on the PRESS side of the air/hydraulic pump
pedal to pull the camshaft bushing into the cylinder head.
As the camshaft bushing oil port comes close to the bore
oil port, let up on the pedal.
Lightly tapping the PRESS side of the air/hydraulic pump
pedal will provide control to stop the camshaft bushing in
the desired position.

Step 19 (for front bushings only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Install the valve camshaft. Refer to Procedure 002-024.


Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Injector
Section 2 - Cylinder Head - Group 02 Page 2-69

Operate the engine to normal operating temperature and


check for leaks.

Overhead Camshaft Bushings, Injector


(002-027)
Initial Check
Remove the injector camshaft. Refer to Procedure
002-025.

Inspect the amount of copper exposure on the camshaft


bushing. If it extends more than 180 degrees around the
bushing, the bushing must be replaced.

Remove
Use service tool, Part Number 3164089, for injector
camshaft bushing removal.
The hydraulic camshaft bushing tool kit, Part Number
3823621, consists of:

Item Part Number Description Qty.


1 3823622 Pump, air hydraulic 1
2 3823623 Center hole ram 1
3 3823624 Hydraulic hose 1
4 3823625 Puller shaft 1
5 3823626 Stop collar 2
Overhead Camshaft Bushings, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-70 Section 2 - Cylinder Head - Group 02

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

Step 1
CAUTION
Make sure to select the proper-size centering guides.
This kit contains different-size centering guides for
journals both with and without bushings installed.
Selection of incorrect centering guides can result in
damage to the journal and/or guides.
Install the centering guides in two of the camshaft bore
ends.
NOTE: The centering guide can be installed in any of the
holes, but keeping the wider distance is preferred.

Step 2
Install the puller shaft through both of the installed
centering guides.

Step 3
Position the receiver spacer on the puller shaft with the
open end facing the cylinder head.
NOTE: A receiver spacer has not been included in the
injector camshaft bushing replacer kit, Part Number
3164088. Use receiver spacer, Part Number 3824864, or
an appropriate-size spacer from another kit.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Injector
Section 2 - Cylinder Head - Group 02 Page 2-71

Step 4
Slide the center hole ram onto the puller shaft until it
touches the receiver spacer.

Step 5
Install the stop collar in the groove of the puller shaft
closest to the center hole ram.

Step 6
CAUTION
Make sure to install the proper-size bushing driver.
Selection of incorrect bushing driver can result in
damage to the camshaft bushing, journal cylinder
head bore, and tool equipment.
Position the bushing driver on the puller shaft next to the
bushing that is being removed.
Slide the bushing driver into the camshaft bushing until it
stops against the flange of the bushing driver.

Step 7 (for inner bushings only)


Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Overhead Camshaft Bushings, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-72 Section 2 - Cylinder Head - Group 02

Step 8 (for inner bushings only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
Push down on the PRESS side of the air/hydraulic pump
pedal and hold until the cam bushing is out of the bore.

Step 9 (for inner bushings only)


Remove the camshaft bushing from the bushing driver.
Remove the bushing driver and stop collar from the puller
shaft.

Step 10 (for inner bushings only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Step 11 (for rear bushing only)


Install the bushing driver onto the puller shaft behind the
outer camshaft bushing.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Injector
Section 2 - Cylinder Head - Group 02 Page 2-73

Step 12 (for rear bushing only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
Push down on the PRESS side of the air/hydraulic pump
pedal and hold until the rear camshaft bushing and
centering guide are out of the bore.

Step 13 (for rear bushing only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Step 14 (for front bushing only)


Install the bushing driver on the puller shaft so that the
larger end of the bushing driver is facing the front
camshaft bushing.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.

Step 15 (for front bushing only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
Push down on the PRESS side of the air/hydraulic pump
pedal and hold until the camshaft bushing and centering
guide are out of the bore.
Overhead Camshaft Bushings, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-74 Section 2 - Cylinder Head - Group 02

Step 16 (for front bushing only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Inspect for Reuse


Clean and inspect the camshaft bores in the cylinder head
for reuse. Use an emery cloth to remove any burrs and
sharp edges from the bore.

Install
Use service tool, Part Number 3164089, for injector
camshaft bushing removal.
The hydraulic camshaft bushing tool kit, Part Number
3823621, consists of:

Item Part Number Description Qty.


1 3823622 Pump, air hydraulic 1
2 3823623 Center hole ram 1
3 3823624 Hydraulic hose 1
4 3823625 Puller shaft 1
5 3823626 Stop collar 2

NOTE:
For inner camshaft bushing installation, follow Steps
1, 2, 5, 6, 7, 8, 9, 10, and 11.
For rear camshaft bushing installation, follow Steps
1, 3, 5, 6, 7, 12, 13, 14, and 15.
For front camshaft bushing installation, follow Steps
1, 4, 5, 6, 7, 16, 17, 18, and 19.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Injector
Section 2 - Cylinder Head - Group 02 Page 2-75

Step 1
CAUTION
Make sure to select the proper-size centering guides.
This kit contains different-size centering guides for
journals both with and without bushings installed.
Selection of incorrect centering guides can result in
damage to the journal and/or guides.
Install the centering guides into both camshaft bore ends.

Step 2 (for inner bushing only)


Slide the puller shaft through the centering guide and into
the number 2 journal. Place a camshaft bushing, if
desired, over the end of the puller shaft.
Move the puller shaft through the number 3 journal and do
the same as above.
Continue through each inner journal until the puller shaft
is completely through the opposite-end centering guide.

Step 3 (for rear bushing only)


Install the puller shaft through the two installed centering
guides.

Step 4 (for front bushing only)


Slide the puller shaft through the centering guide and into
the number 1 journal.
Place a camshaft bushing over the end of the puller shaft.
Continue to slide the puller shaft through the block and
opposite-end centering guide.
Overhead Camshaft Bushings, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-76 Section 2 - Cylinder Head - Group 02

Step 5
Position the receiver spacer on the puller shaft with the
open end facing the cylinder head.

Step 6
Slide the center hole ram onto the puller shaft until it
touches the receiver spacer.

Step 7
Install the stop collar in the groove of the puller shaft
closest to the center hole ram.

Step 8 (for inner bushings only)


CAUTION
Make sure to install the proper-size bushing driver.
Selection of incorrect bushing driver can result in
damage to the camshaft bushing, journal, and tool
equipment.
Position the proper bushing driver on the puller shaft next
to the bushing being installed.
Slide the camshaft bushing over the bushing driver.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Injector
Section 2 - Cylinder Head - Group 02 Page 2-77

Step 9 (for inner bushings only)


CAUTION
It is very important that the oil ports on the camshaft
bushings being installed be aligned with the oil ports
in the journal. Misalignment of cam bushing oil port to
journal oil port can result in damage to the engine.
Push the bushing driver over until the cam bushing just
touches the cylinder head.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Rotate the camshaft bushing until the oil port is aligned
with the oil port of the bore.

Step 10 (for inner bushings only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
Push down on the PRESS side of the air/hydraulic pump
pedal to pull the cam bushing into the cylinder head. As
the camshaft bushing oil port comes close to the bore oil
port, let up on the pedal.
Lightly tapping the PRESS side of the air/hydraulic pump
pedal will provide control to stop the camshaft bushing in
the desired position.

Step 11 (for inner bushings only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.
Overhead Camshaft Bushings, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-78 Section 2 - Cylinder Head - Group 02

Step 12 (for rear bushings only)


CAUTION
Make sure to install the proper-size bushing driver.
Selection of incorrect bushing driver can result in
damage to the cam bushing, journal, and tool
equipment.
Place the camshaft bushing over the end of the puller
shaft.
Position the bushing driver on the puller shaft and slide
the camshaft bushing onto the bushing driver.

Step 13 (for rear bushings only)


CAUTION
It is very important that the oil ports on the camshaft
bushings being installed be aligned with the oil ports
in the journal. Misalignment of camshaft bushing oil
port to journal oil port can result in damage to the
engine.
Push the bushing driver over until the camshaft bushing
just touches the cylinder head.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Rotate the camshaft bushing until the oil port is aligned
with the oil port of the bore.

Step 14 (for rear bushings only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
For front and rear bushing installation, move the centering
guides to journals 2 and 6.
Push down on the PRESS side of the air/hydraulic pump
pedal to pull the camshaft bushing into the cylinder head.
As the camshaft bushing oil port comes close to the bore
oil port, let up on the pedal.
Lightly tapping the PRESS side of the air/hydraulic pump
pedal will provide control to stop the camshaft bushing in
the desired position.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Injector
Section 2 - Cylinder Head - Group 02 Page 2-79

Step 15 (for rear bushings only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Step 16 (for front bushings only)


CAUTION
Make sure to install the proper-size bushing driver.
Selection of incorrect bushing driver can result in
damage to the camshaft bushing, journal, and tool
equipment.
Position the proper bushing driver on the puller shaft.
Slide the camshaft bushing over the bushing driver.

Step 17 (for front bushings only)


CAUTION
It is very important that the oil ports on the camshaft
bushings being installed be aligned with the oil ports
in the journal. Misalignment of camshaft bushing oil
port to journal oil port can result in damage to the
engine.
Push the bushing driver over until the camshaft bushing
just touches the cylinder head.
Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.
Rotate the camshaft bushing until the oil port is aligned
with the oil port of the bore.
Overhead Camshaft Bushings, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-80 Section 2 - Cylinder Head - Group 02

Step 18 (for front bushings only)


WARNING
Keep hands clear of the journal area when operating
the pedal of the air/hydraulic pump. Serious injury can
result if hands are caught between journal and
bushing area when operating the air/hydraulic pump
pedal.
NOTE: The centering guide will be forced into the receiver
spacer when the bushing and driver are pulled into the
bore.
Push down on the PRESS side of the air/hydraulic pump
pedal to pull the camshaft bushing into the cylinder head.
As the camshaft bushing oil port comes close to the bore
oil port, let up on the pedal.
Lightly tapping the PRESS side of the air/hydraulic pump
pedal will provide control to stop the camshaft bushing in
the desired position.

Step 19 (for front bushings only)


Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.

Install the injector camshaft. Refer to Procedure 002-025.


Signature, ISX, and QSX15 Eng [...] Overhead Camshaft End Clearance, Valve
Section 2 - Cylinder Head - Group 02 Page 2-81

Operate the engine to normal operating temperature and


check for leaks.

Overhead Camshaft End Clearance,


Valve (002-028)
Measure
Remove the rocker lever cover. Refer to Procedure
003-011.

Remove the rocker lever shafts. Refer to Procedure


003-009.

Remove the upper gear cover. Refer to Procedure


001-079.
Overhead Camshaft End Clearance, Valve Signature, ISX, and QSX15 Eng [...]
Page 2-82 Section 2 - Cylinder Head - Group 02

Unload the injector camshaft scissor gear. Refer to


Procedure 001-088.
NOTE: End clearance can be checked without removing
the injector camshaft gear on engines equipped with a
non-scissor injector camshaft gear.

CAUTION
The rear camshaft cover plate must be installed.
Use a dial indicator to check the end clearance of the gear.
Push the camshaft to the rear and set the gauge at 0.
Pull the gear forward and measure the end clearance.

Valve Camshaft End Clearance


mm in
0.70 MAX 0.0276
If measurement exceeds specifications, replace the
overhead valve camshaft. Refer to Procedure 002-024.

NOTE: Before loading the injector camshaft scissor gear,


you must read Engine Base Timing. Refer to Procedure
001-088.

Install the upper gear cover. Refer to Procedure 001-079.


Signature, ISX, and QSX15 Eng [...] Overhead Camshaft End Clearance, Injector
Section 2 - Cylinder Head - Group 02 Page 2-83

Install the rocker lever shafts. Refer to Procedure 003-009.

Install the rocker lever cover. Refer to Procedure 003-011.

Operate the engine to normal operating temperature and


check for leaks.

Overhead Camshaft End Clearance,


Injector (002-029)
Measure
Remove the rocker lever cover. Refer to Procedure
003-011.
Overhead Camshaft End Clearance, Injector Signature, ISX, and QSX15 Eng [...]
Page 2-84 Section 2 - Cylinder Head - Group 02

Remove the rocker lever shafts. Refer to Procedure


003-009.

Remove the upper gear cover. Refer to Procedure


001-079.

Unload the injector camshaft scissor gear. Refer to


Procedure 001-088.
NOTE: End clearance can be checked without removing
the injector camshaft gear on engines equipped with a
non-scissor injector camshaft gear.

CAUTION
The rear camshaft cover plate must be installed.
Use a dial indicator to check the end clearance of the gear.
Push the camshaft to the rear and set the gauge at 0.
Pull the gear forward and measure the end clearance.

Injector Camshaft End Clearance


mm in
0.70 MAX 0.0276
If measurement exceeds specifications, replace the
injector overhead camshaft. Refer to Procedure 002-025.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft End Clearance, Injector
Section 2 - Cylinder Head - Group 02 Page 2-85

NOTE: Before loading the injector camshaft scissor gear,


you must read Engine Base Timing. Refer to Procedure
001-088.

Install the upper gear cover. Refer to Procedure 001-079.

Install the rocker lever shafts. Refer to Procedure 003-009.

Install the rocker lever cover. Refer to Procedure 003-011.


Injector Camshaft Scissor Gear Signature, ISX, and QSX15 Eng [...]
Page 2-86 Section 2 - Cylinder Head - Group 02

Operate the engine to normal operating temperature and


check for leaks.

Overhead Camshaft Gear, Valve


(002-030)
Remove
Remove the valve camshaft gear. Refer to Procedure
001-088.

Install
Install the valve camshaft gear. Refer to Procedure
001-088.

Injector Camshaft Scissor Gear


(002-031)
Remove
Remove the injector camshaft concept gear. Refer to
Procedure 001-088.
Signature, ISX, and QSX15 Eng [...] Injector Camshaft Scissor Gear
Section 2 - Cylinder Head - Group 02 Page 2-87

Install
Install the injector camshaft concept gear. Refer to
Procedure 001-088.
Injector Camshaft Scissor Gear Signature, ISX, and QSX15 Eng [...]
Page 2-88 Section 2 - Cylinder Head - Group 02

Notes
Signature, ISX, and QSX15 Eng [...]
Section 3 - Rocker Levers - Group 03 Page 3-a

Section 3 - Rocker Levers - Group 03


Section Contents
Page
Crankcase Breather (External) ..........................................................................................................................3-2
Assemble..........................................................................................................................................................3-4
Automotive With CM871.................................................................................................................................3-4
Clean and Inspect for Reuse.............................................................................................................................3-3
Automotive with CM870..................................................................................................................................3-3
Automotive With CM871.................................................................................................................................3-4
Disassemble.....................................................................................................................................................3-3
Automotive With CM871.................................................................................................................................3-3
Install................................................................................................................................................................3-4
Automotive with CM870..................................................................................................................................3-4
Automotive With CM871.................................................................................................................................3-5
Remove............................................................................................................................................................3-2
Automotive with CM870..................................................................................................................................3-2
Automotive With CM871.................................................................................................................................3-2
Crankcase Breather (Internal) ...........................................................................................................................3-5
Clean and Inspect for Reuse.............................................................................................................................3-6
Finishing Steps.................................................................................................................................................3-8
Install................................................................................................................................................................3-7
Preparatory Steps.............................................................................................................................................3-5
Remove............................................................................................................................................................3-6
Crankcase Breather Element .......................................................................................................................... 3-32
Install..............................................................................................................................................................3-33
Remove.......................................................................................................................................................... 3-32
Overhead Set .....................................................................................................................................................3-8
Adjust............................................................................................................................................................. 3-12
Finishing Steps...............................................................................................................................................3-20
Measure............................................................................................................................................................3-8
General Information........................................................................................................................................3-8
Preparatory Steps...........................................................................................................................................3-12
Rocker Lever Assembly ..................................................................................................................................3-21
Clean and Inspect for Reuse...........................................................................................................................3-22
Finishing Steps...............................................................................................................................................3-30
Install..............................................................................................................................................................3-26
Preparatory Steps...........................................................................................................................................3-21
Remove.......................................................................................................................................................... 3-21
Rocker Lever Cover .........................................................................................................................................3-30
Clean and Inspect for Reuse...........................................................................................................................3-30
Install..............................................................................................................................................................3-32
Remove.......................................................................................................................................................... 3-30
Service Tools ....................................................................................................................................................3-1
Rocker Levers...................................................................................................................................................3-1
Signature, ISX, and QSX15 Eng [...]
Page 3-b Section 3 - Rocker Levers - Group 03

This Page Left Intentionally Blank


Signature, ISX, and QSX15 Eng [...] Service Tools
Section 3 - Rocker Levers - Group 03 Page 3-1

Service Tools
Rocker Levers

The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.

Tool No. Tool Description Tool Illustration


Torque Wrench
Used to adjust the overhead settings.
3398105

Brake Feeler Gauge (7 mm)


Used to adjust the engine brake.
3163530

Overhead Setting Kit

3163167

Inch Pound Torque Wrench

3376592

Feeler Gauge (.014 inch)

3163171

Feeler Gauge (.027 inch)

3163172
Crankcase Breather (External) Signature, ISX, and QSX15 Eng [...]
Page 3-2 Section 3 - Rocker Levers - Group 03

Crankcase Breather (External)


(003-001)
Remove
Automotive with CM870
Remove the breather tube and rubber grommet from
engine.

Remove the four p-clips securing the hose to the front


cover and block.

Disassemble the breather tube.

Automotive With CM871


Disconnect the wiring connector from the breather
pressure sensor.
Loosen the two hose clamps on the inlet hose.
Disconnect hose from breather. Loosen outlet hose
clamp.
Disconnect the outlet hose.
Disconnect the breather oil drain line.
Remove the drain line inline with the connection nipple,
do not bend.
Remove the four mounting capscrews from the crankcase
breather element housing to the breather housing bracket
and remove the housing assembly.
Signature, ISX, and QSX15 Eng [...] Crankcase Breather (External)
Section 3 - Rocker Levers - Group 03 Page 3-3

Disassemble
Automotive With CM871
Disassemble the crankcase breather assembly. Refer to
Procedure 003-019.
NOTE: All capscrews are captive capscrews.

Clean and Inspect for Reuse


Automotive with CM870

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use solvent to clean the inside of the crankcase breather
tube, and dry with compressed air.
Use air pressure to blow through the vent tube.
Replace the vent tube if it is clogged.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Do not use solvent to clean the rubber grommet.
Clean the rubber grommet with soapy water. Dry with
compressed air.
Crankcase Breather (External) Signature, ISX, and QSX15 Eng [...]
Page 3-4 Section 3 - Rocker Levers - Group 03

Inspect the breather tube, hose and rubber grommet for


cracks or other damage. Replace if necessary.

Automotive With CM871

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean breather crankcase housing and breather
crankcase cover with solvent.
Dry with compressed air.
Check for cracks in crankcase breather element housing
and crankcase breather cover. Replace if necessary.

Assemble
Automotive With CM871
Assemble the crankcase breather assembly. Refer to
Procedure 003-019.

Install
Automotive with CM870
Assemble the breather tube as shown.
Signature, ISX, and QSX15 Eng [...] Crankcase Breather (Internal)
Section 3 - Rocker Levers - Group 03 Page 3-5

Two p-clips attach the vent hose to the gear housing and
two p-clips attach the vent hose to the side of the block.
With the breather hose installed on the new cover, the
hose (3) must extend lower than the flywheel housing.
Install the crankcase vent hose (1). Use the four p-clips
(2), to secure the crankcase vent hose to the engine.
Torque Value: 28 Nm [ 21 ft-lb ]

Automotive With CM871


Connect the inlet and outlet rubber hoses, oil drain line,
and install the three hose clamps to the housing. Be sure
to push the hose on until it stops on the housing
connector. Verify that the hose clears the fan blade.
Connect the breather sensor wiring connector to the
breather sensor.
Install and tighten the four mounting capscrews.
Torque Value:
M10 47 Nm [ 35 ft-lb ]
M8 20 Nm [ 15 ft-lb ]
Remove and install the crankcase pressure sensor. Refer
to Procedure 019-445 in the Troubleshooting and Repair
CM871 and CM876 Electronic Control System, ISX and
ISM Engines, Bulletin 4021560.

Crankcase Breather (Internal)


(003-002)
Preparatory Steps
Remove the breather tube. Refer to Procedure
003-001 (Crankcase Breather (External)) in Section
3.
Inspect the breather tube for sludge or debris on or
in the tube.
NOTE: Inspect the tube more frequently in icy conditions.
Crankcase Breather (Internal) Signature, ISX, and QSX15 Eng [...]
Page 3-6 Section 3 - Rocker Levers - Group 03

Remove
Remove the breather tube assembly from the seal carrier.
Remove the breather oil seal (1) from the upper gear
cover.

Remove the upper gear cover.


Refer to Procedure 001-079 (Gear Cover, Upper) in
Section 1.

Remove the four capscrews from the crankcase breather


and remove the breather.

Clean and Inspect for Reuse


Clean and inspect the crankcase breather for reuse.
If the filter element is plugged, replace the filter element.
Signature, ISX, and QSX15 Eng [...] Crankcase Breather (Internal)
Section 3 - Rocker Levers - Group 03 Page 3-7

Install
Make sure the spacer and cam gear have been torqued.
Refer to Procedure 002-024 (Overhead Camshaft, Valve)
in Section 2.

Position the crankcase breather over the spacer.


Pre-start the four crankcase breather capscrews.
Torque the capscrews in a crisscross pattern.
Torque Value: 45 Nm [ 33 ft-lb ]

Lubricate the breather shaft with clean engine oil.


Install the upper gear cover. Refer to Procedure 001-079
(Gear Cover, Upper) in Section 1.

Install the oil seal into the seal carrier.


The groove side (1) must be installed toward the engine.
Make sure the seal carrier is tight in the front cover. If not,
tighten the seal carrier.
Torque Value: 20 Nm [ 177 in-lb ]
Install the breather tube assembly into the seal carrier.
Torque to the breather tube assembly.
Torque Value: 20 Nm [ 15 ft-lb ]
Overhead Set Signature, ISX, and QSX15 Eng [...]
Page 3-8 Section 3 - Rocker Levers - Group 03

Finishing Steps
Install the crankcase breather tube. Refer to
Procedure 003-001 (Crankcase Breather (External))
in Section 3.
Operate the engine until it reaches normal operating
temperature and check for leaks.

Overhead Set (003-004)


Measure
General Information
All overhead lash measurements must be made when the
engine is cold. Stabilized coolant temperature must be at
60C [140F] or below.

Remove the rocker lever cover. Refer to Procedure


003-011 (Rocker Lever Cover) in Section 3.
Make sure the engine base timing is properly set before
attempting to measure, adjust, or set the overhead. Refer
to Procedure 001-088 (Engine Base Timing) in Section 1.

Early engine vibration dampers are marked with BRAKE


SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valves and
injector on the same cylinder.
Locate the valve set marks on the outside of the vibration
damper.
The set marks are A, B, and C:
Set to mark A to adjust cylinder 1 or 6.
Set to mark B to adjust cylinder 2 or 5.
Set to mark C to adjust cylinder 3 or 4.
Two complete revolutions are required to set all valves,
engine brakes, and injectors.
Signature, ISX, and QSX15 Eng [...] Overhead Set
Section 3 - Rocker Levers - Group 03 Page 3-9

If the engine is equipped with an air compressor:


Remove the oil fill connector from the lower gear case
cover.
Insert a 3/4-inch drive ratchet and extension into the air
compressor drive.
Rotate the air compressor drive clockwise, as viewed
from the front of the engine.

WARNING
Do not pull or pry on the fan to manually rotate the
engine. To do so can damage the fan blades.
Damaged fan blades can cause premature fan failures
which can result in serious personal injury or property
damage.
The crankshaft rotation is clockwise, as viewed from the
front of the engine.
The cylinders are numbered from the front of the engine
(1-2-3-4-5-6).
The engine firing order is 1-5-3-6-2-4.

If the engine is not equipped with an air compressor:


Loosen the cover plate capscrews and rotate the cover or
remove the oil fill tube, if equipped.

Use a 1 inch socket to push the barring gear into the


gear mesh and rotate the barring adapter
counterclockwise to bar the engine.
Rock the barring device back and forth until it disengages.
Overhead Set Signature, ISX, and QSX15 Eng [...]
Page 3-10 Section 3 - Rocker Levers - Group 03

Each cylinder has four rocker levers:


The exhaust valve rocker lever (1)
The injector rocker lever (2)
The intake valve rocker lever (3)
The engine brake rocker lever (4).
The intake valve rocker lever is always the long lever on
the valve rocker lever shaft.
Early engine vibration dampers are marked with BRAKE
SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valves and
injector on the same cylinder.
The valves, brakes, and the injectors on the same cylinder
are adjusted at the same index mark on the vibration
damper.

Injector and Valve Adjustment Sequence


Bar Engine
Set Set Set
in Pulley
Cylinder Cylinder Cylinder
Direction Position
Injector Valve Brake
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing Order: 1-5-3-6-2-4

NOTE: For illustrative purposes, position A is shown as


the first step. It is not necessary to start with position A,
as long as the proper sequence is followed.
Use the compressor drive or barring device to bar the
engine over in the direction of engine rotation,
clockwise as viewed from the front of the engine. Align
the A mark on the vibration damper with the pointer on the
gear cover.
Signature, ISX, and QSX15 Eng [...] Overhead Set
Section 3 - Rocker Levers - Group 03 Page 3-11

Check the valve rocker levers on the given cylinder to see


if both intake and exhaust valves are closed.
Both sets of valves are closed when the rocker levers and
the brake lever are loose. If both sets of valves are not
closed, rotate the compressor drive gear one complete
revolution, and align the A mark on the front damper with
the pointer again.

Valve Lash
Use feeler gauges to measure the amount of clearance
(lash) between the crosshead and the rocker lever nose.
Measure and record the intake, exhaust, and brake valve
lash. If the valve lash is not within the specifications listed
below, the valve must be adjusted. See the adjust step in
this procedure.
Press the brake lever down to verify the camshaft follower
is in contact with the camshaft prior to measurement of
the brake lash.

ISX, QSX Series Valve Lash Recheck Limits


Intake 0.23 mm minimum 0.006 in
Intake 0.48 mm maximum 0.019 in
Exhaust 0.56 mm minimum 0.022 in
Exhaust 0.81 mm maximum 0.032 in
Brake 6.87 mm minimum 0.271 in
Brake 7.13 mm maximum 0.281 in

Brake Running Clearance


Rotate the brake lever to the detent (neutral) position.
Check the clearance between the engine brake actuator
piston and the cross head guide pin (1). If the brake
running clearance is not within the specifications listed
below, the running clearance must be adjusted. See the
Adjust step in this procedure.

Brake Running Clearance


mm in
0.635 MIN 0.025
2.79 MAX 0.110
Injector Lash
There is no service procedure to check the injector free
load.
Install the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
Overhead Set Signature, ISX, and QSX15 Eng [...]
Page 3-12 Section 3 - Rocker Levers - Group 03

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.
Disconnect the battery.

Remove the rocker lever cover and gasket. Refer to


Procedure 003-011 (Rocker Lever Cover) in Section 3.
Make sure the engine base timing is properly set before
attempting to adjust/set the overhead. Refer to Procedure
001-088 (Engine Base Timing) in Section 1.
All overhead valve, injector, and brake adjustments
must be made when the engine is cold (any stabilized
coolant temperature at 60C [140F] or below).

Adjust
Read the entire procedure for overhead adjustment before
attempting to perform this operation.
Valves, injectors, and engine brakes (if equipped) must
be correctly adjusted for the engine to operate efficiently.
Valve, injector, and engine brake adjustment must be
performed using the values listed in this section.
After an engine rebuild or any major repair where the
injector and valve setting must be disturbed, set all of the
valves, injectors, and brakes.

Valve, Brake, and Injector Adjustment Values


Injector Adjustment is 8 Nm [70 in-lb]
Intake Valve 0.35 mm [0.014 in]
Exhaust Valve 0.68 mm [0.027 in]
Engine Brake 7.00 mm [0.276 in]
Signature, ISX, and QSX15 Eng [...] Overhead Set
Section 3 - Rocker Levers - Group 03 Page 3-13

Early engine vibration dampers are marked with BRAKE


SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valves and
injector on the same cylinder.
Locate the valve set marks on the outside of the vibration
damper.
The set marks are A, B, and C:
Set to mark A to adjust cylinder 1 or 6.
Set to mark B to adjust cylinder 2 or 5.
Set to mark C to adjust cylinder 3 or 4.
Two complete revolutions are required to set all valves,
engine brakes, and injectors.

If the engine is equipped with an air compressor:


Remove the oil fill connector from the lower gear case
cover.
Insert a 3/4-inch drive ratchet and extension into the air
compressor drive.
Rotate the air compressor drive clockwise, as viewed
from the front of the engine.

WARNING
Do not pull or pry on the fan to manually rotate the
engine. To do so can damage the fan blades.
Damaged fan blades can cause premature fan failures
which can result in serious personal injury or property
damage.
The crankshaft rotation is clockwise as viewed from the
front of the engine.
The cylinders are numbered from the front of the engine
(1-2-3-4-5-6).
The engine firing order is 1-5-3-6-2-4.

If the engine is not equipped with an air compressor:


Loosen the capscrews and rotate the cover or remove the
oil fill tube, if equipped.
Overhead Set Signature, ISX, and QSX15 Eng [...]
Page 3-14 Section 3 - Rocker Levers - Group 03

Use a 1 inch socket to push the barring gear into the


gear mesh and rotate the barring adapter
counterclockwise to bar the engine.
Rock the barring device back and forth until it disengages.

Each cylinder has four rocker levers:


The exhaust valve rocker lever (1)
The injector rocker lever (2)
The intake valve rocker lever (3)
The engine brake rocker lever (4).
The intake valve rocker lever is always the long lever on
the valve rocker lever shaft.
Early engine vibration dampers are marked with BRAKE
SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valves and
injector on the same cylinder.
The valves, brakes, and injectors on the same cylinder are
adjusted at the same index mark on the vibration damper.

Injector and Valve Adjustment Sequence


Bar Engine
Set Set Set
in Pulley
Cylinder Cylinder Cylinder
Direction Position
Injector Valve Brake
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing Order: 1-5-3-6-2-4
Signature, ISX, and QSX15 Eng [...] Overhead Set
Section 3 - Rocker Levers - Group 03 Page 3-15

NOTE: For illustrative purposes, position A is shown as


the first step. It is not necessary to start with position A,
as long as the proper sequence is followed.
Use the compressor drive or barring device to bar the
engine over in the direction of engine rotation,
clockwise as viewed from the front of the engine. Align
the A mark on the vibration damper with the pointer on the
gear cover.

Check the valve rocker levers on the given cylinder to see


if both intake and exhaust valves are closed.
Both sets of valves are closed when the rocker levers and
the brake lever are loose. If both sets of valves are not
closed, rotate the compressor drive gear one complete
revolution, and align the A mark on the front damper with
the pointer again.

Loosen the injector adjusting screw locknut on the


cylinder.
Do not use a click-type torque wrench.
Use a dial-type torque wrench with a range of 0 to 150 in-
lb to tighten the injector rocker lever adjusting screw. If the
screw chatters during setting, repair the screw and lever
as required.
Back out the adjusting screw one or two turns.
Hold the torque wrench in a position that allows you to look
in a direct line at the dial. This is to make sure the dial will
be read accurately.
Make sure the parts are aligned, and squeeze the oil out
of the valve and injector train by tightening the adjusting
screw.
Use this initial adjustment to preload the valve train and
injector.
Overhead Set Signature, ISX, and QSX15 Eng [...]
Page 3-16 Section 3 - Rocker Levers - Group 03

Tighten the injector lever adjusting screw.


Torque Value: 8 Nm [ 71 in-lb ]
Back the adjusting lever screw out 1 or 2 turns.
Tighten the injector lever adjusting screw.
Torque Value: 8 Nm [ 71 in-lb ]

Hold the injector lever adjusting screw and tighten the


adjusting screw locknut.
Torque Value: 75 Nm [ 55 ft-lb ]

After setting the injector on a cylinder, set the valves and


engine brakes on the same cylinder.
Early engine vibration dampers are marked with BRAKE
SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valve and
injector on the same cylinder.

With the set mark aligned with the pointer on the gear
cover and both sets of valves closed on the cylinder,
loosen the locknuts on the intake and exhaust valve
adjusting screws.
Back out the adjusting screws one or two turns.
Signature, ISX, and QSX15 Eng [...] Overhead Set
Section 3 - Rocker Levers - Group 03 Page 3-17

Select a feeler gauge for the correct valve lash


specification.

Valve Lash Specification


mm in
Intake 0.36 NOM 0.014
Exhaust 0.69 NOM 0.027
Insert the feeler gauge between the top of the crosshead
and the rocker lever nose pad.
Make sure the feeler gauge is completely under the
pivoting rocker lever nose pad.

Tighten the adjusting screw.


Torque Value: 0.6 Nm [ 5 in-lb ]

Use a torque wrench and crows foot adapter to tighten the


locknut.
Hold the adjusting screw in this position. The adjusting
screw must not turn when the locknut is tightened.
Torque Value: 45 Nm [ 33 ft-lb ]

After tightening the locknut to the correct torque value,


remove the feeler gauge.
Overhead Set Signature, ISX, and QSX15 Eng [...]
Page 3-18 Section 3 - Rocker Levers - Group 03

CAUTION
To get maximum brake operating efficiency and to
prevent engine damage, the brake adjustment
instructions must be followed.
For older engines, locate the engine brake set marks on
the outside of the vibration damper.
The set marks are BRAKE SET 1-6, and BRAKE SET 2-5,
and BRAKE SET 3-4.
BRAKE SET 1-6: Cylinder 1 or 6 adjust
BRAKE SET 2-5: Cylinder 2 or 5 adjust
BRAKE SET 3-4: Cylinder 3 or 4 adjust

Use the compressor drive or barring device to bar the


engine over in the direction of rotation, clockwise as
viewed from the front of the engine. Align the A mark on
the vibration damper with the pointer on the gear cover.
For illustrative purposes, position A is shown as the first
step. It is not necessary to start with position A, as long
as the proper sequence is followed.

Check the valve rocker levers on the given cylinder to see


if both intake and exhaust valves are closed.
Both sets of valves are closed when the rocker levers and
the brake lever are loose. If both sets of valves are not
closed, rotate the compressor drive gear one complete
revolution, and align the A mark on the front damper with
the pointer again.

Press the engine brake lever down to verify the camshaft


follower is in contact with the camshaft.
Signature, ISX, and QSX15 Eng [...] Overhead Set
Section 3 - Rocker Levers - Group 03 Page 3-19

Loosen the locknut on the brake lever adjusting screw,


and back out the adjusting screw one turn.
Insert the feeler gauge, Part Number 3163530, between
the bottom of the engine brake piston and the top of the
exhaust valve pin on the exhaust valve crosshead.

Brake Lever Lash Specification


mm in
7.00 NOM 0.276

Tighten the adjusting screw until drag on the feeler gauge


is felt. Proper drag means that there is no motion of the
brake lever camshaft follower against the cam lobe.

Hold the engine brake lever adjusting screw and tighten


the locknut.
Torque Value: 20 Nm [ 177 in-lb ]
Remove the feeler gauge.
Overhead Set Signature, ISX, and QSX15 Eng [...]
Page 3-20 Section 3 - Rocker Levers - Group 03

CAUTION
Engine damage can occur if the running clearance is
not within specifications.
Check the running clearance:
1. Rotate the engine brake rocker lever to the detente
(neutral) position.
2. Check the clearance (1) between the engine brake
lever actuator piston and the crosshead guide pin.

Engine Brake Rocker Lever Running Clearance


mm in
0.635 MIN 0.025
2.790 MAX 0.110
If the running clearance does not meet specification,
loosen, but do not remove the rocker shaft capscrews,
and rotate the shaft in the direction required to bring the
running clearance within the listed specification. It is
critical that this clearance be set and verified on all six
brake levers. Engine damage can result if this task is
not completed.
Check the brake running clearance.
The rocker lever shafts must be adjusted so that all three
engine brake levers fall within the given running clearance
specification.
Repeat the process to adjust all injectors, engine brakes,
and valves according to the chart shown below.

Injector and Valve Adjustment Sequence


Bar Engine
Set Set Set
in Pulley
Cylinder Cylinder Cylinder
Direction Position
Injector Valve Brake
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing Order: 1-5-3-6-2-4

Finishing Steps
Install the rocker lever cover and gasket. Refer to
Procedure 003-011 (Rocker Lever Cover) in Section
3.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Assembly
Section 3 - Rocker Levers - Group 03 Page 3-21

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.
Connect the battery.
If coolant, oil, excessive fuel, or excessive black smoke,
has entered the exhaust system, Refer to Procedure
014-013 (Aftertreatment Testing) in Section 14..

Rocker Lever Assembly (003-009)


Preparatory Steps
Remove the engine brake solenoid valve wiring harness.
Remove the rocker lever cover. Refer to Procedure
003-011.
Remove the engine brake wiring harness. Refer to
Procedure 020-015.

Remove
There are four rocker lever shafts:
Front - valve and brake rocker lever shaft
Rear - valve and brake rocker lever shaft
Front - injector rocker lever shaft
Rear - injector rocker lever shaft.

CAUTION
Some valves will not be loose. Do not tighten or
bottom adjusting screw against lever. Engine damage
can occur.
Loosen the valve and injector adjusting screw locknuts on
each rocker lever.
Turn the adjusting screws counterclockwise until the
rocker levers are loose.
Rocker Lever Assembly Signature, ISX, and QSX15 Eng [...]
Page 3-22 Section 3 - Rocker Levers - Group 03

CAUTION
Use care when handling shafts. Rocker levers can fall
off the shaft during removal and damage the levers.
Remove the valve and brake, rocker lever shaft
capscrews, and the rocker lever shaft assemblies.
Remove the injector, rocker lever shaft capscrews, and
the rocker lever shaft assemblies.
Remove the valve crossheads.
To prevent increased wear, mark each crosshead and
rocker lever shaft assembly as it is removed so it can be
installed back in its original location.

Remove the rocker levers and brake levers from the


shafts.
Remove the rocker lever spacers from the shaft.
Remove the locknuts and the adjusting screws from the
rocker levers.
To prevent increased wear, mark each adjusting screw as
it is removed so it can be installed back in its original
rocker lever.

Clean and Inspect for Reuse

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

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

WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use steam or solvent to clean the rocker lever shaft.
Dry with compressed air.
Be sure to blow out the oil passages.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Assembly
Section 3 - Rocker Levers - Group 03 Page 3-23

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

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

WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use steam or solvent to clean the valve crossheads,
rocker lever adjusting screw, and nuts.
Dry with compressed air.

Inspect the valve and brake rocker lever shaft for cracks
or damage.
Measure the valve and brake rocker lever shaft outside
diameter in the bushing wear area.

Valve and Brake Rocker Lever Shaft Outside Diameter


mm in
34.950 MIN 1.3760
35.000 MAX 1.3780
If the valve or brake rocker lever shaft is not within
specifications, it must be replaced.

Inspect the valve and brake rocker lever shaft for wear in
the brake detent pockets.
A raised edge on one side of the detent pocket is normal
and does not need replaced.
An elongated detent pocket, typically toward the cam
follower end of the brake rocker lever, is excessive wear
and must be replaced.
Rocker Lever Assembly Signature, ISX, and QSX15 Eng [...]
Page 3-24 Section 3 - Rocker Levers - Group 03

Measure the injector rocker lever shaft outside diameter


in the bushing wear area.

Injector Rocker Lever Shaft Outside Diameter


mm in
44.950 MIN 1.7697
45.000 MAX 1.7717
If the rocker lever shaft is not within specifications, it
must be replaced.

Inspect the rocker levers for cracks or unusual wear and


thread condition.

Measure the valve and brake rocker lever bushing bore


inside diameter.

Valve and Brake Rocker Lever Bushing Bore Inside


Diameter
mm in
35.037 MIN 1.3794
35.138 MAX 1.3834
If the valve or brake rocker lever bushing is not within
specifications, the rocker lever must be replaced.

Measure the injector rocker lever bushing bore inside


diameter.

Injector Rocker Lever Bushing Bore Inside Diameter


mm in
45.037 MIN 1.7731
45.138 MAX 1.7771
If the injector rocker lever bushing is not within
specifications, the rocker lever must be replaced.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Assembly
Section 3 - Rocker Levers - Group 03 Page 3-25

Inspect the valve crossheads and crosshead guide pins


for damage.

The contact area on the crossheads must be smooth with


an even seating pattern.
If any distortions or cracks are found on the valve
crossheads or adjusting screws, they must be replaced.

Inspect the injector rocker lever adjusting screw socket for


excessive wear.
If excessive wear is found, the injector rocker lever
adjusting screw must be replaced.

Measure the intake and exhaust valve adjusting screws


for wear. Be sure the adjusting screw is perpendicular for
measurement.

Intake and Exhaust Valve Adjusting Screw Length


mm in
46 MIN 1.81
Rocker Lever Assembly Signature, ISX, and QSX15 Eng [...]
Page 3-26 Section 3 - Rocker Levers - Group 03

Measure the rocker lever spacers for wear.

Rocker Lever Spacer Width


mm in
11.5 MIN 0.453
If the rocker lever spacer is not within specification, it
must be replaced.

Install
Install the adjusting screw and locknut into each rocker
lever. Do not tighten the locknuts.

Install the injector rocker levers on the shaft.


Install the exhaust (1), intake (2), and engine brake (3)
rocker levers onto the shaft.

WARNING
Clear the rocker lever assembly mounting capscrew
holes of oil and debris. Extensive engine damage can
result if this warning instruction is not followed.
Install the valve crossheads.
Position the valve/brake rocker lever assemblies onto the
cylinder head.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Assembly
Section 3 - Rocker Levers - Group 03 Page 3-27

CAUTION
To reduce the possibility of valve rocker shaft damage
due to inadequate brake rocker lever running
clearance, follow the specified procedure to seat the
valve rocker shafts on the cylinder head pedestals (1).
Each valve rocker shaft must be seated in the cylinder
head pedestals prior to tightening the rocker shaft
capscrews.
The front and rear rocker lever shaft assemblies will seat
separately as the engine is rotated in the clockwise
direction.

Use the compressor drive or barring device to bar the


engine over in the direction of rotation, clockwise as
viewed from the front of the engine.
Align the A mark on the vibration damper with the timing
mark on the gear cover.

Either the front or the rear rocker shaft assembly will be


fully seated on the cylinder head pedestals at this point.
Check the position of the front and rear valve rocker shaft
assemblies to determine which one is fully seated.
Lubricate the capscrews of the fully seated rocker shaft
with clean 15W-40 oil.
Rocker Lever Assembly Signature, ISX, and QSX15 Eng [...]
Page 3-28 Section 3 - Rocker Levers - Group 03

CAUTION
To reduce the possibility of valve rocker shaft damage
because of inadequate brake rocker lever running
clearance, follow the specified capscrew torque
procedure. The valve rocker lever shaft has a
machined flat on the front of the shaft to provide
proper brake rocker lever position. Therefore, the
front rocker shaft capscrew (1) must be tightened first
to control brake rocker lever position. Brake lever
running clearance must always be checked after valve
rocker lever shaft installation.
Check the brake running clearance. Refer to Procedure
003-004.
Tighten the front mounting capscrew for the fully seated
valve rocker lever shaft to the initial torque value to locate
the shaft.
Torque Value: 30 Nm [ 22 ft-lb ]
Tighten all the capscrews to the final torque value using
the torque plus angle method. Tighten the capscrews from
the center out.
Torque Value: Step1 30 Nm [ 22 ft-lb ]
Step2 Rotate 60 degrees

Use the compressor drive or barring device to bar the


engine over in the direction of rotation, clockwise as
viewed from the front of the engine.
Align the B mark on the vibration damper with the timing
mark on the gear cover.
The remaining rocker shaft will be fully seated at this point.
Lubricate the capscrews of the fully seated rocker shaft
with clean 15W-40 oil.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Assembly
Section 3 - Rocker Levers - Group 03 Page 3-29

CAUTION
To reduce the possibility of valve rocker shaft damage
because of inadequate brake rocker lever running
clearance, follow the specified capscrew torque
procedure. The valve rocker lever shaft has a
machined flat on the front of the shaft to provide
proper brake rocker lever position. Therefore, the
front rocker shaft capscrew must be tightened first to
control brake rocker lever position. Brake lever
running clearance must always be checked after valve
rocker lever shaft installation.
Check the brake running clearance. Refer to Procedure
003-004.
Tighten the front mounting capscrew for the remaining
valve rocker lever shaft to the initial torque value to locate
the shaft.
Torque Value: 30 Nm [ 22 ft-lb ]
Tighten all the capscrews to the final torque value using
the torque plus angle method. Tighten the capscrews from
the center out.
Torque Value: Step1 30 Nm [ 22 ft-lb ]
Step2 Rotate 60 degrees

Position the injector rocker lever assemblies onto the


cylinder head.
Lubricate the injector rocker lever shaft capscrews with
clean 15W-40 oil. Install the capscrews and washers.
Tighten all the mounting capscrews.
Torque Value: 68 Nm [ 50 ft-lb ]

Loosen capscrews one at a time 360 and tighten again,


using the torque-plus-angle method. Tighten capscrews
from center out.
Torque Value: Step1 30 Nm [ 22 ft-lb ]
Step2 Rotate 60 degrees
Adjust the valve, injectors, and brake.
Refer to Procedure 003-004.
Rocker Lever Cover Signature, ISX, and QSX15 Eng [...]
Page 3-30 Section 3 - Rocker Levers - Group 03

Finishing Steps
Install the engine brake wiring harness. Refer to
Procedure 020-015.
Install the rocker lever cover. Refer to Procedure 003-011.
Install the engine brake solenoid valve wiring harness.

Rocker Lever Cover (003-011)


Remove
NOTE: Engines built before September 7, 2006, and have
a the separate cover and separate gasket.
Remove the eight capscrews and isolator assemblies from
the rocker lever cover.
Remove the cover and gasket from the head separately.
The rocker lever cover gasket is reusable. Do not damage
the gasket when removing or cleaning.

NOTE: Engines built after September 7, 2006, or engines


that have the cover gasket embedded in the rocker lever
cover.
Completely loosen the eight capscrews and isolator
assemblies.
Remove the rocker lever cover, the cover gasket and the
isolators all together as an assembly.
The cover gasket is reusable. Do not damage the cover
gasket when removing the cover or when setting the
assembly aside during repair.

Clean and Inspect for Reuse


Clean the contaminated lube oil from the cylinder head
cavities.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Cover
Section 3 - Rocker Levers - Group 03 Page 3-31

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Steam clean the cover. Dry with compressed air.

CAUTION
Do not use solvent to clean the rocker lever cover
gasket. Solvent will damage the gasket material and
cause it to swell. Prolonged exposure can also cause
degradation of the gasket material.
Clean the reusable gasket with a dry, lint-free cloth,
making sure no oil remains between the sealing beads.
NOTE: Engines built before September 7, 2006, have the
separate rocker lever cover and a separate cover gasket,
make certain that no lubricating oil remains between the
sealing beads.

Inspect the rocker lever cover for cracks or damage.


Replace if necessary.

Inspect the cover gasket beads for cuts, missing beads,


kinks, twists, wear, or other damage.
A gouged hole is acceptable if the bead is not damaged.
Replace if necessary.
Crankcase Breather Element Signature, ISX, and QSX15 Eng [...]
Page 3-32 Section 3 - Rocker Levers - Group 03

Install
NOTE: Engines built after September 7, 2006, or engines
that have the cover gasket embedded in the rocker lever
cover.
If the cover gasket was removed, install the cover
gasket as soon as possible to avoid swelling of the
cover gasket as the cover gasket swells due to its
prior exposure to lubricating oil.
If a new cover gasket is required, use P80
lubriplate, Part Number 3163086, or soapy water to
lubricate the cover gasket.
If the cover gasket was removed or requires replacement,
start the installation of the cover gasket at each bolt hole
and press the cover gasket into the groove in the rocker
level cover around each bolt hole.
After the cover gasket is in place around all bolt holes,
press the cover gasket into the grove of the rocker level
cover starting from the bolt holes moving to the center of
each span.
Inspect and make certain that there are no kinks, twists or
other damage.

Align the capscrew holes in the cylinder head to the cover


gasket, and rocker lever cover prior to installing the
capscrews and isolator assemblies.
Install the eight capscrews and isolator assemblies.
NOTE: Engines built before September 7, 2006, have the
separate cover and a separate gasket, install the eight
capscrews and isolator assemblies.
Tighten capscrews in sequence shown.
Torque Value: 25 Nm [ 18 ft-lb ]

Crankcase Breather Element (003-019)


Remove
Loosen the eight cover mounting captive capscrews.
Remove the element cover.
NOTE: Discard the crankcase breather element in
accordance with local environmental regulations.
Remove and discard the crankcase breather element.
Wipe out any excess dirt or oil from the inside of the cover.
Signature, ISX, and QSX15 Eng [...] Crankcase Breather Element
Section 3 - Rocker Levers - Group 03 Page 3-33

Install
Install the new crankcase breather element in the breather
housing.
Make sure the element is properly seated in the housing
so its seal will not be cut, crimped, or otherwise
compromised when installing the housing cover.
Install the cover.
Tighten the eight captive mounting capscrews.
Torque Value: 5.2 Nm [ 46 in-lb ]
Crankcase Breather Element Signature, ISX, and QSX15 Eng [...]
Page 3-34 Section 3 - Rocker Levers - Group 03

Notes
Signature, ISX, and QSX15 Eng [...]
Section 5 - Fuel System - Group 05 Page 5-a

Section 5 - Fuel System - Group 05


Section Contents
Page
Fuel Consumption .............................................................................................................................................5-3
Maintenance Check..........................................................................................................................................5-3
Fuel Inlet Pre-Filter ..........................................................................................................................................5-47
Clean..............................................................................................................................................................5-49
General Information.........................................................................................................................................5-47
Install..............................................................................................................................................................5-50
Remove.......................................................................................................................................................... 5-48
Fuel Lift Pump .................................................................................................................................................5-14
Clean and Inspect for Reuse...........................................................................................................................5-20
Finishing Steps...............................................................................................................................................5-24
Initial Check....................................................................................................................................................5-14
Install..............................................................................................................................................................5-22
Preparatory Steps...........................................................................................................................................5-17
Pressure Test..................................................................................................................................................5-16
Remove.......................................................................................................................................................... 5-17
Replace.......................................................................................................................................................... 5-21
Resistance Check...........................................................................................................................................5-14
Test................................................................................................................................................................ 5-16
Voltage Check.................................................................................................................................................5-15
Fuel Pump .........................................................................................................................................................5-4
Clean and Inspect for Reuse.............................................................................................................................5-6
Finishing Steps.................................................................................................................................................5-7
Install................................................................................................................................................................5-6
Leak Test..........................................................................................................................................................5-4
Preparatory Steps.............................................................................................................................................5-5
Pressure Test....................................................................................................................................................5-4
Prime................................................................................................................................................................5-8
Remove............................................................................................................................................................5-5
Fuel Pump Pulsation Damper ...........................................................................................................................5-9
Clean and Inspect for Reuse...........................................................................................................................5-10
Automotive with CM870................................................................................................................................5-10
Automotive, Industrial with CM570 and Power Generation without CM570....................................................5-10
Finishing Steps...............................................................................................................................................5-11
All Applications.............................................................................................................................................5-11
Install..............................................................................................................................................................5-10
Automotive with CM870................................................................................................................................5-10
Automotive, Industrial with CM570 and Power Generation without CM570....................................................5-11
Preparatory Steps.............................................................................................................................................5-9
All Applications..............................................................................................................................................5-9
Remove............................................................................................................................................................5-9
Automotive with CM870..................................................................................................................................5-9
Automotive, Industrial with CM570 and Power Generation without CM570....................................................5-10
Fuel Shutoff Valve ...........................................................................................................................................5-11
Inspect for Reuse............................................................................................................................................5-12
Install..............................................................................................................................................................5-13
Remove.......................................................................................................................................................... 5-11
Integrated Fuel System Module (IFSM) .......................................................................................................... 5-30
Assemble........................................................................................................................................................5-34
Clean and Inspect for Reuse...........................................................................................................................5-32
Disassemble................................................................................................................................................... 5-32
Finishing Steps...............................................................................................................................................5-46
Install..............................................................................................................................................................5-44
Preparatory Steps...........................................................................................................................................5-30
Remove.......................................................................................................................................................... 5-31
Service Tools ....................................................................................................................................................5-1
Fuel System......................................................................................................................................................5-1
Stall Speed Test ..............................................................................................................................................5-25
Signature, ISX, and QSX15 Eng [...]
Page 5-b Section 5 - Fuel System - Group 05

Stall Speed Check...........................................................................................................................................5-25


Stall Speed Check List....................................................................................................................................5-28
Stall Speed Too Low.................................................................................................................................... 5-28
Stall Speed Too High....................................................................................................................................5-29
Time Speed Check..........................................................................................................................................5-27
Signature, ISX, and QSX15 Eng [...] Service Tools
Section 5 - Fuel System - Group 05 Page 5-1

Service Tools
Fuel System

The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.

Tool No. Tool Description Tool Illustration


Vacuum Gauge (0-30 in. Hg)
Used to check intake air restriction, and also check fuel filter
ST-434 restriction on the suction side of the gear pump. Fuel restriction
adapters, Part Number ST-434-1, 3375845, and 3376922, are
required and must be ordered separately.

Hose Adapter
Used with vacuum gauge Part Number ST-434. Use Part Number
ST-434-1 ST-434-1 with Number 8 hose. Use Part Number ST-434-2 with
ST-434-2 Number 10 hose.

Sight Glass
ST-998 Check for air in fuel suction line. Use Part Number ST-998 with
3375362 Number 10 hose. Use Part Number 3375362 with Number 12 hose,
3375808 and Part Number 3375808 with Number 16 hose.

Slack Tube Manometer


Used to measure fuel drain line restriction.
ST-1111-3

Chip Removing Unit


Used to remove carbon from the top of the piston.
3164019

Pressure Gauge and Hose (0 to 300 psi)


Used to measure oil pressure or measure fuel pump pressure.
3375932 Includes necessary hoses and hardware to attach to a fuel pump.
Part Number ST-435-1 is the hose and Part Number ST-435-6 is the
pressure gauge.
Service Tools Signature, ISX, and QSX15 Eng [...]
Page 5-2 Section 5 - Fuel System - Group 05

Tool No. Tool Description Tool Illustration


Fuel Measurement Device
Used to measure fuel rate of the engine.
3376375

Remote Starter Switch


Turn engine on and off from a remote location.
3376506

Filter Wrench
Used to remove or tighten spin on fuel filters.
3398145

Pressure Gauge (0 to 100 psi)


Used to measure fuel pressure during cranking.
3375388

Safety Solvent
Used to clean parts and tools safely.
3824510

Optical Tachometer
Measure engine rpm.
3377462

Pressure/Vacuum Module
Used with 3377161 Digital Multimeter or 3824648 Automotive Meter.
3824645 The pressure transducer range is 500 psi and the vacuum range is
29.92 in Hg.
Signature, ISX, and QSX15 Eng [...] Fuel Consumption
Section 5 - Fuel System - Group 05 Page 5-3

Fuel Consumption (005-010)


Maintenance Check
Refer to the Fuel Consumption Checklist sheets in the
back of Section TS.
NOTE: The most accurate method to check the fuel
consumption is to weigh the fuel used. Use a scale
capable of measuring within 0.045 kg [0.1 lb] to weigh the
fuel tank. Use a remote-mount tank with enough capacity
to run 80 km [50 mi].
Fill the fuel tank. Weigh the tank with the fuel. The weight
on No. 2 diesel fuel is nominally 0.844 kg per l [7.03 lb per
gal].

Install the remote tank (1).

Measure the distance traveled with an accurate odometer.


The odometer accuracy can be checked by using
measured miles or kilometers.

After traveling the route, remove the tank and weigh the
remaining fuel. Compute the fuel used in liters [gallons] as
required.
Fuel Pump Signature, ISX, and QSX15 Eng [...]
Page 5-4 Section 5 - Fuel System - Group 05

Compute the kilometers per liter or miles per gallon.

Fuel Pump (005-016)


Pressure Test
Monitor the rail fuel pressure, use INSITE electronic
service tool or connect a pressure gauge, Part Number
3824877, on the Compuchek fitting (as shown), and read
the rail fuel pressure.
The rail pressure while cranking at 130 rpm for at least 10
seconds is 689 kPa [100 psi]. Make sure the fuel system
is primed for at least 30 seconds.
The rail fuel pressure with EGR must be 1585 to 1889 kPa
[230 to 274 psi] at engine idle.
The rail fuel pressure with EGR must be 1896 to 2068 kPa
[275 to 300 psi] at 2100 rpm.
The rail fuel pressure without EGR must be 1551 to 1889
kPa [225 to 274 psi] at engine idle.
The rail fuel pressure without EGR must be 1758 to 1999
kPa [255 to 290 psi] at 2100 rpm.
If the rail fuel pressure is below 689 kPa [100 psi], check
to make sure there is fuel supply to the pump and that it
is not restricted.

Leak Test
Clean the area surrounding the fuel pump. Run the engine
at idle rpm.
Inspect for fuel leakage at the ECM cooling plate supply
and return lines and fittings. If a leak is detected, stop the
test immediately and replace the damaged o-ring(s) or
ECM cooling plate supply or return line(s).
Inspect for fuel or oil leakage at the fuel pump weep hole
and integrated fuel system module. If leaks are detected
at the fuel pump weep hole or integrated fuel system
module, stop the test immediately and replace the failed
component.
Inspect for fuel or oil leakage at the fuel pump mounting
gasket and o-rings. If leaks are detected in these areas,
stop the test immediately and replace the damaged
component.
Inspect the head gasket for leaks.
Signature, ISX, and QSX15 Eng [...] Fuel Pump
Section 5 - Fuel System - Group 05 Page 5-5

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.
Disconnect the batteries and cables. Refer to
Procedure 013-009 in Section 13.

Remove
Automotive with CM870 and CM871
Clean the area surrounding the pump.
Disconnect the ECM cooling plate return line from the
back of the fuel pump.
Remove the four fuel pump capscrews and remove the
fuel pump from the integrated fuel system module.

Remove and discard the gasket.

Automotive, Industrial with CM570 and Power


Generation without CM570
Remove the fuel control cover.
Clean the area surrounding the pump.
Remove the four fuel pump capscrews and remove the
fuel pump from the integrated fuel system module.
Discard the o-ring seals or gasket.
Fuel Pump Signature, ISX, and QSX15 Eng [...]
Page 5-6 Section 5 - Fuel System - Group 05

Clean and Inspect for Reuse


All Applications
Clean the gasket surfaces of the pump with a lint-free
cloth.
Inspect the o-ring seal on the fuel gear pump. Replace the
o-ring, if it is damaged.

Inspect the mounting surfaces for cracks or damage. If


cracks or damage are found, replace the fuel pump or
integrated fuel system module.
Turn the fuel pump gear. If it spins without resistance or
does not spin at all, replace the fuel pump.
Inspect the idler gear for wear or damage.
If the idler gear is worn or damaged, the integrated fuel
system module must be replaced.

Install
Automotive with CM870 and CM871
Install a new gasket.

Install the pump onto the integrated fuel system module.


Install and tighten the four fuel pump capscrews in the
sequence.
Torque Value: 6.5 Nm [ 50 in-lb ]
Tighten the four fuel pump capscrews in the sequence
shown.
Torque Value: 13 Nm [ 100 in-lb ]
Signature, ISX, and QSX15 Eng [...] Fuel Pump
Section 5 - Fuel System - Group 05 Page 5-7

Connect the ECM cooling plate return line to the back of


the fuel pump.
Torque Value: 25 Nm [ 221 in-lb ]

Automotive, Industrial with CM570 and Power


Generation without CM570
Replace the o-ring seals or gasket.
Install the pump onto the integrated fuel system module.

Install and tighten the four fuel pump capscrews in the


sequence.
Torque Value: 7 Nm [ 62 in-lb ]
Tighten the four fuel pump capscrews in sequence.
Torque Value: 13.5 Nm [ 120 in-lb ]
Install the fuel control cover.

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.
Connect the batteries and cables. Refer to Procedure
013-009 in Section 13.
Operate the engine and check for leaks.
Fuel Pump Signature, ISX, and QSX15 Eng [...]
Page 5-8 Section 5 - Fuel System - Group 05

Prime
With Fuel Lift Pump
NOTE: Several different versions of the priming pump
exist. All versions are covered in this step.
The integrated (Integrated Fuel System Module mounted)
and the automotive and industrial timing module priming
pumps are activated by turning the ignition switch to the
ON position. The pump will shut off automatically after two
minutes.
The engine can then be started.

The manual switch priming pump can be activated by


either the toggle switch on the priming pump or by
cranking the engine.
If the fuel system has lost prime, hold the switch on the
pump to the ON position.
Run the priming pump for two minutes, then turn it off.
The engine can then be started.
The engine will possibly run rough for several minutes
until the air is out of the system.

Without Fuel Lift Pump


The Signature, ISX, or QSX15 fuel system can require
priming.
If the engine is equipped with a priming pump, see the
priming pump equipped procedure above.

CAUTION
Fuel system damage can occur if debris is introduced
into the clean side of the filter during the prefilling
procedure.
Prefill the filter with a clean source of fuel.
Signature, ISX, and QSX15 Eng [...] Fuel Pump Pulsation Damper
Section 5 - Fuel System - Group 05 Page 5-9

Remove the top outboard M14 pressure side plug using a


6-mm Allen wrench.
NOTE: Later versions of the integrated fuel system
module have a 19-mm external hex plug at this location.

Crank the engine until fuel begins to flow from the top
plug. Retighten the plug.
Crank the engine for 20 seconds. If the engine does not
start within 20 seconds, wait 2 minutes. If necessary,
repeat these steps until the engine starts.
The engine will possibly run rough for several minutes
until the air is out of the system.

Fuel Pump Pulsation Damper


(005-031)
Preparatory Steps
All Applications
Remove the integrated fuel system module. Refer to
Procedure 005-073.

Remove
Automotive with CM870
There are two pulsation dampers.
Remove the top two capscrews and fuel pulsation
dampers.
Fuel Pump Pulsation Damper Signature, ISX, and QSX15 Eng [...]
Page 5-10 Section 5 - Fuel System - Group 05

Automotive, Industrial with CM570 and Power


Generation without CM570
There are three pulsation dampers.
Remove three torx screws, cover, and dampers.

Clean and Inspect for Reuse


Automotive with CM870
Remove the final capscrew and remove the housing from
the cover. Remove the steel diaphragm. Discard the o-
rings. Inspect the nylon washer and discard if damaged.
Check for corrosion, wear, or cracks in the cover or the
diaphragm. Replace all damaged parts.
To check the diaphragm for hidden cracks, drop it on a
flat, hard surface. It must have a clear ring. If it produces
a flat sound, replace the diaphragm.

Automotive, Industrial with CM570 and Power


Generation without CM570
Remove the housing from the cover. Remove the steel
diaphragm. Discard the o-rings. Inspect the nylon washer
and discard it if it is damaged.
Check for corrosion, wear, or cracks in the cover or the
diaphragm. Replace the damaged parts.
To check the diaphragm for hidden cracks, drop it on a
flat, hard surface. It must have a clear ring. If it produces
a flat sound, replace the diaphragm.

Install
Automotive with CM870
Assemble the fuel pulsation damper with new o-rings, a
new steel diaphragm, and a new nylon washer, if needed.
Install the lower fuel pulsation damper capscrew.
Torque Value:
Lower 9.5 Nm [ 84 in-lb ]
Verify the seal (1) is in the groove of the fuel pulsation
damper (2) and add Lubriplate to hold the seal in place.
Attach the fuel pulsation damper (2) with capscrews (3).
Torque Value: 9.5 Nm [ 84 in-lb ]
Signature, ISX, and QSX15 Eng [...] Fuel Shutoff Valve
Section 5 - Fuel System - Group 05 Page 5-11

Automotive, Industrial with CM570 and Power


Generation without CM570
Assemble the fuel pulsation damper with new o-rings, a
new steel diaphragm, and a new nylon washer, if needed.
Install the lower fuel pulsation damper capscrew.
Torque Value:
Screws A and B 9.5 Nm [ 84 in-lb ]
Screw C 5.5 Nm [ 48 in-lb ]

Finishing Steps
All Applications
Install the integrated fuel system module. Refer to
Procedure 005-073.

Fuel Shutoff Valve (005-043)


Remove
Use a wrench to hold the nut at the base of the post.
Use a 3/8-inch wrench to remove the nut holding the
electrical connection of the fuel shutoff valve coil.
Remove the connection.

Remove the four Allen head capscrews.


Remove the coil (1) and the fuel shield (2).
Remove the valve spring washer (3), valve disc (4), and
actuator disc (5) from the actuator housing (7) from the
IFSM (8).
Discard the o-rings (6).
Fuel Shutoff Valve Signature, ISX, and QSX15 Eng [...]
Page 5-12 Section 5 - Fuel System - Group 05

Inspect for Reuse

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

WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
Use mineral spirits. Clean all of the parts except the coil
assembly.
NOTE: Do not get solvent on the coil. Clean the coil with
a dry cloth. Use a 200-grit emery cloth and a flat surface
to polish the coil surface.
Check the valve disc, valve seat, and actuator disc for dirt,
metal parts, bonding separation, corrosion, cracks, or
wear. Replace if necessary.

Use a wire brush to clean any corrosion from the coil


terminal.

Check the coil assembly with a multimeter. Replace the


solenoid if the resistance is not to specification.

Fuel System Shutoff Valve Solenoid Specifications


Voltage Resistance Resistance
Minimum (Ohms) Maximum (Ohms)
6 VDC 1 5
12 VDC 6 15
24 VDC 24 50
32 VDC 42 80
36 VDC 46 87
48 VDC 92 145
74 VDC 315 375
115 VAC 645 735

NOTE: If the coil assembly shows 0 ohm, there is an


electrical short in the coil.
Signature, ISX, and QSX15 Eng [...] Fuel Shutoff Valve
Section 5 - Fuel System - Group 05 Page 5-13

Install
Assemble the shutoff valve as shown. Install these parts
as follows.
Install a new o-ring between the spacer and the electronic
control valve body.
Install the spacer o-ring groove toward the coil.
Install the actuator disc with the cup side toward the coil.
Install the spring washer with the cup side toward the coil.

Align the actuator disc, spacer, and valve disc on the


electronic control valve body.
Install a new o-ring.
Put the spring washer on the valve disc with the cavity side
positioned upward.
NOTE: The coil must be oriented with the electrical
connection post on the bottom.
NOTE: Make sure the shutoff valve coil is the correct
voltage (12 VDC). The coil voltage and part number are
cast into the terminal connection end of the coil.
Install the fuel shield and coil onto the front cover.
Install a new o-ring and tighten the Allen head capscrews.
Torque Value: 3.4 Nm [ 30 in-lb ]

Install the electrical connection on the fuel shutoff valve.


Install the nut onto the threaded post of the coil.
Use a wrench to hold the nut at the base of the post firmly
while tightening the connection nut.
Torque Value: 3 Nm [ 25 in-lb ]
Fuel Lift Pump Signature, ISX, and QSX15 Eng [...]
Page 5-14 Section 5 - Fuel System - Group 05

Fuel Lift Pump (005-045)


Initial Check
Inspect the engine harness, the lift pump power
connector, the lift pump relay power connector, and the
lift pump relay pins for the following:
Loose connector
Corroded pins
Bent or broken pins
Pushed back or expanded pins
Moisture in or on the connection
Missing or damaged connector seals
Dirt or debris in or on the connector pins
Connector shell broken
Wire insulation damage
Damaged connector locking tab.
See the service manual for the proper procedure for
replacing or repairing connectors, pins, or harnesses.

Resistance Check
CAUTION
Do not use probes or leads other than Part Number
3822758 and Part Number 3822917. The connector
will be damaged. The leads must fit tightly in the
connector without expanding the pins in the
connector.
Check for an open circuit in the fuel lift pump return circuit.
Disconnect the 2-pin fuel lift pump power connector at the
fuel lift pump.
Disconnect the fuel lift pump relay power connector where
the OEM harness connects to the engine harness.
Measure the resistance of the fuel lift pump return
between these two connectors.
The resistance must be 10 ohms or less.
If the resistance is greater than 10 ohms, repair or replace
the engine harness.
Signature, ISX, and QSX15 Eng [...] Fuel Lift Pump
Section 5 - Fuel System - Group 05 Page 5-15

CAUTION
Do not use probes or leads other than Part Number
3164572. The connector will be damaged. The leads
must fit tightly in the connector without expanding the
pins in the connector.
Check for an open circuit in the fuel lift pump relay return
line.
Measure the resistance from the fuel lift pump relay return
pin in the engine harness relay connector to engine block
ground.
The resistance must be 10 ohms or less.
If the resistance is greater than 10 ohms, repair or replace
the engine harness ground.

Measure the resistance of the fuel lift pump relay.


Measure the resistance between the fuel lift pump relay
signal pin and the fuel lift pump relay return pin on the
relay.
The resistance must be between 70 and 80 ohms.
If the resistance is not between 70 and 80 ohms, replace
the fuel lift pump relay.

Voltage Check
CAUTION
Do not use probes or leads other than Part Number
3822758 and Part Number 3822917. The connector
will be damaged. The leads must fit tightly in the
connector without expanding the pins in the
connector.
Remove the fuel lift pump power connector at the fuel lift
pump.
Turn the keyswitch to the ON position.
Measure the voltage between the fuel lift pump supply pin
and the fuel lift pump return pin on the harness connector.
The voltage must be battery voltage.
If voltage is not present, check the fuse on the fuel lift
pump relay supply line. Replace if necessary.
If the voltage is not correct, disconnect the 2-pin
connector between the OEM harness and the engine
harness that supplies the fuel lift pump relay with
unswitched battery power.
Measure the voltage at the 2-pin connector on the OEM
harness.
The voltage must be battery voltage.
If voltage is not present, repair or replace the OEM wiring
or contact a Cummins Authorized Dealer.
Fuel Lift Pump Signature, ISX, and QSX15 Eng [...]
Page 5-16 Section 5 - Fuel System - Group 05

Check the fuel lift pump relay for proper operation.


Unplug the fuel lift pump relay from the engine harness
connector.
Check the voltage at the fuel lift pump relay supply pin.
The voltage must be battery voltage.
If voltage is not present, recheck the fuses and the OEM/
engine harness for shorts and open circuits.
With the keyswitch in the ON position, measure the
voltage at the fuel lift pump relay signal pin on the engine
harness relay connector.
A measurement of 12-VDC must be indicated.
If 12-VDC is not indicated, check the ECM for the proper
calibration and contact a Cummins Authorized Repair
Location.

Test
Unplug the fuel lift pump relay from the engine harness
connector.
Connect the 2-pin fuel lift pump power connector to the
fuel lift pump.
Insert a jumper wire between the fuel lift pump relay
supply pin and the fuel lift pump supply pin in the engine
harness relay connector.
If the fuel lift pump is functioning correctly, the fuel lift
pump will operate.
If the lift pump does not operate when using the jumper
wire, Refer to Procedure 019-396 in the CM870 Electronic
Control System, Signature and ISX Engines
Troubleshooting and Repair Manual, Bulletin 4021334, for
replacing the lift pump.

Pressure Test
Turn the ignition switch to the ON position to activate
integrated fuel system mounted, automotive, or industrial
timing module priming pumps. Repeat if necessary.
Measure the fuel pressure at the gear pump inlet
Compuchek fitting.
If 69 kPa [10 psi] or greater is indicated, the lift pump is
operating correctly.
If less than 69 kPa [10 psi] is indicated, check the pressure
while drawing fuel from a bucket.
Signature, ISX, and QSX15 Eng [...] Fuel Lift Pump
Section 5 - Fuel System - Group 05 Page 5-17

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.

CAUTION
If the unit has recently switched to Bio-diesel or Ultra
Low Sulfur diesel and has a fuel leak, the entire lift
pump must be replaced, not only the gasket.
Remove or disconnect the following:
Battery cables. Refer to Procedure 013-009.
Engine wiring harness from the fuel lift pump.
EGR differential pressure sensor tubes. Refer to
Procedure 011-026.
EGR differential pressure sensor. Refer to Procedure
019-043 in the CM870 Electronic Control System,
Signature and ISX Engines Troubleshooting and
Repair Manual, Bulletin 4021334.

Remove
Automotive Engine Mounted
NOTE: The fuel lift pump is bolted to a mounting plate and
must be removed as an assembly.
Remove the four capscrews.
Remove the fuel lift pump.

Remove and discard the gasket.


Fuel Lift Pump Signature, ISX, and QSX15 Eng [...]
Page 5-18 Section 5 - Fuel System - Group 05

Industrial Engine Mounted


Disconnect the fuel pump wiring harness and the power
supply connections at the starter.
Tag the wires for location at installation.

Disconnect the fuel outlet line from the top of the


Integrated Fuel System Module (IFSM).
Disconnect the fuel inlet line from the rear of the IFSM.

Remove the fuel lift pump assembly mounting capscrews


and the fuel lift pump assembly.

Remote Mounted
Disconnect the ground wire from the cylinder block.
Signature, ISX, and QSX15 Eng [...] Fuel Lift Pump
Section 5 - Fuel System - Group 05 Page 5-19

Disconnect the fuel pump wiring harness and the power


supply connections at the starter.
Tag the wires for location at installation.

Disconnect the fuel inlet and outlet lines from the fuel
pump.

Remove the mounting capscrews and mounting plate.


Remove the fuel pump assembly.

Remove the large internal hex plug from the fuel pump.
Remove the filter screen and the gasket.
Fuel Lift Pump Signature, ISX, and QSX15 Eng [...]
Page 5-20 Section 5 - Fuel System - Group 05

Clean and Inspect for Reuse


Automotive Engine Mounted
Clean the mounting surfaces.

Inspect the fuel lift pump mounting plate for leaks, cracks,
and other damage.
If any damage is found, replace the fuel lift pump.

Remote Mounted

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

WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use solvent to clean the parts.
Flush debris from the filter screen.
Dry with compressed air.
Clean the mounting surfaces.
Signature, ISX, and QSX15 Eng [...] Fuel Lift Pump
Section 5 - Fuel System - Group 05 Page 5-21

Inspect the fuel lift pump mounting surface for cracks or


other damage.
If any damage is found, replace the fuel lift pump.
Use an Allen wrench to check for free movement of the
check valve.
Replace the check valve assembly, if damaged.

Replace
CAUTION
The fuel lift pump is extremely sensitive to debris. A
small amount of debris in the lift pump can cause the
lift pump to fail, causing it to need replacement. Only
service the lift pump in clean areas and use care not
to allow debris into the system.

CAUTION
The lift pump contains many loose parts. Use care
when removing the lift pump body from the adaptor
and keep the lift pump vertical.
This step includes the method for removing and installing
the fuel lift pump gasket.

Remove the three bolts that connect the adapter to the lift
pump body.

Replace the fuel lift pump gasket.


Fuel Lift Pump Signature, ISX, and QSX15 Eng [...]
Page 5-22 Section 5 - Fuel System - Group 05

Connect the adapter and lift pump assembly.


Tighten the bolts.
Torque Value: 12.5 Nm [ 110 in-lb ]

Install
Automotive Engine Mounted
Install a new gasket between the fuel lift pump mounting
plate and the IFSM.

Install the fuel lift pump and the four capscrews.


Tighten the capscrews.
Torque Value: 18 Nm [ 159 in-lb ]
To verify the lift pump is not leaking, turn the keyswitch to
the ON position with the engine off, operate the lift pump
for three minutes, and check for leaks.

Industrial Engine Mounted


Install the fuel lift pump assembly and mounting
capscrews.
Torque Value: 25 Nm [ 212 in-lb ]
Signature, ISX, and QSX15 Eng [...] Fuel Lift Pump
Section 5 - Fuel System - Group 05 Page 5-23

Be sure both copper washers are in place on the top fitting


when installing the fuel outlet line.
Install two new sealing washers on the fuel outlet line.
Install the fuel outlet line.
Torque Value: 27 Nm [ 239 in-lb ]
Install the fuel inlet line to the IFSM.

Connect the wiring harness connectors to the starter.

Remote Mounted
Install a new filter sealing ring.
Install the clean filter.
Install the large plug with a new o-ring.
Tighten the plug.
Torque Value: 23 Nm [ 204 in-lb ]

Install the fuel lift pump, mounting plate, and capscrews.


Torque Value: 45 Nm [ 33 ft-lb ]
Fuel Lift Pump Signature, ISX, and QSX15 Eng [...]
Page 5-24 Section 5 - Fuel System - Group 05

Install the fuel inlet and outlet lines.

Install the ground wire to the cylinder block.

Install the power supply connections to the starter.

Finishing Steps
Install or connect the following:
EGR differential pressure sensor. Refer to Procedure
019-043 in the CM870 Electronic Control System,
Signature and ISX Engines Troubleshooting and
Repair Manual, Bulletin 4021334.
EGR differential pressure sensor tubes. Refer to
Procedure 011-026.
Engine wiring harness to the fuel lift pump.
Battery cables. Refer to Procedure 013-009.
Prime the fuel system. Refer to Procedure 005-016 in
Section 5.
Start the engine and check for leaks.
Signature, ISX, and QSX15 Eng [...] Stall Speed Test
Section 5 - Fuel System - Group 05 Page 5-25

Stall Speed Test (005-054)


Stall Speed Check
The stall speed is the engine speed (rpm) obtained at full
throttle when the converter output shaft is locked.
NOTE: It is possible that the vehicle brakes will not hold
an electronically controlled transmission.

CAUTION
Do not exceed 120C [250F] converter oil
temperature. Overheating can result and converter
damage can occur. If the oil temperature exceeds
120C [250F], put the transmission in NEUTRAL and
operate the engine until the oil temperature is below
120C [250F].
Check the converter oil level.

The following equipment is needed for this check:


Stopwatch
Optical tachometer, Part Number 3377462 or
INSITE
Equipment manufacturer's stall speed and time-to-
stall specifications.

Place the gear selector in the highest gear or full forward.


Stall Speed Test Signature, ISX, and QSX15 Eng [...]
Page 5-26 Section 5 - Fuel System - Group 05

Make certain the vehicle has good brakes and air pressure
in the brake system.
NOTE: The brakes must prevent the vehicle from moving
when the engine is at full throttle. Engage the vehicle
brakes to keep the vehicle from moving.

Operate the engine until the converter temperature is 80


C [180F] or above.

Bring the engine speed back to low idle.

CAUTION
Do not exceed 120C [250F] converter oil
temperature. Overheating can result and converter
damage can occur. If the oil temperature exceeds
120C [250F], put the transmission in NEUTRAL and
operate the engine until the oil temperature is below
120C [250F].
Quickly move the throttle to the full-open position.
Signature, ISX, and QSX15 Eng [...] Stall Speed Test
Section 5 - Fuel System - Group 05 Page 5-27

Check the engine speed (rpm) at the point of stall:


Always hold the speed until it is stable.
Take several readings.
Make certain the readings are accurate.

Check the speed (rpm) against the specifications for the


equipment, converter, or automatic transmission.
NOTE: The stall speed for the engine and converter/
transmission can vary 8 percent from the
manufacturer's specifications.

If the stall speed is not within the specifications, refer to


the Stall Speed Checklist at the end of this section.
Check the equipment manufacturer's troubleshooting
procedures for other reasons for stall speed problems.

Time Speed Check


Perform the previous Stall Speed Check procedure
through the "check the engine speed (rpm) at the point of
stall" step, then:
Quickly move the throttle to the full-open position
and start the stopwatch at the same time.
Stall Speed Test Signature, ISX, and QSX15 Eng [...]
Page 5-28 Section 5 - Fuel System - Group 05

When the engine speed is 90 percent of the stall


speed rpm, stop the stopwatch.
Example: Stall speed rpm 2089 [2089 x 0.90 = 1880
rpm].
NOTE: The type of unit and the stall speed rpm can make
the stall speed time a maximum of 10 seconds.

Refer to the equipment manufacturer's specifications for


the time to stall or the acceleration time.

Stall Speed Check List


Stall Speed Too Low
If the Stall Speed is too low, check the following:
1. The tachometer is in error.
a. Yes
b. No
2. The engine is up to or above 70C [160F].
a. Yes
b. No
3. The converter oil is up to 80C [180F].
a. Yes
b. No
4. The stall has been held long enough for the engine to accelerate to full power.
a. Yes
b. No
5. The match curve stall speed was recorded correctly.
a. Yes
b. No
6. The converter oil meets the converter manufacturer's recommendation (SAE 30 rather than SAE 10, for
instance).
a. Yes
b. No
7. The engine-driven accessory power requirements exceed 10 percent of the gross engine power. Check for
abnormal accessory horsepower losses such as hydraulic pumps, large fans, oversize compressors, and so on.
Either remove the accessory or accurately determine the power requirement and adjust accordingly.
a. Yes
b. No
8. The unit is operating at an altitude high enough to affect the engine power.
a. Yes
b. No
9. The converter charging pressure is correct.
a. Yes
Signature, ISX, and QSX15 Eng [...] Stall Speed Test
Section 5 - Fuel System - Group 05 Page 5-29

b. No
10. The converter blading is interfering, or in a stage of failure. Check the sump or filter for particles.
a. Yes
b. No
11. The converter stators are freewheeling rather than locking up.
a. Yes
b. No
12. The engine is set for power other than that specified on the power curve.
a. Yes
b. No
13. The converter is wrong due to improper build or rebuild of unit.
a. Yes
b. No
14. The converter is performing to the published absorption curve.
a. Yes
b. No
15. The engine and converter match is correct. Check the engine and converter models for the proper match.
a. Yes
b. No
16. The engine is matched to too large of a converter. If this condition is believed to exist, please report the engine-
converter accessory information to the factory.
a. Yes
b. No
17. The engine power is down. Perform a cylinder performance test to find the cylinder with low power.
a. Yes
b. No
Stall Speed Too High
If the Stall Speed is too high, check the following:
1. The engine is high in power.
a. Yes
b. No
2. The tachometer is in error.
a. Yes
b. No
3. The accessory power requirements are less than 10 percent of the gross engine power.
a. Yes
b. No
4. The converter oil is aerating or foaming. Check for low oil level, air leaks in suction line, lack of foam inhibitor in
the oil, or suction screen or filter. Would be accompanied by a noticeable loss of machine performance.
a. Yes
b. No
5. The converter is being held at full stall. Check for slipping front disconnect clutch or a rotating output shaft. On
the converter-transmission package, this can be impossible to check.
a. Yes
b. No
6. The converter turbine element is beginning to fail and lose blades, or the converter was originally built with the
wrong size element.
a. Yes
b. No
7. The engine and converter match is correct due to a revision in the engine rating or the converter performance.
a. Yes
b. No
8. If the oil level is too high on the transmission-converter units with the oil sump in the transmission, it can cause
severe aeration due to parts dipping in the oil.
a. Yes
b. No
9. The converter is performing to the published absorption curve.
a. Yes
b. No
10. The converter charging pressure is correct.
a. Yes
b. No
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
Page 5-30 Section 5 - Fuel System - Group 05

The reasons for abnormal stall speeds listed above are some that have been encountered by Cummins representatives
and probably do not include all possible causes. The correction of the problem is either covered in the vehicle service
manual, the converter service manual, or is self-explanatory.

Integrated Fuel System Module (IFSM)


(005-073)
Preparatory Steps
With CM870

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.
Disconnect the battery cables. Refer to Procedure
013-009 in Section 13.
Remove the EGR mixer. Refer to Procedure 011-021
in Section 11.
Disconnect the air intake connection. Refer to
Procedure 010-080 in Section 10.
Remove engine wiring harness from all temperature
and pressure sensors, fueling and timing actuators,
the fuel shutoff valve, the water-in-fuel sensor, and the
fuel lift pump.
Remove the EGR differential pressure sensor tubes.
Refer to Procedure 011-026 in Section 11.
Remove the EGR differential pressure sensor. Use the
following procedure in the Troubleshooting and Repair
Manual, CM870 Electronic Control System,
Signature and ISX Engines, Bulletin 4021334. Refer
to Procedure 019-370 in Section 19.
Remove the EGR differential pressure sensor adapter.
Refer to Procedure 011-028 in Section 11.
Remove the customer accessory bracket.
Disconnect the fuel supply and fuel drain lines. Refer
to Procedure 006-024 in Section 6.
Remove the lift pump. Use the following procedure in
the Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature and ISX
Engines, Bulletin 4021334. Refer to Procedure
019-396 in Section 19.
Remove the ECM cooling plate fuel supply line
(bottom) from the IFSM and the ECM cooling plate fuel
return line (top) from the fuel pump. Refer to Procedure
006-006 in Section 6.
Remove the fuel filter. Refer to Procedure 006-015 in
Section 6.
Remove the accessory bracket located above the
integrated fuel system module (IFSM). Refer to
Procedure 001-082 in Section 1.
Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
Section 5 - Fuel System - Group 05 Page 5-31

CM570

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.
Disconnect the battery cables. Refer to Procedure
013-009 in Section 13.
Remove the air inlet piping. Refer to Procedure
010-080 in Section 10.
Disconnect the engine wiring harness from all
pressure and temperature sensors, fueling and timing
actuators, the fuel shut off valve, the water-in-fuel
sensor, and the fuel lift pump.
Remove the fuel control covers.
Disconnect the air intake connection. Refer to
Procedure 010-080 in Section 10.
Remove the customer accessory bracket.
Remove the fuel supply and fuel drain lines. Refer to
Procedure 006-024 in Section 6.
Remove the fuel filter. Refer to Procedure 006-015 in
Section 5.

Remove

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Remove two mounting capscrews from the IFSM.
Install two guide studs.
Remove the remaining capscrews, IFSM, and gasket.
Discard the gasket, if damaged.
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
Page 5-32 Section 5 - Fuel System - Group 05

Disassemble
With CM870
Remove all components:
Sensors
Regulators
Check valve
Fuel and timing actuators
Fuel shut-off valve
Gear pump (Only remove the four long capscrews, as
shown in the illustration.)
Fuel inlet and drain fittings
Fuel dampers (Only remove the two top capscrews of
the damper assembly, as shown in the illustration.)
All threaded plugs, o-rings, and gaskets.

CM570
Remove all components:
Sensors
Regulators
Check valve
Fuel and timing actuators
Fuel shut-off valve
Gear pump (Only remove the four long capscrews, as
shown in the illustration.)
Fuel inlet and drain fittings
Fuel dampers (Only remove the two top capscrews of
the damper assembly, as shown in the illustration.)
All threaded plugs, o-rings, and gaskets.

Clean and Inspect for Reuse


With CM870
Inspect the anti-drain back valve for damage or improper
sealing. Replace if necessary.
Verify that the anti-drain back valve seats properly and is
free of damage or debris. If damage is found, replace the
valve.
Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
Section 5 - Fuel System - Group 05 Page 5-33

Inspect the mounting capscrew holes for cracks. Inspect


the IFSM for leaks or cracks. Replace the module if cracks
are found.

Inspect the 1724 kPa [250 psi] and the 2620 kPa [380 psi]
fuel regulators for debris or damage (including the spring
inside the regulators). Replace the regulator if damage is
found.

CM570
Inspect the mounting capscrew holes for cracks.

Remove the 1724 kPa [250 psi] fuel pressure regulator.


Inspect for debris or other damage. Replace the regulator,
if necessary.
Install the fuel pressure regulator and tighten.
Torque Value: 27 Nm [ 239 in-lb ]
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
Page 5-34 Section 5 - Fuel System - Group 05

Remove the 2206 kPa [320 psi] fuel pressure regulator.


Inspect for debris or other damage. Replace the regulator,
if necessary.
Install the fuel pressure regulator and tighten.
Torque Value: 27 Nm [ 239 in-lb ]

Remove the check valves located in the fuel inlet and fuel
filter head.
Verify both seat properly and are free of damage or debris.
Replace if necessary.
Install both check valves and tighten.
Torque Value: 17 Nm [ 150 in-lb ]

Check the inlet filter screen for debris. Clean the filter, or
replace if necessary.
Install the inlet filter screen.

Assemble
With CM870
Verify the seal (1) is in the groove of the fuel control
damper (2) and add Lubriplate multi-purpose lubricant to
hold the seal in place.
Attach the fuel control damper (2) with capscrews (3) and
tighten.
Torque Value: 9.5 Nm [ 84 in-lb ]
Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
Section 5 - Fuel System - Group 05 Page 5-35

Install the o-rings (2 and 3) onto the pressure regulator (1).


Install the (2620 kPa) [380 psi] pressure regulator (1) into
the IFSM housing and tighten.
Torque Value: 27 Nm [ 239 in-lb ]

Install the o-rings (2 and 3) onto the pressure regulator (1).


Install the (1724 kPa) [250 psi] fuel pressure regulator into
the IFSM housing and tighten.
Torque Value: 27 Nm [ 239 in-lb ]

Install the o-ring seal (2) onto the fuel pressure sensor (1).
Install the fuel pressure sensor (1) into the IFSM housing
and tighten.
Torque Value: 23 Nm [ 204 in-lb ]

Install the o-ring seal (2) onto the fuel temperature sensor
(1).
Install the fuel temperature sensor into the IFSM housing
and tighten.
Torque Value: 23 Nm [ 204 in-lb ]
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
Page 5-36 Section 5 - Fuel System - Group 05

Install the o-ring (2) onto the Compuchek fitting (1).


Install both Compuchek fittings (1) into the IFSM housing
and tighten.
Torque Value: 9.5 Nm [ 84 in-lb ]

Install the o-ring (2) onto the anti-drain back valve (1).
Install the anti-drain back valve (1) into the housing and
tighten.
Torque Value: 17 Nm [ 150 in-lb ]

Install the o-ring (2) onto the cooling plate fuel supply
fitting (1).
Install the cooling plate fuel supply fitting (1) into the
housing and tighten.
Torque Value: 27 Nm [ 239 in-lb ]
Install the o-ring (3) onto the front face of the cooling plate
fuel supply fitting.

Install the o-ring (2) onto the fuel drain fitting (1).
Install the fuel drain fitting (1).
Turn the nut all the way to the top of the fitting.
Thread the fitting all the way into the IFSM housing, until
it stops.
Turn the fitting back until the threaded end is oriented
directly over the regulator.
Lock the fitting into position and tighten the locking nut.
Torque Value: 45 Nm [ 33 ft-lb ]
Maintain the correct orientation.
Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
Section 5 - Fuel System - Group 05 Page 5-37

Use a small amount of Lubriplate multi-purpose lubricant


in the grooves on the bottom of the metering actuators (2).
Install the actuator gasket (3) onto each actuator. Make
sure to align each properly.
Install the actuators (2) onto the IFSM housing.
Use three capscrews (1) to mount each actuator to the
housing and tighten the capscrews.
Torque Value: 15 Nm [ 133 in-lb ]

Use a small amount of Lubriplate multi-purpose lubricant


in the grooves on the bottom of the timing actuators (2).
Install the actuator gasket (3) onto each actuator. Make
sure to align each properly.
Install the actuators (2) onto the IFSM housing.
Use three capscrews (1) to mount each actuator to the
housing and tighten the capscrews.
Torque Value: 15 Nm [ 133 in-lb ]

Etch the same part number of the original IFSM on the


data tag (1).
Attach the tag to the housing by pressing the screws (2)
into the housing.
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
Page 5-38 Section 5 - Fuel System - Group 05

Install the seal (1) into the groove in the IFSM housing.
Place the actuator disc (2) over the seal (1), small diameter
down.
Place the valve disc (3) onto the actuator disc (2) with the
sealing surface down (spring pilot diameter up).
Place the valve spring (4) into the actuator housing (5) with
the inside diameter on the valve disc pilot (3).
Place the actuator housing (5) over the actuator disc (2).
Install the seal (1) into the groove in the actuator housing
(5).
Place the shutoff valve shield (6) over the actuator housing
(5).
Align the hole pattern of the shutoff valve shield (6).
Place the solenoid (7) over the shutoff valve shield (6)
taking care to align the holes and not pinch any seals.
Orient the terminal facing the gear pump.
Use four capscrews (8) to attach the assembly to the
housing and use an x pattern.
Torque Value: 5.5 Nm [ 49 in-lb ]

Install the o-ring (2) onto the threaded plug (1).


Install the three threaded plugs (1) into the housing.
Torque Value: 17 Nm [ 150 in-lb ]
Install the o-ring (4) onto the large threaded plug (3).
Install the large threaded plug (3) into the housing.
Torque Value: 14 Nm [ 124 in-lb ]

Install the o-rings (2) onto the threaded plugs (1).


Install the two threaded plugs (1) into the housing.
Torque Value: 17 Nm [ 150 in-lb ]
Install the o-ring (4) onto the fuel supply fitting (3).
Install the fuel supply fitting (3) into the housing.
Torque Value: 27 Nm [ 239 in-lb ]
Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
Section 5 - Fuel System - Group 05 Page 5-39

Install the o-ring (1) onto the fuel inlet fitting ( 2) from the
ECM cooling plate.
Install the fitting (2) into the fuel gear pump and tighten.
Torque Value: 27 Nm [ 239 in-lb ]
Install the o-ring (3) onto the fuel inlet fitting (2).

Install the o-ring (3) onto the fuel gear pump (2).
Apply Lubriplate multi-purpose lubricant to the o-ring (3).
Install the gasket (4) onto the gear fuel pump.
Use four capscrews (1) to install the pump to the IFSM
housing.
Torque Value: 11 Nm [ 97 in-lb ]

Install the lift pump gasket (1) onto the lift pump (2).
Use four capscrews (3) to install the lift pump to the
housing.
Torque Value: 18 Nm [ 159 in-lb ]

CM570
Verify the seal (1) is in the groove of the fuel control
damper (2) and add Lubriplate multi-purpose lubricant to
hold the seal in place.
Attach the fuel control damper (2) with capscrews (3) and
tighten.
Torque Value: 9.5 Nm [ 84 in-lb ]
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
Page 5-40 Section 5 - Fuel System - Group 05

Install the o-rings (2 and 3) onto the pressure regulator (1).


Install the 2206 kPa [320 psi] pressure regulator (1) into
the IFSM housing and tighten.
Torque Value: 27 Nm [ 239 in-lb ]

Install the o-rings (2 and 3) onto the pressure regulator (1).


Install the 1724 kPa [250 psi] fuel pressure regulator into
the IFSM housing and tighten.
Torque Value: 27 Nm [ 239 in-lb ]

Install the o-rings (2) onto the fuel pressure sensor (1).
Install the fuel pressure sensor (1) into the IFSM housing
and tighten.
Torque Value: 23 Nm [ 204 in-lb ]
NOTE: Some IFSMs contain an additional fuel pressure
sensor.

Install the air bleed (2) onto the air bleed orifice into the
IFSM (1) through the opening for the Compuchek fitting.
Torque Value: 7.9 Nm [ 70 in-lb ]
Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
Section 5 - Fuel System - Group 05 Page 5-41

Install the o-ring (2) onto the Compuchek fitting (1).


Install both Compuchek fittings (1) into the IFSM housing
and tighten.
Torque Value: 9.5 Nm [ 84 in-lb ]

Install the o-ring (2) onto the anti-drain back valve (1).
Install the anti-drain back valve (1) into the housing and
tighten.
Torque Value: 17 Nm [ 150 in-lb ]

Install the o-ring (2) onto the anti-drain back valve (1).
Install the anti-drain back valve (1) for the fuel filter into
the housing and tighten.
Torque Value: 17 Nm [ 150 in-lb ]

Install the filter screen (1), compression spring (2) , o-ring


(3), and filter cap (4) into the housing.
Torque Value: 17 Nm [ 150 in-lb ]
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
Page 5-42 Section 5 - Fuel System - Group 05

Install the o-ring seal (2) onto the fuel drain fitting (1).
Install the fuel drain fitting (1).
Turn the nut all the way to the top of the fitting.
Thread the fitting all the way into the IFSM housing until
it stops.
Turn the fitting back until the threaded end is oriented
directly over the regulator.
Lock the fitting into position and tighten the locking nut.
Torque Value: 45 Nm [ 33 ft-lb ]
Maintain the correct orientation.

Use a small amount of Lubriplate multi-purpose lubricant


in the grooves on the bottom of the metering actuators (2).
Install the actuator gasket (3) onto each actuator, making
sure to align each properly.
Install the actuators (2) onto the IFSM housing.
Mount each actuator to the housing using three
capscrews (1) and tighten the capscrews.
Torque Value: 15 Nm [ 133 in-lb ]

Use a small amount of Lubriplate multi-purpose lubricant


in the grooves on the bottom of the timing actuators (2).
Install the actuator gasket (3) onto each actuator, making
sure to align each properly.
Install the actuators (2) onto the IFSM housing.
Mount each actuator to the housing using three
capscrews (1) and tighten the capscrews.
Torque Value: 15 Nm [ 133 in-lb ]

Etch the same part number of the original IFSM on the


data tag (1).
Attach the tag to the housing by pressing the screws (2)
into the housing.
Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
Section 5 - Fuel System - Group 05 Page 5-43

Install the seal (1) into the groove in the IFSM housing.
Place the actuator disc (2) over the seal (1), small diameter
down.
Place the valve disc (3) onto the actuator disc (2) with the
sealing surface down (spring pilot diameter up).
Place the valve spring (4) into the actuator housing (5) with
the inside diameter on the valve disc pilot (3).
Place the actuator housing (5) over the actuator disc (2).
Install the seal (1) into the groove in the actuator housing
(5).
Place the shutoff valve shield (6) over the actuator housing
(5).
Align the hole pattern of the shutoff valve shield (6).
Place the solenoid (7) over the shutoff valve shield (6),
taking care to align the holes and not pinch any seals.
Orient the terminal facing the gear pump.
Attach the assembly to the housing using four capscrews
(8) and tighten using an x pattern.
Torque Value: 5.5 Nm [ 49 in-lb ]

Install the o-ring (2) onto the threaded plug (1).


Install the three threaded plugs (1) into the housing.
Torque Value: 17 Nm [ 150 in-lb ]
Install the o-ring (4) onto the large threaded plug (3).
Install the larger threaded plug (3) into the housing.
Torque Value: 14 Nm [ 124 in-lb ]

Install the o-ring onto the fuel supply fitting.


Install the fuel supply fitting into the housing.
Torque Value: 27 Nm [ 239 in-lb ]
Install the o-ring onto the fuel inlet fitting.
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
Page 5-44 Section 5 - Fuel System - Group 05

Install the o-ring (3) onto the fuel gear pump (2).
Apply Lubriplate multi-purpose lubricant to the o-ring (3).
Install the gasket (4) onto the gear fuel pump.
Use four capscrews (1) and install the pump to the IFSM
housing.
Torque Value: 11 Nm [ 97 in-lb ]

Install the lift pump gasket (1) onto the lift pump (2).
Install the lift pump to the housing using three capscrews
(3).
NOTE: Some early engines were not equipped with a lift
pump. These engines use a hand priming pump or they
have been fitted with an auxilary lift pump.
Torque Value: 18 Nm [ 159 in-lb ]

Install
Install two guide pins into the mounting holes on the
cylinder head.

Install a new gasket onto the guide pins.


Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
Section 5 - Fuel System - Group 05 Page 5-45

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Install the IFSM on the guide pins.
Install and tighten the capscrews.
Remove the guide pins.
Install and tighten the remaining capscrews.
Torque Value: 45 Nm [ 33 ft-lb ]
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
Page 5-46 Section 5 - Fuel System - Group 05

Finishing Steps
With CM870

WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
(-) battery cable first and attach the negative (-) battery
cable last.
Install the accessory bracket. It is located above the
IFSM. Refer to Procedure 001-082 in Section 1.
Install the ECM cooling plate fuel supply line (bottom)
to the IFSM and ECM cooling plate fuel return line (top)
to the fuel pump. Refer to Procedure 006-006 in
Section 6.
Install the lift pump. Use the following procedure in the
Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature and ISX
Engines, Bulletin 4021334. Refer to Procedure
019-396 in Section 19.
Install the customer accessory bracket. Tighten to 18
Nm [159 in-lb].
Connect the fuel supply and fuel drain lines. Refer to
Procedure 006-024 in Section 6.
Install the EGR differential pressure sensor adapter.
Refer to Procedure 011-028 in Section 11.
Install the EGR differential pressure sensor. Use the
following procedure in the Troubleshooting and Repair
Manual, CM870 Electronic Control System,
Signature and ISX Engines, Bulletin 4021334. Refer
to Procedure 019-370 in Section 19.
Install the EGR differential pressure sensor tubes.
Refer to Procedure 011-026 in Section 11.
Connect the engine wiring harness to all temperature
and pressure sensors, fueling and timing actuators,
the fuel shutoff valve, the water-in-fuel sensor, and the
fuel lift pump.
Connect the air intake connection. Refer to Procedure
010-080 in Section 10.
Connect the EGR mixer to the air intake connection.
Refer to Procedure 011-021 in Section 11.
Connect the battery cable. Refer to Procedure 013-009
in Section 13.
Install the fuel filter. Refer to Procedure 006-015 in
Section 6.
Prime the fuel system.
Operate the engine to normal operating temperature
and check for leaks.
Signature, ISX, and QSX15 Eng [...] Fuel Inlet Pre-Filter
Section 5 - Fuel System - Group 05 Page 5-47

CM570

WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
(-) battery cable first and attach the negative (-) battery
cable last.
Install the fuel filter. Refer to Procedure 006-015 in
Section 5.
Connect the fuel supply and fuel drain lines. Refer to
Procedure 006-024 in Section 6.
Install the customer accessory bracket. Tighten to 18
Nm [159 in-lb]).
Connect the air intake connection. Refer to Procedure
010-080 in Section 10.
Install the fuel control covers.
Connect the engine wiring harness from all pressure
and temperature sensors, fueling and timing actuators,
the fuel shut off valve, the water-in-fuel sensor, and the
fuel lift pump.
Connect the air inlet piping. Refer to Procedure
010-080 in Section 10.
Connect the battery cables. Refer to Procedure
013-009 in Section 13.
Operate the engine to normal operating temperature
and check for leaks.

Fuel Inlet Pre-Filter (005-096)


General Information
The fuel inlet pre-filter is designed to protect the priming
pump from debris from the fuel tanks.
Three versions of the fuel inlet pre-filter have been used
on the ISX/QSX15 engine.
Early engines utilized a 300 micron pre-filter located in the
fuel inlet to the Integrated Fuel System Module or a 36
micron filter located on the Integrated Fuel System
Module.
Many of these Integrated Fuel System Module mounted
pre-filters were removed due to the small area of the filter
which become plugged easily. Remote mount automotive
priming pumps contained a fuel pre-filter located in the
priming pump manifold.
Fuel Inlet Pre-Filter Signature, ISX, and QSX15 Eng [...]
Page 5-48 Section 5 - Fuel System - Group 05

Later engines utilize a larger, serviceable 300 micron pre-


filter located in a housing at the Integrated Fuel System
Module fuel inlet.
Some engines are not equipped with a pre-filter.

Remove
Remove the fuel supply line to the Integrated Fuel System
Module. Refer to Procedure 006-024.

Remove the fuel inlet fitting, pre-filter snap ring, and pre-
filter.

Remove the fuel pump screen cap (36-micron screen).


Discard the screen.
Signature, ISX, and QSX15 Eng [...] Fuel Inlet Pre-Filter
Section 5 - Fuel System - Group 05 Page 5-49

Remove the large pre-filter from the Integrated Fuel


System Module.

Clean
Disassemble the inlet pre-filter.
NOTE: The filter media is not removable from the inlet
fitting.

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use solvent to back-flush the pre-filter element.
Dry with compressed air.

Assemble the inlet pre-filter.


Torque Value: 60 Nm [ 44 ft-lb ]
Fuel Inlet Pre-Filter Signature, ISX, and QSX15 Eng [...]
Page 5-50 Section 5 - Fuel System - Group 05

Install
Install the pre-filter on the Integrated Fuel System Module.
Torque Value: 60 Nm [ 44 ft-lb ]

NOTE: Do not use a new style inlet screen combined with


an old style inlet screen. Excessive fuel inlet restriction will
result.
Install the pre-filter, snap ring, and fuel inlet fitting into the
Integrated Fuel System Module.

Install the fuel pump screen, compression spring, o-ring,


and cap. Tighten the cap.
Torque Value: 17 Nm [ 150 in-lb ]

Install the fuel inlet line. Refer to Procedure 006-024.


Signature, ISX, and QSX15 Eng [...]
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-a

Section 6 - Injectors and Fuel Lines - Group 06


Section Contents
Page
Air in Fuel ..........................................................................................................................................................6-2
Initial Check......................................................................................................................................................6-2
ECM Cooling Plate, Fuel Cooled .......................................................................................................................6-2
Clean and Inspect for Reuse.............................................................................................................................6-3
Finishing Steps.................................................................................................................................................6-5
Install................................................................................................................................................................6-5
Preparatory Steps.............................................................................................................................................6-2
Remove............................................................................................................................................................6-3
Fuel Drain Line Restriction ...............................................................................................................................6-6
Measure............................................................................................................................................................6-6
Fuel Filter (Spin-On Type) .................................................................................................................................6-6
Clean................................................................................................................................................................6-9
Initial Check......................................................................................................................................................6-6
Install................................................................................................................................................................6-9
Remove............................................................................................................................................................6-8
Fuel Inlet Restriction .......................................................................................................................................6-11
Measure..........................................................................................................................................................6-11
With Pressurized Fuel Filtering.....................................................................................................................6-11
With Vacuum Fuel Filtering.......................................................................................................................... 6-12
Fuel Supply Lines ............................................................................................................................................6-13
Inspect for Reuse............................................................................................................................................6-13
Remove.......................................................................................................................................................... 6-13
Injector .............................................................................................................................................................6-14
Assemble........................................................................................................................................................6-23
Disassemble................................................................................................................................................... 6-19
Finishing Steps...............................................................................................................................................6-27
Inspect for Reuse............................................................................................................................................6-18
Install..............................................................................................................................................................6-27
Leak Test........................................................................................................................................................6-14
Preparatory Steps...........................................................................................................................................6-16
Remove.......................................................................................................................................................... 6-17
Service Tools ....................................................................................................................................................6-1
.........................................................................................................................................................................6-1
Signature, ISX, and QSX15 Eng [...]
Page 6-b Section 6 - Injectors and Fuel Lines - Group 06

This Page Left Intentionally Blank


Signature, ISX, and QSX15 Eng [...] Service Tools
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-1

Service Tools

The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.

Tool No. Tool Description Tool Illustration


Manometer
Used to measure fuel drain line restriction.
ST-1111-3

Sight Glass
Check for air in fuel suction line. Use Part Number ST-998 with
ST-998 Number 10 hose.

Injector Leak Test Kit


Use in conjunction with a manometer (ST1111-3) to test injectors for
3164001 leaks that cause an engine to exhibit slow shutdown or excessive run-
on after a key-off condition.

Filter Wrench
Used to remove or tighten spin-on fuel filters.
3376807

Chip Removing Unit


Used to remove carbon from the top of the piston.
3823461

Pressure/Vacuum Module
Used with 3377161 Digital Multimeter or 3824648 Automotive Meter.
3824645 The pressure transducer range is 500 psi and the vacuum range is
29.92 in Hg.
ECM Cooling Plate, Fuel Cooled Signature, ISX, and QSX15 Eng [...]
Page 6-2 Section 6 - Injectors and Fuel Lines - Group 06

Air in Fuel (006-003)


Initial Check
To perform a pressure-side air-in-fuel check, use the
following items:
Quick-disconnect fitting, Part Number 3376859
Pressure valve (capable of 2758 kPa [400 psi])
Clean clear tubing
Clean container.

Connect the equipment to the quick-connect fitting at the


fuel module as shown.
Put a coil in the clear hose.
Put the end of the clear hose in the clean container.
Operate the engine at idle with no load.
Slightly open the valve until a steady stream of fuel is
visible.
If there is an air leak, bubbles will be visible in the coil of
the clear tubing.
If an air leak is found, inspect the center seal ring in the
fuel filter for deformation.
If the seal ring is not damaged, continue to test and look
for air leaks until there are no bubbles visible.
Remove the air-in-fuel check equipment.

ECM Cooling Plate, Fuel Cooled


(006-006)
Preparatory Steps
NOTE: Some chassis will allow the ECM to be moved
aside with the wiring harness attached, for access to the
cooling plate.
Disconnect the engine wiring harness and OEM
harness connectors, if necessary. Refer to
Procedure 019-031 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
Signature, ISX, and QSX15 Eng [...] ECM Cooling Plate, Fuel Cooled
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-3

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

Remove the five ECM mounting capscrews and the ECM.


Remove the six cooling plate mounting capscrews and
washers.
Remove the cooling plate and gasket.

Remove five insulating washers and the one ground


washer from the cooling plate mounting holes.

Clean and Inspect for Reuse

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the cooling plate mounting surfaces with solvent.
Dry with compressed air.
ECM Cooling Plate, Fuel Cooled Signature, ISX, and QSX15 Eng [...]
Page 6-4 Section 6 - Injectors and Fuel Lines - Group 06

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
NOTE: If the sealing bead or groove is dirty, a leak can
result.
Clean the ECM cooling plate gasket sealing bead with a
dry cloth.
Make sure no rust or soot has accumulated in the grooves
on either side of, or on top of, the sealing bead.
Use compressed air to remove debris from the grooves, if
necessary.

Inspect the five insulating washers and the one ground


washer for cracks or other damage.
Replace any washer that is damaged.

Check for cracks or damage to the cooling plate.


Replace the cooling plate if cracks or damage is found.

Check the cooling plate fuel supply and return line fittings
on the ECM cooling plate, integrated fuel system module,
and fuel pump to make sure the o-rings are installed
properly and are not damaged.
Replace the o-ring, fitting, or cooling plate if damaged.
Signature, ISX, and QSX15 Eng [...] ECM Cooling Plate, Fuel Cooled
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-5

Install
Install five insulating washers. The one ground washer
must be installed in the upper left cooling plate mounting
capscrew hole.

CAUTION
Make sure that the insulating washers and the ground
washer are installed properly on the cooling plate or
malfunction of the ECM can occur.
Install the cooling plate gasket.
Install the six cooling plate mounting capscrews and
washers.
Torque Value: 20 Nm [ 15 ft-lb ]
Install the ECM.
Install and tighten the five ECM mounting capscrews.
Torque Value: 20 Nm [ 15 ft-lb ]

Install the ECM cooling plate fuel supply line (bottom) to


the integrated fuel system module and the ECM cooling
plate.
Install the ECM cooling plate fuel return line (top) to the
fuel pump and the ECM cooling plate.
Torque Value: 25 Nm [ 18 ft-lb ]

Finishing Steps
Connect the ECM harness and engine wiring
harness. Refer to Procedure 019-031 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
Start the engine and check for fuel leaks.
Fuel Filter (Spin-On Type) Signature, ISX, and QSX15 Eng [...]
Page 6-6 Section 6 - Injectors and Fuel Lines - Group 06

Fuel Drain Line Restriction (006-012)


Measure
Remove the fuel drain hose and install adapter, Part
Number ST-434-1.
Install a 0-763 mm-Hg [0-30 in Hg] pressure gauge onto
the adapter.
Operate the engine at high idle and no load. Check and
record the restriction reading.

Fuel Drain Line Restriction


mm Hg in Hg
With Check Valve 165 MAX 6.5
Without Check Valve 229 MAX 9
If restriction exceeds specifications, inspect the drain lines
for the cause of the restriction. Fuel coolers and fuel
heaters can cause excessive drain line restriction.
Excessive restriction can cause low power and poor fuel
economy.
Remove the adapter and pressure gauge. Install the fuel
drain hose.
Torque Value: 35 Nm [ 26 ft-lb ]
If damage resulted in coolant, oil, excessive fuel or
excessive black smoke entering the exhaust system, the
aftertreatment system must be inspected. Refer to
Procedure 014-013 in Section 14.

Fuel Filter (Spin-On Type) (006-015)


Initial Check
With Pressurized Fuel Filtering
Install a pressure gauge, Part Number 3824877 (2758 kPa
[400 psi]), on the fuel pump Compuchek fitting, to
measure the fuel pressure before the fuel filter.

Start the engine and operate at high idle and no load.


Measure and record the fuel pressure.
Shut the engine off.
Remove the pressure gauge from the fuel pump.
Signature, ISX, and QSX15 Eng [...] Fuel Filter (Spin-On Type)
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-7

Install a pressure gauge, Part Number 3824877 (275 kPa


[400 psi]), on the rail fuel pressure Compuchek fitting
located on the IFSM to measure the fuel pressure after the
filter.

Start the engine and operate at high idle and no load.


Measure and record the fuel pressure.
Shut the engine off.
Remove the pressure gauge from the rail fuel pressure
Compuchek fitting.
The pressure difference between the rail fuel pressure and
fuel pump pressure is the differential pressure.

Fuel Filter Restriction


kPa psi
517 MAX 75
If the fuel filter restriction is above specifications, replace
the filter.

With Vacuum Fuel Filtering


Connect a vacuum gauge to either suction-side
Compuchek fitting.
NOTE: Some engines equipped with priming pumps do
not have a lower Compuchek fitting and have an air
bleed line plumbed into the upper location. Reference the
Install Section for measuring inlet restriction.

Disconnect the air bleed line from the upper location on


the IFSM. Insert a Compuchek fitting in this location and
run a line to a catch container.
Fuel Filter (Spin-On Type) Signature, ISX, and QSX15 Eng [...]
Page 6-8 Section 6 - Injectors and Fuel Lines - Group 06

Start the engine.


After the fuel lift pump stops running and with the engine
operating at idle, disconnect the hose to the catch
container.
Connect the vacuum gauge to the Compuchek fitting and
measure the fuel inlet restriction.

Operate the engine at high idle and no load.

Fuel Inlet Restriction


mm Hg in Hg
Upper Location 356 MAX 14
Lower Location 305 MAX 12
An inlet restriction greater than specification indicates
either a dirty fuel filter or a restriction in the OEM fuel
supply plumbing. Inlet restriction at the fuel supply
connection must be checked to identify the correct
source of the restriction.

Remove
With Pressurized Fuel Filtering

WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot
lights, arcing equipment, and switches out of the work
area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when
working on the fuel system.
Clean the area around the fuel filter head and filter.
Remove the fuel filter with filter wrench, Part Number
3400157.

With Vacuum Fuel Filtering

WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot
lights, arcing equipment, and switches out of the work
area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when
working on the fuel system.
Clean the area around the fuel filter head and filter.
Disconnect the wiring harness from the water-in-fuel
sensor, if equipped.
Remove the fuel filter with filter wrench, Part Number
3400158.
Signature, ISX, and QSX15 Eng [...] Fuel Filter (Spin-On Type)
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-9

Clean
All Applications
Use a clean, lint-free cloth to clean the filter head gasket
surface.

Install
With Pressurized Fuel Filtering
Use the correct filter(s) for your engine. It must remove a
minimum of 95 percent of free and emulsified water. It
must also have a minimum of 98.7 percent 15-micron
particle-removal efficiency.
Refer to Procedure 018-024 in Section V.
Apply a thin coating of clean engine oil to the filter gasket
surface.

CAUTION
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
NOTE: Engines equipped with priming pumps do not
require the fuel filter to be filled prior to installation, if the
following filling procedure is followed:
Install the filter onto the filter head. Turn the filter until the
gasket contacts the filter head surface.
Tighten the filter an additional of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.

To perform the priming procedure, use the following


ittems to fabricate a fuel bypass hose:
2- Quick-disconnect fittings, Part Number 3376859
Clear tubing (capable of 2758 kPa [400 psi])
Install the fuel bypass hose fabricated above between the
suction-side Compuchek fitting at the top of the IFSM
and the fuel pump Compucheck fitting located on the head
of the fuel pump.
Connect the clear hose and the shutoff valve normally
used to check for air in fuel to the rail Compuchek fitting.
Refer to Procedure 006-003 in Section 6. Place the open
end of the tube in a suitable container and fully open the
shutoff valve in the hose.
Fuel Filter (Spin-On Type) Signature, ISX, and QSX15 Eng [...]
Page 6-10 Section 6 - Injectors and Fuel Lines - Group 06

Fill the fuel filter by turning the ignition switch to the ON


position, but do not start the engine. The fuel lift pump
should begin to operate. Monitor the open end of the bleed
line from the rail Compuchek. When fuel is seen coming
out of this line, turn the ignition OFF. Remove the bleed
line and the air in fuel test line.

With Vacuum Fuel Filtering and Priming Pump


Use the correct filter(s) for your engine. It must remove a
minimum of 95 percent of free and emulsified water. It
must also have a minimum of 98.7 percent at 25-micron
particle-removal efficiency.
Refer to Procedure 018-024 in Section V.
Apply a thin coating of clean engine oil to the filter gasket
surface and the center seal.

CAUTION
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
NOTE: Engines equipped with priming pumps do not
require the fuel filter to be filled prior to installation, if the
following filling procedure is followed:
Install the filter onto the filter head. Turn the filter until the
gasket contacts the filter head surface.
Tighten the filter an additional 3/4 of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.
If the filter is equipped with a water-in-fuel sensor, rotate
the sensor to the desired location and connect the wiring
harness.

NOTE: The engine will, perhaps, run rough for several


minutes until the air is out of the system.
Fill the fuel filter by turning the ignition keyswitch to the
ON position. The priming pump will operate for 2 minutes,
which will adequately fill the fuel filter. The engine can
then be started.
Some engines utilize a manual, remote mount priming
pump. Flip the priming pump mounted toggle switch to the
ON position. Operate the pump for 2 minutes and shut it
off. The engine can then be started.
Signature, ISX, and QSX15 Eng [...] Fuel Inlet Restriction
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-11

With Vacuum Fuel Filtering and Without Priming


Pump
Use the correct filter(s) for your engine. It must remove a
minimum of 95 percent of free and emulsified water. It
must also have a minimum of 98.7 percent at 25-micron
particle-removal efficiency.
Refer to Procedure 018-024 in Section V.
Apply a thin coating of clean engine oil to the filter gasket
surface and the center seal.

CAUTION
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
NOTE: Engines equipped with priming pumps do not
require the fuel filter to be filled prior to installation, if the
following filling procedure is followed:
Install the filter onto the filter head. Turn the filter until the
gasket contacts the filter head surface.
Tighten the filter an additional 3/4 of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.
If the filter is equipped with a water-in-fuel sensor, rotate
the sensor to the desired location and connect the wiring
harness.

NOTE: The engine will, perhaps, run rough for several


minutes until the air is out of the system.
Fill the fuel filter by turning the ignition switch to the ON
position. The priming pump will operate for 2 minutes,
which will adequately fill the fuel filter. The engine can
then be started.

Fuel Inlet Restriction (006-020)


Measure
With Pressurized Fuel Filtering
Connect a vacuum gauge to the suction side Compuchek
fitting on top of the integrated fuel system module.
Fuel Inlet Restriction Signature, ISX, and QSX15 Eng [...]
Page 6-12 Section 6 - Injectors and Fuel Lines - Group 06

Operate the engine at rated speed no load.


Observe the reading on the gauge.
Fuel Inlet Restriction
Clean Suction Filter 203 mm Hg [ 8 in Hg ]
Dirty Suction Filter 305 mm Hg [ 12 in Hg ]
If the restriction exceeds the specifications, correct the
restriction in the suction filter, lines, heaters, or fuel tank.
Refer to the OEM troubleshooting and repair manual.

Remove the fuel supply hose.


Install a vacuum gauge, Part Number ST434, using
adapter, Part Number ST434-2.

Hold the vacuum gauge at the same level as the fuel inlet
connection.
Operate the engine at rated speed no load.
Observe the reading on the gauge.
Maximum Inlet Restriction (With Clean Suction Filter)
127 mm Hg [ 5 in Hg ]
If the restriction exceeds the specifications, correct the
restriction in the suction filter, lines, heaters, or fuel tank.
Refer to the OEM troubleshooting and repair manual.

With Vacuum Fuel Filtering


Remove the fuel supply hose to the integrated fuel system
module.
Remove the inlet filter screen, if equipped. Refer to
Procedure 005-073..
Install a vacuum gauge, Part Number ST-434, using
adapter, Part Number 3375845, and hose, Part Number
3376922.
NOTE: Use the appropriate hose adapter for the specific
engine as described in the Service Tools list in the
Troubleshooting and Repair Manual, Signature Engines,
Bulletin Number 3666239.
Signature, ISX, and QSX15 Eng [...] Fuel Supply Lines
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-13

Hold the vacuum gauge at the same level as the


integrated fuel system module connection.

Operate the engine at high idle and no load.


Observe the reading on the vacuum gauge.

Fuel Inlet Restriction


mm Hg in Hg
Without remote fuel 76 MAX 3
filter
With remote fuel filter 254 MAX 10
If the inlet restriction measured at the fuel supply
connection is above specification, the OEM fuel supply
lines, remote mount filter, or remote mount priming pump
(if equipped) is obstructed.
If the inlet restriction at the fuel supply connection is below
specification, the inlet pre-filter should be inspected for
debris and/or the fuel filter changed.

Fuel Supply Lines (006-024)


Remove
Remove the fuel supply hose to the integrated fuel system
module.

Inspect for Reuse


Inspect the inside of the hose.
The inner lining of the hose can be separate from the
center hose section.
A separation or flap can cause a restriction in the fuel
flow.
Replace the fuel hose if damage is found.
Injector Signature, ISX, and QSX15 Eng [...]
Page 6-14 Section 6 - Injectors and Fuel Lines - Group 06

Injector (006-026)
Leak Test
This test checks for combustion gas leaks back through the injector rail check valve, or other conditions that will allow
gas leakage through the injector into the fuel rail.
When the engine is barred over, back pressure is created against the injector by the piston coming up on the
compression stroke.
During the test, if the rail check valve is leaking, air is pushed through the rail check valve and into the fuel rail, where
pressure is sensed at the test fixture which is in place of the metering actuator. If a manometer is connected to the
test fixture, pressure will be measured as air escapes through the leaking rail check valve. If a container of water is
used instead of a manometer, bubbles will be seen as air escapes through the leaking rail check valve.
The overhead set marks on the damper are used to identify which cylinder is on the compression stroke, and therefore
which injector has malfunctioned, if a change in manometer pressure or bubbles are seen.
Verify the run-on after key OFF complaint.
If the engine exhibits an excessive amount of run-on after
key OFF (greater than 3 seconds), continue with this
procedure.

The complaint must be verified to continue the


troubleshooting.
Vary the operating conditions until the complaint of run-
on/slow shutdown can be reproduced.

Shut the engine off.


Signature, ISX, and QSX15 Eng [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-15

The fuel-metering actuators are the actuators located on


each end of the unit.
Remove the fuel-metering actuator for the front three
cylinders. Use the ISX Fuel System Troubleshooting and
Repair Manual, Bulletin 3666259. Refer to Procedure
019-110 in Section 19.
Install the Injector Leak Test Kit, Part Number 3164001, in
place of the fuel-metering actuator.
Torque Value: 15.3 Nm [ 135 in-lb ]
Connect the flexible tubing to the hose fitting on the
mounting plate.
Place the flexible tubing into a container of water.

Bar the engine over while watching for bubbles in the


container.
The engine will need to be barred over two complete
revolutions to evaluate each bank.
There can be a few bubbles observed immediately before
reaching a timing mark. The leak indicator is if bubbles
occur for an extended period between the timing marks.
NOTE: An alternative to barring the engine is to remove
the 4-pin power connector from the ECM and then crank
the engine. Disconnecting the 4-pin power connector will
prevent the engine from starting. If bubbles are observed
in the container, proceed with barring over the engine to
determine which injector is leaking.

Note between which two timing marks the bubbles occur.


Determine the leaking injector by following the diagram.
If bubbles occur between:
A and B (number 3 injector is leaking)
B and C (number 1 injector is leaking)
C and A (number 2 injector is leaking).

Remove the mounting plate connected to the port for the


front three cylinders. Install the fuel-metering actuator
removed previously. Use the ISX Fuel System
Troubleshooting and Repair Manual, Bulletin 3666259.
Refer to Procedure 019-110 in Section 19.
Remove the fuel-metering actuator for the rear three
cylinders.
Install the Injector Leak Test Kit, Part Number 3164001, in
place of the rear fuel-metering actuator.
Torque Value: 15.3 Nm [ 135 in-lb ]
Place the flexible tubing into a container of water.
Repeat the above procedure for the rear three cylinders.
Injector Signature, ISX, and QSX15 Eng [...]
Page 6-16 Section 6 - Injectors and Fuel Lines - Group 06

Bar the engine over and note between which two timing
marks the bubbles occur.
If the bubbles occur between:
A and B (number 4 injector is leaking)
B and C (number 6 injector is leaking)
C and A (number 5 injector is leaking).

Replace the leaking injector(s). Go to the remove section


in this procedure.

Preparatory Steps

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the coolant to below the cylinder head level.
Refer to Procedure 008-018 in Section 8.
Remove the rocker lever cover. Refer to Procedure
003-011 in Section 3.
Disconnect the engine brake solenoid wiring harness.
Refer to Procedure 020-015 in Section 20.
Signature, ISX, and QSX15 Eng [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-17

Remove
CAUTION
Do not bottom out adjusting screws. Engine damage
can occur if adjusting screws are bottomed out.
Remove only the valve and injector shaft for the injector
(s) being removed.
Loosen the injector rocker lever adjusting screws.
Remove the six capscrews and injector rocker lever shaft.
Do not let the rocker levers come off of the shaft during
removal.

Rotate the engine to the valve set mark for the injector
being removed. Refer to Procedure 003-004 in Section 3.

Loosen and back off the valve lash adjusting screws


counterclockwise to allow the intake and exhaust valve
crossheads to be removed.
Remove the intake crosshead.
Mark the crossheads to make certain they are installed in
the same position.

Position the exhaust valve crosshead toward the exhaust


side of the engine to allow the injector to be removed.
Injector Signature, ISX, and QSX15 Eng [...]
Page 6-18 Section 6 - Injectors and Fuel Lines - Group 06

Loosen the injector clamp capscrew.


Use a small magnet to remove the injector clamp
capscrew and washer.
Remove the injector clamp capscrew and washer.

CAUTION
Do not use a heel bar to pry the injector loose from
the cylinder head. Damage to the injector can occur.
Use injector puller, Part Number 3823579, to remove the
injectors.
If the injector spring does come loose from the spring
retainer, it can be reassembled by using a screwdriver to
compress the spring back under the retainer.

Inspect for Reuse


Inspect the injector for missing or damaged o-rings.
Replace o-rings as necessary.

Inspect the injector cup for missing plug balls. Replace the
injector if necessary.
Signature, ISX, and QSX15 Eng [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-19

Disassemble
Oil Seals, Roll pin retained load ring
Thoroughly clean the oil and dirt from the outside of the
injector.
Place the injector into the injector holding fixture.
Place the injector holding fixture into a vise. Tighten the
vise to hold the fixture in place.
Align the load ring capscrew bracket with the cutout in the
fixture plate.

Use a T45 Torx drive (long version) to loosen the injector


coupling retainer capscrew.

Make certain the injector remains upright; this will prevent


the lower plunger and spring from falling out.
Remove the retainer capscrew and bracket.
Remove the upper plunger/coupling assembly and
coupling spring.
Some injector parts are not interchangeable.
Place each of the individual injector assembly parts
together on a lint free cloth.

Remove the spring clip from the load ring.


The load ring drilling is designed to remove and install the
roll pin in only one direction. Remove in the direction
shown.
Use a 5/32 inch punch to lightly tap the roll pin loose and
remove it from the load ring.
Discard the roll pin.
Injector Signature, ISX, and QSX15 Eng [...]
Page 6-20 Section 6 - Injectors and Fuel Lines - Group 06

Remove the load ring from the injector body.

Install the coupling/plunger assembly into the injector


body bore to prevent debris from entering the bore.

The base of the oil seal is visible through the four


machined holes in the side of the injector body.

CAUTION
Its very important that a 3/32 inch punch be used so
the barrel is not damaged during oil seal removal.
Use a 3/32 inch punch. Place the punch at an upward
angle, as shown in the illustration, against the base of the
oil seal.
Use a hammer to gently tap the punch against the base
of the oil seal. To prevent damage to the seal bore in the
barrel, alternate between the four holes in the barrel so
that the seal comes out evenly and does not score the
barrel.
Signature, ISX, and QSX15 Eng [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-21

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Slide the oil seal up the plunger.
Use a can of safety solvent to blow debris away from the
oil seal area before removing the plunger.

Make certain the injector remains upright.


Remove the oil seal and plunger assembly from the
injector.
Remove the old oil seal from the plunger.
Remove the injector holding fixture and the injector from
the vise.
Place the fixture and injector onto the arbor press table.

Oil Seals, Clip retained load ring


Thoroughly clean the oil and dirt from the outside of the
injector.
Place a clean, lint free shop towel folded in quarters over
the edge of a work bench.
While holding the injector firmly in one hand, place the
upper plunger against the outer edge of the work bench
with the load ring just above the working surface of the
bench.
Lean in on the injector to partially compress the upper
spring and plunger. Use care not to come in contact with
the nozzle of the injector.

Use a pick to remove the injector load ring retaining clip.


Injector Signature, ISX, and QSX15 Eng [...]
Page 6-22 Section 6 - Injectors and Fuel Lines - Group 06

Slowly, remove pressure from the injector, releasing the


upper spring.
Stand the injector upright and remove the load ring, the
upper plunger/coupling assembly, and the spring.
NOTE: Some of the injector parts are not
interchangeable.
Place each of the individual injector assembly parts
together on a lint free cloth.

Place the injector in the holding fixture, mounted in a


bench vise.

Locate the outer edge of the upper seal.


Use a punch, held at a slight angle, as shown in the
illustration, to carefully fold the edge of the seal in and
down.
Fold the edge of the seal in, 180 degrees from the first
fold.
Use care not to damage the injector body.

When the seal begins to rotate in the bore of the injector


body, carefully insert a small pry bar into the center of the
seal.
Carefully pry the seal out of the injector body bore.
Use care not to damage the injector body.
Signature, ISX, and QSX15 Eng [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-23

Assemble
Oil Seals, Roll pin retained load ring

CAUTION
Do not install the oil seal upside down. Failure to
install the seal correctly will cause damage to the oil
seal.
The oil seal will fit on the tool tightly if installed correctly.
The spring side of the oil seal (as shown) faces up when
installed in the injector.
Install a new oil seal onto the installation tool.

With the new oil seal positioned on the tool, position the
tool over the seal bore.
Use the arbor press to gently place pressure onto the
installation tool until the outer diameter face of the tool
contacts the injector body.
When properly installed, the seal height will not be flush
with the injector body. The height will be approximately
0.5 mm [0.020 in] above the injector.

Place the injector holding fixture with injector into the vise.
Tighten the vise to hold the fixture in place.
Install the load ring on the injector. Align the load ring
capscrew hole end with the cutout on the injector fixture.

Install a new roll pin into the load ring. By design, the roll
pin holes are a different size on each side, so the roll pin
must be installed in the correct direction, as illustrated.
Use a 5/32 inch punch to gently tap the roll pin into both
holes in the load ring. Continue driving the roll pin into the
load ring until the pin is centered evenly in both holes and
is an equal distance from both sides.
Injector Signature, ISX, and QSX15 Eng [...]
Page 6-24 Section 6 - Injectors and Fuel Lines - Group 06

Inspect the oil seal and plunger bore for debris. If debris
is present, clean with a lint free cloth.
Clean the injector coupling spring with a lint free cloth.
Assemble the spring onto the load ring.
Clean the plunger and coupling assembly with a lint free
cloth.

Lubricate the plunger with clean calibration fluid.

Slightly angle and rotate the upper plunger while installing


the plunger into the oil seal.
Hold the plunger vertically and rotate while installing the
plunger into the injector bore.

Use a flashlight to view through the coupling spring.


Inspect the oil seal to verify the garter spring (1) is still in
the correct location around the seal.
Signature, ISX, and QSX15 Eng [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-25

Install the spring retainer bracket.


Tighten the retainer capscrew.
Torque Value: 30 Nm [ 22 ft-lb ]
Install new injector o-rings.

Oil Seals, Clip retained load ring

CAUTION
Do not install the oil seal upside down. Failure to
install the seal correctly will cause damage to the oil
seal.
The oil seal will fit on the tool tightly, if installed correctly.
The spring side of the oil seal (as shown) faces up when
installed in the injector.
Install a new oil seal onto the installation tool.

With the new oil seal positioned on the tool, position the
tool over the seal bore.
Use the arbor press to gently place pressure onto the
installation tool until the outer diameter face of the tool
contacts the injector body.
When properly installed, the seal height will not be flush
with the injector body. The height will be approximately
0.5 mm [0.020 in] above the injector.

Lubricate the plunger with clean calibration fluid.


Carefully install the spring and load ring on the upper
plunger.
Injector Signature, ISX, and QSX15 Eng [...]
Page 6-26 Section 6 - Injectors and Fuel Lines - Group 06

Holding the injector up right in one hand, slightly angle


and rotate the upper plunger while installing the plunger
into the oil seal.
Hold the plunger vertically and rotate while installing the
plunger into the injector bore.

Use a flashlight to view through the coupling spring.


Inspect the oil seal to verify the garter spring (1) is still in
the correct location around the seal.

Place a clean, lint free shop towel folded in quarters over


the edge of a work bench.
While holding the injector firmly in one hand, place the
upper plunger against the outer edge of the work bench
with the load ring just above the working surface of the
bench.
Lean in on the injector to partially compress the upper
spring and plunger. Use care not to come in contact with
the nozzle of the injector.

Install the clip onto the injector load ring.


Slowly, remove pressure from the injector, releasing the
upper spring against the load ring.
Install new injector o-rings.
Signature, ISX, and QSX15 Eng [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-27

Install
Use clean 15W-40 lubricating oil to lubricate the o-rings.

CAUTION
Make sure the injector hold down clamp is properly
aligned before tightening the capscrew. It is possible
for the clamp to contact a nearby ledge, and result in
low clamp load.
Install the injector into the cylinder head.
Install the injector clamp and the capscrew with washer.
Tighten the capscrew.
Torque Value: 80 Nm [ 59 ft-lb ]
Install the crossheads.

Finishing Steps
Install the injector rocker lever and valve rocker lever
assemblies. Refer to Procedure 003-009 in Section 3.
Connect the engine brake solenoid wiring harness, if
equipped. Refer to Procedure 020-015 in Section 15.
Adjust the overhead set as needed. Refer to Procedure
003-004 in Section 3.
Install the rocker lever cover. Refer to Procedure
003-011 in Section 3.
Fill the cooling system. Refer to Procedure 008-018 in
Section 8.
Operate the engine to normal operating temperature
and check for leaks.
If damage resulted in coolant, oil, excessive fuel or
excessive black smoke entering the exhaust system, the
aftertreatment system must be inspected. Refer to
Procedure 014-013 in Section 14.
Injector Signature, ISX, and QSX15 Eng [...]
Page 6-28 Section 6 - Injectors and Fuel Lines - Group 06

Notes
Signature, ISX, and QSX15 Eng [...]
Section 7 - Lubricating Oil System - Group 07 Page 7-a

Section 7 - Lubricating Oil System - Group 07


Section Contents
Page
Centinel System ............................................................................................................................................7-58
General Information.........................................................................................................................................7-58
Lubricating Oil and Filter Analysis .................................................................................................................7-58
Inspect............................................................................................................................................................7-58
Lubricating Oil..............................................................................................................................................7-58
Lubricating Oil Filter.....................................................................................................................................7-59
Lubricating Oil Cooler .......................................................................................................................................7-4
Clean and Inspect for Reuse.............................................................................................................................7-6
All Applications..............................................................................................................................................7-6
Finishing Steps...............................................................................................................................................7-10
Automotive with CM870................................................................................................................................7-10
Automotive, Industrial with CM570 and Power Generation without CM570....................................................7-11
Install..............................................................................................................................................................7-10
All Applications.............................................................................................................................................7-10
Leak Test..........................................................................................................................................................7-8
All Applications..............................................................................................................................................7-8
Preparatory Steps.............................................................................................................................................7-4
Automotive with CM870..................................................................................................................................7-4
Automotive, Industrial with CM570 and Power Generation without CM570......................................................7-5
Remove............................................................................................................................................................7-5
All Applications..............................................................................................................................................7-5
Lubricating Oil Cooler Element .......................................................................................................................7-11
Assemble........................................................................................................................................................7-14
Single-Element.............................................................................................................................................7-14
Dual-Element............................................................................................................................................... 7-14
Clean and Inspect for Reuse...........................................................................................................................7-12
Disassemble................................................................................................................................................... 7-11
Single-Element.............................................................................................................................................7-11
Dual-Element............................................................................................................................................... 7-11
Finishing Steps...............................................................................................................................................7-15
Preparatory Steps...........................................................................................................................................7-11
Pressure Test..................................................................................................................................................7-13
Lubricating Oil Dipstick ...................................................................................................................................7-15
Calibrate.........................................................................................................................................................7-15
Lubricating Oil Dipstick Tube .........................................................................................................................7-16
Install..............................................................................................................................................................7-16
Automotive with CM870................................................................................................................................7-16
Automotive With CM871...............................................................................................................................7-17
Remove.......................................................................................................................................................... 7-16
Automotive with CM870................................................................................................................................7-16
Automotive With CM871...............................................................................................................................7-16
Lubricating Oil Fill Tube ................................................................................................................................. 7-52
Clean and Inspect for Reuse...........................................................................................................................7-54
Automotive with CM870................................................................................................................................7-54
Automotive With CM871...............................................................................................................................7-54
Install..............................................................................................................................................................7-55
Automotive with CM870................................................................................................................................7-55
Automotive With CM871...............................................................................................................................7-56
Remove.......................................................................................................................................................... 7-52
Automotive with CM870................................................................................................................................7-52
Automotive With CM871...............................................................................................................................7-53
Lubricating Oil Filter (Spin-On) .......................................................................................................................7-17
General Information.........................................................................................................................................7-17
Install..............................................................................................................................................................7-19
Measure..........................................................................................................................................................7-18
Remove.......................................................................................................................................................... 7-19
Lubricating Oil Filter Bypass Valve ................................................................................................................7-20
Signature, ISX, and QSX15 Eng [...]
Page 7-b Section 7 - Lubricating Oil System - Group 07

Clean..............................................................................................................................................................7-21
General Information.........................................................................................................................................7-20
Inspect for Reuse............................................................................................................................................7-21
Install..............................................................................................................................................................7-22
Remove.......................................................................................................................................................... 7-20
Lubricating Oil Filter Head Adapter ................................................................................................................7-23
Clean and Inspect for Reuse...........................................................................................................................7-24
Finishing Steps...............................................................................................................................................7-25
Install..............................................................................................................................................................7-24
Preparatory Steps...........................................................................................................................................7-23
Remove.......................................................................................................................................................... 7-23
Lubricating Oil High Pressure Relief Valve ....................................................................................................7-25
General Information.........................................................................................................................................7-25
Inspect for Reuse............................................................................................................................................7-26
Install..............................................................................................................................................................7-26
Remove.......................................................................................................................................................... 7-25
Lubricating Oil Leaks ......................................................................................................................................7-27
General Information.........................................................................................................................................7-27
Lubricating Oil Pan ..........................................................................................................................................7-29
Clean and Inspect for Reuse...........................................................................................................................7-30
Finishing Steps...............................................................................................................................................7-31
Install..............................................................................................................................................................7-30
Preparatory Steps...........................................................................................................................................7-29
Remove.......................................................................................................................................................... 7-30
Lubricating Oil Pressure Gauge ......................................................................................................................7-32
Test................................................................................................................................................................ 7-32
Lubricating Oil Pump ......................................................................................................................................7-32
Assemble........................................................................................................................................................7-40
Clean and Inspect for Reuse...........................................................................................................................7-34
Disassemble................................................................................................................................................... 7-33
Finishing Steps...............................................................................................................................................7-44
Install..............................................................................................................................................................7-42
Preparatory Steps...........................................................................................................................................7-32
Remove.......................................................................................................................................................... 7-32
Lubricating Oil Suction Tube (Block-Mounted) ..............................................................................................7-45
Finishing Steps...............................................................................................................................................7-46
Inspect for Reuse............................................................................................................................................7-45
Install..............................................................................................................................................................7-46
Preparatory Steps...........................................................................................................................................7-45
Remove.......................................................................................................................................................... 7-45
Lubricating Oil System ....................................................................................................................................7-47
Drain...............................................................................................................................................................7-47
Fill...................................................................................................................................................................7-49
Prime..............................................................................................................................................................7-47
Lubricating Oil Thermostat .............................................................................................................................7-50
Inspect for Reuse............................................................................................................................................7-50
Install..............................................................................................................................................................7-51
Remove.......................................................................................................................................................... 7-50
Service Tools ....................................................................................................................................................7-1
.........................................................................................................................................................................7-1
Signature, ISX, and QSX15 Eng [...] Service Tools
Section 7 - Lubricating Oil System - Group 07 Page 7-1

Service Tools
Lubricating Oil System

The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.

Tool No. Tool Description Tool Illustration


Pressure Gauge
Used to measure engine intake manifold pressure.
ST-1273

Battery Black Light/Lamp (100 Watt)


Used in conjunction with Part Number 3376891 and Part Number
3163337 3377438, fluorescent tracers, for fuel, oil, and coolant leaks.

Battery Black Light/Lamp (50 Watt)


Use in conjunction with Part Number 3376891 and Part Number
3163338 3377438, fluorescent tracers, for fuel, oil, and coolant leaks.

Silicone Sealant
Used for sealing tee-joints. Replaces silicone sealant, Part Number
3164067 3823494.

Filter Head Adapter Replacer


Used to remove and install the lubrication oil filter head adapter
3165082 (Service Tool Kit 3165074 includes both lubrication oil filter head
adapter and seal Loctite 2760).

Sealing/Retaining Compound
Loctite 2760 or Loctite 277 is used to secure the lubrication oil filter
3165083 head adapter to the lubricating oil filter head (Service Tool Kit
3165074 includes both lubrication oil filter head adapter and seal
Loctite 2760).
Service Tools Signature, ISX, and QSX15 Eng [...]
Page 7-2 Section 7 - Lubricating Oil System - Group 07

Tool No. Tool Description Tool Illustration


Tube Filter Cutter
Used for inspection of the filter element.
3376579

Fluorescent Tracer Dye


Added to oil. Used with black light to find leaks.
3376891

Female Quick Connect Coupler


Used to connect the priming pump to the engine.
3376859

Oil Filter Wrench


Used to remove spin-on filter. Replaces oil filter wrench, Part Number
3400157 3397929.

Silicone Sealant
Used for sealing tee-joints.
3823494

Oil Cooler Leak Test Kit


Used to pressurize the oil cooler assembly in order to check for leaks.
4918200 Used with air pressure regulator, Part Number 3164231 or
equivalent.

Filter Head Adapter Replacer


Used to remove and install the lubrication oil filter head adapter
4918222 (Service Tool Kit 3165074 includes both lubrication oil filter head
adapter and seal Loctite 2760). This filter head adapter replacer is
equivalent to the filter head adapter replacer, Part Number 3165082.

Remote Filter Head Adapter Replacer


Used to remove and install the remote lubrication oil filter head
4919518 adapter.
Signature, ISX, and QSX15 Eng [...] Service Tools
Section 7 - Lubricating Oil System - Group 07 Page 7-3

Tool No. Tool Description Tool Illustration


Protective Plug Kit
Used to plug oil passages and drillings during a repair process.
4918319
Lubricating Oil Cooler Signature, ISX, and QSX15 Eng [...]
Page 7-4 Section 7 - Lubricating Oil System - Group 07

Lubricating Oil Cooler (007-003)


Preparatory Steps
Automotive with CM870

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
Remove the lubricating oil filter. Refer to Procedure
007-013 (Lubricating Oil Filter (Spin-On) in Section
7.
Remove the variable geometry turbocharger. Refer
to Procedure 010-033 (Turbocharger) in Section 10.
Remove the EGR valve. Refer to Procedure 011-022
(EGR Valve) in Section 11.
Remove the EGR cooler connection. Refer to
Procedure 011-024 (EGR Cooler Connection) in
Section 11.
Remove the EGR cooler. Refer to Procedure
011-019 (EGR Cooler) in Section 11.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Cooler
Section 7 - Lubricating Oil System - Group 07 Page 7-5

Automotive, Industrial with CM570 and Power


Generation without CM570

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
Remove the lubricating oil filter. Refer to Procedure
007-013 (Lubricating Oil Filter (Spin-On)) in Section
7.
Remove the turbocharger. This step is not required
with a die cast oil cooler. Refer to Procedure 010-033
(Turbocharger) in Section 10.
Remove the alternator. Refer to Procedure 013-001
(Alternator) in Section 13.

Remove
All Applications
Remove two oil cooler mounting capscrews and install the
guide pins.
Clean the area above the oil cooler to prevent debris entry
into the oil passages.
Lubricating Oil Cooler Signature, ISX, and QSX15 Eng [...]
Page 7-6 Section 7 - Lubricating Oil System - Group 07

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Remove the remaining 18 capscrews, oil cooler, and
gasket. Discard the gasket.

CAUTION
Immediately upon removal of the lubricating oil cooler
assembly, a plug must be inserted into the housing
and cylinder block oil passage drillings. Failure to
insert the oil passage plug can result in a bearing
failure, crankshaft failure, or both.
The reusable plugs, Part Numbers 4918322, 4918324,
and 4918340, are included in protective plug kit, Part
Number 4918319. These plugs are necessary to prevent
debris from entering the lubrication system during the
repair.
Plug the oil cooler housing filtered oil passage with plug,
Part Number 4918323, the block filtered oil passage with
plug, Part Number 4918340, and the block oil pump
passage with plug, Part Number 4918322.
Firmly push the plugs into the oil passages to prevent all
debris from entering the lubrication system when cleaning
the gasket surface.

Clean and Inspect for Reuse


All Applications
Inspect the oil thermostat seat depth.
Remove the oil thermostat. Refer to Procedure 007-039
(Lubricating Oil Thermostat) in Section 7.
Measure from the spot face to the oil thermostat seat.
Reference graphic for measurement points. If the
measured diminsion for lubricating oil cooler housing with
integrated filter head is less than the minimum dimension,
the oil cooler housing will need to be replaced.

Lubricating Oil Cooler Housing Seat Depth


mm in
123.47 MIN 4.861
Install the oil thermostat. Refer to Procedure 007-039
(Lubricating Oil Thermostat) in Section 7.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Cooler
Section 7 - Lubricating Oil System - Group 07 Page 7-7

CAUTION
Do not reuse an oil cooler core after a debris related
engine failure since there is no practical method for
cleaning the cooler core. Metal particles which can
circulate through the lubricating system can remain in
the cooler core and cause engine damage. Do not
allow dirt to enter the oil passages when cleaning the
oil cooler.

WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.

CAUTION
Do not allow dirt or foreign material to enter oil
passages in the cooler housing when cleaning the
gasket sealing surfaces. Connecting rod bearing
failures can be caused if debris is introduced into the
cylinder block or lubricating oil cooler housing oil
passages.
Plug the oil cooler passages with rubber plugs, Part
Numbers 4918322, 4918323, and 4918340, included in
kit, Part Number 4918319, to prevent debris from entering
the cooler when cleaning the gasket surface.
Clean gasket surfaces by hand with a gasket scraper or
cleaning pad, Part Number 3823258. If the gasket material
residue can not be felt with a finger, the surface is ready
to accept the new gasket.
Use solvent to clean and flush the oil cooler passages and
cores.
Blow dry with compressed air.
Remove the rubber plugs when cleaning is complete.
Lubricating Oil Cooler Signature, ISX, and QSX15 Eng [...]
Page 7-8 Section 7 - Lubricating Oil System - Group 07

CAUTION
Do not allow dirt or foreign material to enter oil
passages in the cylinder block when cleaning the
gasket sealing surfaces. Connecting rod bearing
failures can be caused if debris is introduced into the
cylinder block or lubricating oil cooler housing oil
passages. Therefore, use of power tools combined
with abrasive pads to clean gasket surfaces is not
recommended.
Plug the oil passages in the cylinder block with rubber
plugs.
Clean the oil cooler to cylinder block gasket surface with
Scotch-Brite 7448 abrasive pad.
Remove the rubber plugs when cleaning is complete.

Leak Test
All Applications
It is important to leak test the oil cooler assembly as a unit,
so leaks at the mounting joints can be identified. These
leaks can not be found when testing individual elements
that have been removed from the assembly. An element
is replaced only if it is found to be leaking.
This procedure is most effective when the oil cooler
assembly is tested in water below 7C [44F].
Use the mounting capscrews from the lubricating oil
cooler to attach the two plates and corresponding o-rings
from oil cooler leak test kit, Part Number 4918200, to the
lubricating oil cooler housing.

Remove the threaded male union that connects to the


turbocharger oil supply.
Install the threaded plug, Part Number 3089567.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Cooler
Section 7 - Lubricating Oil System - Group 07 Page 7-9

Insert the o-ring from the oil filter into the filter head cap,
Part Number 4918204.
Use engine oil to lubricate the gasket surface and install
the filter head cap.

Attach air pressure regulator, Part Number 3164231, to


the outlet plate air fitting and pressurize the assembly to
689 kPa [100 psi].

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Place the oil cooler assembly under water.
If bubbles are observed, carefully determine the source of
the bubbles and replace the components as necessary.
If the element is suspected of leaking, refer to Procedure
007-007 (Lubricating Oil Cooler Element) in Section 7. for
leak testing individual elements. Mounting joint leaks are
much more common than element leaks. Do not replace
components that do not leak.
If no leaks are found and the engine serial number is in
the range of 14023600 to 1405000 and 7900000 to
79012457, replace the capscrews and gaskets if the
elements are to be reused.
If no leaks are found and the engine serial number is not
in the above ranges, the element does not get removed,
but the capscrew torque is to be checked and then
tightened to the specified torque.
Lubricating Oil Cooler Signature, ISX, and QSX15 Eng [...]
Page 7-10 Section 7 - Lubricating Oil System - Group 07

Install
All Applications

WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
When installing a new two-element oil cooler on an older
engine, be sure the cooler element mounting capscrews
do not interfere with the cylinder block.
Install the guide pins.
Remove the protective plugs from the oil passages. Make
sure no debris enters the lubrication system. Using a clean
shop towel, carefully wipe out the oil passages and inspect
to make sure no debris is left in these passages.
Install a new mounting gasket and the oil cooler housing
assembly.
Install the 18 capscrews.

Remove the guide pins and install the two capscrews.


Tighten the capscrews in a circular motion from the center
out.
Torque Value: 47 Nm [ 35 ft-lb ]

Finishing Steps
Automotive with CM870
Install the EGR cooler. Refer to Procedure 011-019
(EGR Cooler) in Section 19.
Install the EGR cooler connections. Refer to
Procedure 011-024 (EGR Cooler Connection ) in
Section 11.
Install the EGR valve. Refer to Procedure 011-022
(EGR Valve ) in Section 11.
Install the lubricating oil filter. Refer to Procedure
007-013 (Lubricating Oil Filter (Spin-On)) in Section
7.
Install the variable geometry turbocharger. Refer to
Procedure 010-033 (Turbocharger) in Section 10.
Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
Prime the lubricating oil system. Refer to Procedure
007-037 (Lubricating oil System) in Section 7.
Fill the engine with clean oil.
Operate engine to normal operating range and check
for oil and coolant leaks.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Cooler Element
Section 7 - Lubricating Oil System - Group 07 Page 7-11

Automotive, Industrial with CM570 and Power


Generation without CM570
Install the oil filter. Install the alternator. Refer to
Procedure 013-001 (Alternator) in Section 13.
Install the turbocharger. Refer to Procedure 010-033
(Turbocharger) in Section 10.
Fill the cooling system. Refer to Procedure 008-018
(Cooling System) in Section 8.
Prime the lubricating oil system. Refer to Procedure
007-037 (Lubricating oil System) in Section 7.
Fill the engine with clean oil.
Operate the engine to normal operating range and
check for oil and coolant leaks.

Lubricating Oil Cooler Element


(007-007)
Preparatory Steps
Remove the lubricating oil cooler. Refer to Procedure
007-003.

Disassemble
Single-Element
Remove the element from the lubricating oil filter head.
Discard the gaskets.

Dual-Element
Remove the elements from the lubricating oil filter head.
Remove the oil cooler tube.
Discard the gaskets.
Lubricating Oil Cooler Element Signature, ISX, and QSX15 Eng [...]
Page 7-12 Section 7 - Lubricating Oil System - Group 07

CAUTION
Do not damage the oil cooler tube when cutting the
vibration isolators to remove them. Engine damage
can occur.
Remove the vibration isolators by cutting a slit in them.
Discard the isolators.

Clean and Inspect for Reuse

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.

CAUTION
Do not allow dirt or foreign material to enter oil
passages in the cooler element when cleaning. Rod
bearing failures can be caused if debris is introduced
into the lube cooler housing oil passages.
Use solvent to clean the element.
Remove all old gasket material from the element.
Dry with compressed air.

Inspect the oil cooler tube for cracks. Replace the cooler
tube if cracks are found.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Cooler Element
Section 7 - Lubricating Oil System - Group 07 Page 7-13

Pressure Test
NOTE: An oil cooler element pressure test plate can be
constructed from a thin aluminum plate that allows the oil
cooler element to be mounted and air pressure applied to
the element inlet. An oil cooler pressure test tool does
not exist.
Install the oil cooler element and gaskets to the pressure
test plate.
Torque Value: 20 Nm [ 15 ft-lb ]

Apply 689 kPa [100 psi] regulated shop air.


Inspect the test plate and gaskets for leaks.
Submerge in a tank of room temperature water.
Replace the oil cooler element if a steady stream of
bubbles is observed from the element.
Slow forming bubbles (less than one rising to the surface
of the water every 30 seconds) do not constitute a leaking
oil cooler element.
Do not replace non-leaking oil cooler elements. If no oil
cooler element leaks are found install the existing oil
cooler element with new gaskets and new capscrews.
To clean contaminated lubricating oil from the engine,
refer to Procedure 007-037.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.

CAUTION
Do not allow dirt or foreign material to enter the oil
cooler element passages when cleaning. Engine
damage can result.
Remove the cooler element from the tank.
Remove the test equipment and dry with compressed air.
Lubricating Oil Cooler Element Signature, ISX, and QSX15 Eng [...]
Page 7-14 Section 7 - Lubricating Oil System - Group 07

Assemble
Single-Element

CAUTION
The single-element oil cooler assembly is for use only
on ISX1 and ISX2 engines. Engine oil overheating can
result if used on ISX3, and Signature 600 engines.
Install non-leaking lubricating oil cooler elements onto the
lubricating oil filter head with new gaskets and capscrews.
Assemble the cooler element(s) to the housing with the
following parts from the engine oil cooler kit.

Engine Oil Cooler Kit Contents


Quantity Description
4 Capscrews (short)
2 Capscrews (long)
3 Gaskets (rubber flash)

Install and tighten the capscrews.


Torque Value: 20 Nm [ 15 ft-lb ]
Install the lubricating oil cooler assembly. Refer to
Procedure 007-003.

Dual-Element
NOTE: The vibration isolators must be cut to allow
assembly over the cooler tube. Make sure the vibration
isolators are oriented so the slit is not tightened against
the oil cooler housing or the oil cooler elements.
Install two new vibration isolators onto the oil cooler tube
as shown.

Install new gaskets.


Install the oil cooler tube.
Re-install non-leaking lubricating oil cooler elements onto
the lubricating oil filter head.
Install new capscrews and tighten.
Torque Value: 20 Nm [ 15 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Dipstick
Section 7 - Lubricating Oil System - Group 07 Page 7-15

Finishing Steps
Install the lubricating oil cooler. Refer to Procedure
007-003.
Operate the engine to normal operating temperature and
check for leaks.

Lubricating Oil Dipstick (007-009)


Calibrate
NOTE: This procedure must begin with the oil pan
drained and the vehicle on level ground.
Install the dipstick into the dipstick tube housing.
Use the correct volume of clean 15W-40 oil to fill the oil
pan to the specified LOW oil level. Refer to Lubricating Oil
System - Specifications in this section for the correct
engine oil capacity for your application.

CAUTION
Use care when marking the dipstick, or the dipstick
will break if the scribe mark is too deep.
Remove the dipstick and scribe a mark across the stick at
the oil level. Label the mark with an L to indicate the LOW
oil level.
If a new blank dipstick is being used, cut the dipstick off
approximately 38 mm [1.5 in] below the LOW oil level
mark.

Wipe off the dipstick and install it into the dipstick tube
housing.
Use the correct volume of oil to fill the oil pan to the
specified HIGH oil level. Refer to Lubricating Oil System
Specifications in this section for engine oil capacity.
Lubricating Oil Dipstick Tube Signature, ISX, and QSX15 Eng [...]
Page 7-16 Section 7 - Lubricating Oil System - Group 07

Remove the dipstick and scribe a mark across the stick at


the oil level. Label the mark with an H to indicate the HIGH
oil level.

Lubricating Oil Dipstick Tube


(007-011)
Remove
Automotive with CM870
Remove the dipstick tube clamp capscrew, nut, and
clamp.
Remove the dipstick and dipstick tube.

Automotive With CM871


Remove the dipstick tube clamp capscrew, nut, and
clamp.
Remove the dipstick and dipstick tube.

Install
Automotive with CM870
Install the dipstick tube and tighten the nut finger-tight.
Install the dipstick tube clamp, capscrew, and nut.
Tighten the dipstick tube nut.
Torque Value: 70 Nm [ 52 ft-lb ]
Tighten the clamp.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Filter (Spin-On)
Section 7 - Lubricating Oil System - Group 07 Page 7-17

Automotive With CM871


Install the dipstick tube and tighten the nut finger-tight.
Install the dipstick tube clamp, capscrew, and nut.
Tighten the dipstick tube nut.
Torque Value: 70 Nm [ 52 ft-lb ]
Tighten the clamp.

Lubricating Oil Filter (Spin-On)


(007-013)
General Information
A combination oil filter is present on the engine. The upper
portion of the combination filter contains the full-flow filter
element while the lower portion contains the bypass filter
element.
The venturi design has been optimized to distribute oil
flow during normal engine operation; however during
extreme engine oil conditions (additive dropout,
contamination, soot etc.) the improvements increase the
overall filtration effectiveness.
Oil circulates through the full-flow portion of the filter, into
the oil cooler housing, and is directed to the engine oil
rifles.
A smaller portion of the oil circulates through the lower
bypass portion of the filter and is directed to the engine oil
rifles.

Lubricating Oil
Use Valvoline Premium Blue 15W-40 multiviscosity oil,
or its equivalent, which meets CES 20081 and CES 20078
oil classifications for turbocharged engines.
Refer to Cummins Engine Oil and Oil Analysis
Recommendations, Bulletin 3810340, for additional oil
information.
Lubricating Oil Filter (Spin-On) Signature, ISX, and QSX15 Eng [...]
Page 7-18 Section 7 - Lubricating Oil System - Group 07

CAUTION
Limited use of oils such as 5W-30 or 10W-30 can aid
in starting the engine and providing sufficient oil flow
at ambient temperatures below -5C [23F]. However,
the continuous use of low-viscosity oils can decrease
engine life.
See the accompanying chart to determine the best weight
of oil for the engine operating conditions.

Measure
Remove the oil plugs from the lubricating oil cooler
housing at the filter inlet (2) and outlet (1) pressure ports
and install manual gauges.
The following parts, or equivalent, are available for use:
Part Number Description
3824844 Compuchek fitting for port size
M14x1.5
3376920 Compuchek coupling (1/4-inch pipe
thread
3164491 Electronic pressure adapter for
multimeter (1/4-NPT pipe)
3164488 or Electronic digital multimeter
3164489

Start and operate the engine until the oil temperature


reaches or exceeds 70C [160F].
Engine Information
Oil filter type:
Miles on filter:
Oil type:
Operate the engine at each rpm called for and record the
corresponding pressure values:
Oil Temperature
Start of test:
End of Test
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Filter (Spin-On)
Section 7 - Lubricating Oil System - Group 07 Page 7-19

Engine Oil Pressure Filter Oil Pressure Filter Inlet - Outlet = INSITE electronic
RPM Inlet Outlet Differential Pressure service tool
Low Idle
High Idle
A pressure drop greater than 172 kPa [25 psi], at operating temperature using 15W-40 oil, indicates the filter is
plugged.
Identify the causes of a plugged filter. Verify the Cummins Inc. maintenance guidelines are being met.
Refer to Procedure For possible fluid contamination, 007-083 (Lubricating Oil Filter and Filter Analysis) in Section 7.
Change both the lubricating oil and lubricating oil filter, if plugged.
Reference symptom tree t103-56 (Lubricating Oil Filter Plugged) in Section TS.
For additional information about lubricating oil filter plugging, refer to Cummins Engine Oil and Oil Analysis
Recommendations, Bulletin 3810340.
Remove

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
NOTE: If the lubricating oil filter head adapter comes off
during the removal of the lubricating oil filter, then reinstall
the oil filter head adapter. Use a small amount of Loctite
on the threads of the oil filter head adapter and tighten.
Refer to Procedure 007-018 (Lubricating Oil Filter Head
Adaptor) in Section 7.
Use oil filter wrench, Part Number 3375049, 3397929, or
3400157 to remove the oil filter.

Install
NOTE: The o-ring can stick onto the filter head. Make sure
it is removed before installing a new filter.
Clean the oil filter head surface.
Use clean engine oil to lubricate the gasket surface of the
filter.
Lubricating Oil Filter Bypass Valve Signature, ISX, and QSX15 Eng [...]
Page 7-20 Section 7 - Lubricating Oil System - Group 07

CAUTION
Mechanical overtightening can distort the threads or
damage the filter element seal.
Fill the oil filter with clean 15W-40 oil.
Install the oil filter onto the oil filter head. Tighten the filter
until the gasket contacts the filter head surface.
Use oil filter wrench, Part Number 3375049, 3397929, or
3400157 to tighten the filter an additional 3/4 to 1 turn, or
follow the instructions supplied with the filter.

Confirm that the oil level in the pan is to the full mark.
Operate the engine until the water temperature reaches
82C [180F].
Check the oil pressure and for leaks.

Lubricating Oil Filter Bypass Valve


(007-014)
General Information
Whenever the pressure drop across the lubricating oil
filter exceeds 862 kPa [125 psi], the oil filter bypass valve
opens and allows lubricating oil to bypass the lubricating
oil filter.
This condition can occur during cold ambient (cold
lubricating oil) engine start-ups.
The purpose of the bypass valve is to maintain lubricating
oil flow to the engine and prevent an oil filter collapse.

Remove

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
Loosen the retaining plug with a 7-millimeter Allen wrench.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Filter Bypass Valve
Section 7 - Lubricating Oil System - Group 07 Page 7-21

Remove the retaining plug (1), spring (2), and plunger (3)
from the lubricating oil cooler housing (4).

Clean

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

WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
bodily injury.
Clean the spring, plunger, and retaining plug with solvent.
Dry with compressed air.

Inspect for Reuse


Inspect the o-ring on the retaining plug for cuts or tears.
Replace the o-ring if damaged.
Lubricating Oil Filter Bypass Valve Signature, ISX, and QSX15 Eng [...]
Page 7-22 Section 7 - Lubricating Oil System - Group 07

Use a spring compression tester, Part Number 3375182,


to measure the relief valve spring tension.
Compress the spring to 29.65-mm [1.17-in] height. The
force required to compress the spring must be:

Force Required to Compress Spring to 29.65 mm [1.17


in]
N lbf
115.7 NOM 26
If the spring does not meet this specification, it must be
replaced.

Install
CAUTION
The notched end of the bypass valve (3) must be
installed toward the spring (2). If the bypass valve is
installed incorrectly, it will bypass the filter
continuously which can cause engine damage.
Lubricate all pieces and the o-ring seal. Install the plunger
(3) with the notched end toward the spring into the
lubricating oil cooler housing (4).
Install the spring (2), and retaining plug (1) into the
lubricating oil cooler housing (4).
Tighten the retaining plug.
Torque Value: 45 Nm [ 33 ft-lb ]

Prime the lubricating oil system. Refer to Procedure


007-037.

Operate the engine to normal operating temperature and


check for leaks.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Filter Head Adapter
Section 7 - Lubricating Oil System - Group 07 Page 7-23

Lubricating Oil Filter Head Adapter


(007-018)
Preparatory Steps

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
NOTE: The lubricating oil filter head housing assembly
does not need to be removed to replace the oil filter head
adapter.
Remove the lubricating oil filter. Refer to Procedure
007-013 in Section 7.

Remove

WARNING
To reduce the possibility of personal injury or
equipment damage. Use only a 3/4-inch drive
extension and ratchet for the removal of the adapter.
NOTE: If the engine is equipped with a remote filter, first
remove the remote lubricating oil filter head adapter from
the lubricating oil filter head. Use service tool, Part
Number 4919518, or equivalent, to remove the remote
lubricating oil filter head.
If the pinned adapter has come loose or if the staking pin
is missing, and the oil filter head adapter can be removed
by hand or without damaging the threads in the housing,
then follow the procedure as described below for cleaning
and installing the adapter. The missing staking pin will
not be replaced.
NOTE: If the housing threads are found damaged, the
housing must be replaced.

Use service tool, Part Number 3165082 or Part Number


4918222, to remove the adapter from the housing.
Lubricating Oil Filter Head Adapter Signature, ISX, and QSX15 Eng [...]
Page 7-24 Section 7 - Lubricating Oil System - Group 07

Clean and Inspect for Reuse

WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
Clean the threads of both the adapter and the oil filter head
housing with a clean towel and contact cleaner to remove
any residual Loctite and lubricating oil.
Inspect the adapter for cracks or other damage.

Install

WARNING
To reduce the possibility of personal injury or
equipment damage. Use only a 3/4-inch drive
extension and ratchet for the installation of the
adapter.

CAUTION
Do not use an impact wrench, to reduce the possibility
of damage to the oil filter head housing, adapter, or
tool.
Apply clean engine oil to the adapter-to-housing interface.
Apply service tool Loctite 2760, Part Number 3165083 to
the adapter. Apply Loctite to three threads, starting three
threads down from the top of the adapter and around the
entire circumference of adapter.

Install the adapter hand-tight into the housing. Torque the


filter head adapter with service tool, Part Number 3165082
or Part Number 4918222.
Torque Value: 450 Nm [ 332 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Lubricating Oil High Pressure Relief Valve
Section 7 - Lubricating Oil System - Group 07 Page 7-25

Finishing Steps
Fill the new oil filter with clean lubricating oil.
Install the lubricating oil filter. Refer to Procedure
007-013 in Section 7.
Operate the engine to normal operating temperature
and check for leaks.

Lubricating Oil High Pressure Relief


Valve (007-021)
General Information
The high-pressure relief valve (1) is held in the closed
position by spring force (2). The valve remains in the
closed position until the oil pressure exceeds 1034 kPa
[150 psi] in the lubricating oil pump.
When the oil pressure exceeds 1034 kPa [150 psi] in the
lubricating oil pump, for instance, during cold start-up, the
oil pressure in the pump overcomes the relief valve spring
force.
This allows the excess oil to return to the oil pan,
preventing possible damage to the lubricating system
components.

Remove

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
Remove and disassemble the lubricating oil pump. Refer
to Procedure 007-031.
Lubricating Oil High Pressure Relief Valve Signature, ISX, and QSX15 Eng [...]
Page 7-26 Section 7 - Lubricating Oil System - Group 07

Inspect for Reuse


Inspect the ball. A slight ring around the ball from contact
with the pump body and spring is acceptable.

Measure the spring free length.

High Pressure Relief Valve Spring Free Length


mm in
68.91 NOM 2.713

Use a spring compression tester to determine if the spring


is defective.
Replace the spring with a new spring if it is defective.

High Pressure Relief Valve Spring (Compressed


Length) Load at 45.82 mm [1.804 in]
N lbf
281.47 MIN 63.277
298.87 MAX 67.189

Install
Assemble and install the lubricating oil pump. Refer to
Procedure 007-031.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Leaks
Section 7 - Lubricating Oil System - Group 07 Page 7-27

Operate the engine to normal operating temperature and


check for leaks.

Lubricating Oil Leaks (007-024)


General Information
The cause of external oil leaks is hard to diagnose and correct because of the potential number of factors involved.
Although the location of a leak can sometimes seem obvious, it can also be difficult to isolate the exact location due
to fan blast and road grime that would cause the leak to migrate.
Before doing any repairs, it is important to locate the exact root cause of the leak to prevent misdiagnosis and further
downtime. Please use the diagrams below to troubleshoot any external oil leaks.
Begin by determining which quadrant of the engine the leak is located in. It will be necessary to start out by steam
cleaning the engine and then operating it on a dynamometer to look for the leak. Keep in mind where the oil looks the
most concentrated before the steam clean, as this will give a good indication of where to start looking for leaks.

Once the quadrant has been determined, look at the following diagram to get a good indication of where the leak can
be coming from on the exhaust side of the engine.
1. Lower front gear cover gasket leak 6. Oil spill from oil filter change
2. Gear housing gasket leak 7. Oil slobber from exhaust manifold
3. Oil pan gasket leak 8. Cam cover gaskets leaks
4. Flywheel housing gasket leak 9. Valve cover gasket leak
5. Lube cooler gasket leak
Lubricating Oil Leaks Signature, ISX, and QSX15 Eng [...]
Page 7-28 Section 7 - Lubricating Oil System - Group 07

Look at this diagram to get a good indication of where the leak can be coming from on the intake side of the engine.
1. Valve cover gasket leak 7. Crankshaft position sensor o-ring leak
2. Cam covers gaskets leaks 8. Gear cover gasket leak
3. Crankcase blowby tube 9. Air compressor or power steering pump gasket leak
4. Flywheel housing gasket leak 10. Oil fill tube cracked or leak
5. Dipstick tube leak 11. Upper front gear cover cracked or gasket leak
6. Gear housing gasket leak

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

CAUTION
Protect all electrical components, openings, and
wiring from the full force of the cleaner spray nozzle.
Use a steam cleaner or a high-pressure washer to clean
the engine.

Check the engine crankcase breather element, hose, and


tube for restriction. Refer to Procedure 003-001.
Add fluorescent dye tracer, Part Number 3376891, to the
oil.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pan
Section 7 - Lubricating Oil System - Group 07 Page 7-29

Check for a loose or missing oil dipstick tube, dipstick, or


oil filler cap.

Operate the engine until the water temperature reaches


82C [180F]. Inspect the exterior of the engine for
leaking gaskets, seals, o-rings, pipe plugs, or fittings.
Use a black light, Part Number 3377394, to locate leaks.
Follow the manufacturer's operating instructions to use
the black light.
NOTE: Before removing and replacing any gaskets, check
the capscrews to make sure they are tightened to the
correct torque values.

Lubricating Oil Pan (007-025)


Preparatory Steps

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
Drain the lubricating oil. Refer to Procedure 007-037
(Lubricating Oil System) in Section 7.
Lubricating Oil Pan Signature, ISX, and QSX15 Eng [...]
Page 7-30 Section 7 - Lubricating Oil System - Group 07

Remove
Remove the oil pan mounting capscrews, oil pan, and
gasket.
Discard the oil pan gasket.

Clean and Inspect for Reuse

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
bodily injury.
Steam clean and dry with compressed air.

Inspect the inside and the outside of the oil pan for cracks.
Replace the oil pan if cracked or broken.

Install
Apply a 1.97 mm [1/8 in] bead of silicon sealant, Part
Number 3164067, to each of the four T-joints where the
front gear housing and flywheel housing gaskets intersect
the oil pan gasket.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pan
Section 7 - Lubricating Oil System - Group 07 Page 7-31

Install a new oil pan gasket.


Install the oil pan onto the cylinder block. Install one of the
13 mm oil pan mounting capscrews, hand tight, on each
side of the oil pan, halfway between the front and the rear
of the oil pan.
Finger-tighten all or the mounting capscrews.

Tighten the thirty-two 13 mm capscrews in the sequence


shown.
At the end of the sequence, loosen and tighten capscrew
number 1again.
Torque Value: 55 Nm [ 41 ft-lb ]
Install the oil drain plug.
Torque Value: 47 Nm [ 35 ft-lb ]

Finishing Steps
Fill the lubricating oil pan. Refer to Procedure 007-037
(Lubricating Oil System) in Section 7.
Operate the engine until the water temperature reaches
82C [180F], and check for leaks.
Lubricating Oil Pump Signature, ISX, and QSX15 Eng [...]
Page 7-32 Section 7 - Lubricating Oil System - Group 07

Lubricating Oil Pressure Gauge


(007-028)
Test
1. Check for the following:
Electrical wiring broken
Oil pressure sensor malfunction (refer to step
No. 2)
Plumbing loose, leaking, or broken.
2. Use a master gauge of known accuracy to verify the
reading of the suspect sensor or gauge.
3. Replace the oil pressure sensor or gauge if it is
defective.
NOTE: The arrow points to a combination oil pressure and
oil temperature sensor on the cylinder block below the
integrated fuel system module.

Lubricating Oil Pump (007-031)


Preparatory Steps

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion and prolonged contact with used engine oil.
If not reused, dispose of in accordance with local
environmental regulations.
Drain the lubricating oil. Refer to Procedure 007-037 in
Section 7.
Remove the lubricating oil pan. Refer to Procedure
007-025 in Section 7.
Remove the lubricating oil suction tube. Refer to
Procedure 007-035 in Section 7.

Remove
CAUTION
Do not discard shims, if equipped. They must be
installed in the original location. Failure to do so can
result in engine damage.
Remove four capscrews, oil pump, and shims if equipped.
When installing a new oil pump, new shims will possibly
be needed to acquire acceptable lash.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-33

Disassemble

WARNING
The pressure regulator spring is under compression.
Slowly remove the cap to reduce the possibility of
personal injury.
Remove the lubricating oil pressure regulator and spring
by removing the split pin that secures the spring cap to the
lubricating oil pump.
Discard the o-ring.

The external idler gear retaining capscrew has a left-hand


thread. capscrew.
Remove the external idler gear from the lubricating oil
pump.
Save the retaining capscrew for reuse.

WARNING
The high pressure relief valve is under compression.
Apply pressure to the cover while removing the
capscrews. Slowly release the pressure to reduce the
possibility of personal injury.
Remove the six assembly capscrews and the lube pump
cover.

Press off the external drive gear from the internal drive
gear shaft.
Lubricating Oil Pump Signature, ISX, and QSX15 Eng [...]
Page 7-34 Section 7 - Lubricating Oil System - Group 07

Remove the high-pressure relief spring and ball.

Remove the idler pumping gear from the shaft in the


lubricating oil pump body.

Clean and Inspect for Reuse

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

WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.

CAUTION
Do not allow dirt or gasket material to enter the oil
passages. Bearing damage can result.
Clean the lubricating oil pump components with solvent.
Use a bristle brush to clean any internal ports.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-35

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a steam cleaner to rinse the components.
Dry with compressed air.

Inspect the following areas of the lubricating oil pump for


damage or blockage.
Lubricating oil pump body gear cavity
Inlet and outlet ports
Internal oil passages
Lubricating oil pump housing body
Pressure regulator bore
High pressure relief bore and seat.
If the lubricating pump housing is damaged, it must be
replaced.

Inspect the lubricating oil pump cover for damage.


Inspect the bushing for scuffing and wear.
If the marks on the lubricating pump cover can be felt with
a fingernail, the part must be replaced.

Measure the regulator bore for beat-in.

Regulator Bore Depth Specification


mm in
186.95 MIN 7.3602
187.45 MAX 7.380
If the regulator bore depth is not within the specifications,
the housing must be replaced.
Lubricating Oil Pump Signature, ISX, and QSX15 Eng [...]
Page 7-36 Section 7 - Lubricating Oil System - Group 07

Inspect the pressure regulator spool for scuffing.


Minor spool scuff is acceptable. If the scuff can be felt by
a fingernail, the spool will need to be replaced.
Insert the spool in the bore and check for smooth
movement in and out of the bore. If any hesitation is felt,
the spool must be replaced and the bore inspected for
burrs.
Remove any burrs found in the bore before installing a
new spool.

Inspect the pressure regulator spring for a broken coil or


rust.

Measure the free length of the pressure regulator spring.

Oil Pressure Regulator Spring Free Length


mm in
109.55 NOM 4.313

Use a spring compression tester, Part Number 3375182,


to measure the pressure regulator valve spring at working
height, 70 mm [2.756 in].

Lubricating Oil Pressure Regulator Spring Load at 70


mm [2.756 in]
N lbf
131.8 MIN 29.6
135.3 MAX 30.4
If the regulator spring is not within the specifications, the
spring must be replaced.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-37

Inspect the high pressure relief spring for a broken coil or


rust.

Measure the free length of the high pressure relief spring.

High Pressure Relief Valve Spring Free Length


mm in
68.91 NOM 2.713

Use a spring compression tester, Part Number 3375182,


to measure the high pressure relief spring at working
height, 45.82 mm [1.804 in].

High Pressure Relief Valve Spring (Compressed


Length) Load at 45.82 mm [1.804 in]
N lbf
281.5 MIN 63.3
298.9 MAX 67.2
If the pressure relief valve spring is not within the
specification, the spring must be replaced.

Inspect the high pressure relief ball. A slight ring around


the ball from contact with the pump body and spring is
acceptable.
Lubricating Oil Pump Signature, ISX, and QSX15 Eng [...]
Page 7-38 Section 7 - Lubricating Oil System - Group 07

Inspect the external idler gear retainer.


Minor retainer scuff is acceptable. If the scuff can be felt
by a fingernail, replace the retainer.

Inspect the external idler gear for cracks, chips, and


broken teeth.
If the external idler gear is damaged, the gear must be
replaced.
Check the idler gear bushing for wear and scuffing.

Measure the inside diameter of the bushing in the external


idler gear.

External Idler Gear Bushing Inside Diameter


mm in
32.044 MIN 1.2616
32.069 MAX 1.2626
If the external idler gear bushing is not within
specifications, the bushing must be replaced.

Inspect the external drive gear for cracks, chips, and


broken teeth.
If the external drive gear is damaged, the gear must be
replaced.
Check the drive gear bushing for wear and scuffing.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-39

Measure the inside diameter of the external drive gear.

External Drive Gear Inside Diameter (No Bushing)


mm in
24.909 MIN 0.9807
24.935 MAX 0.9817
If the external drive gear is not within specifications, the
gear must be replaced.

Inspect the lubricating oil pump internal gears for


excessive wear, cracks, or broken teeth.
Erosion and pitting on the tip and root of the gear tooth is
not acceptable. The gear must be replaced.

Measure the inside diameter of the internal idler gear.

Internal Idler Gear Inside Diameter


mm in
24.909 MIN 0.9807
24.935 MAX 0.9817
If the internal idler gear is not within specifications, it
must be replaced.

Inspect the internal idler shaft for damage. Measure the


outside diameter of the idler shaft.

Internal Idler Shaft Outside Diameter


mm in
24.858 MIN 0.9787
24.871 MAX 0.9792
If the idler shaft is not within specifications, it must be
replaced.
Lubricating Oil Pump Signature, ISX, and QSX15 Eng [...]
Page 7-40 Section 7 - Lubricating Oil System - Group 07

Inspect the internal drive gear and shaft assembly for


damage. Measure the outside diameter of the internal
drive gear shaft.

Internal Drive Gear Shaft Outside Diameter


mm in
24.858 MIN 0.9787
24.871 MAX 0.9792
If the drive shaft is not within specifications, it must be
replaced.

Assemble
Lubricate the drive shaft with clean 15W-40 lubricating oil.
Install the internal idler gear onto the shaft.

Insert the internal drive gear and shaft assembly into the
lubricating oil pump cover.
Press the external drive gear onto the shaft.

Install the ball first, then the spring.


Install the high pressure relief ball and spring into its bore
in the lube pump housing.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-41

No gasket is used when installing the lube pump cover.


Install the cover to the lube pump.
Tighten the center capscrews first, then the outside
capscrews.
Install the six capscrews and tighten.
Torque Value: 29 Nm [ 21 ft-lb ]

Install the external idler gear.


Insert the external idler gear retainer such that the holes
are at the 3 and 9 o'clock position.
The idler gear retaining capscrew has left-hand threads.
Torque Value: 115 Nm [ 85 ft-lb ]

Lubricate the oil pressure regulator valve and bore with


clean engine oil.
Install the spring, valve, and cap with a new o-ring.
Use a new split pin to secure the cap to the lubricating oil
pump body.

Turn the main drive gear by hand to check the gears for
freedom of rotation.
Lubricating Oil Pump Signature, ISX, and QSX15 Eng [...]
Page 7-42 Section 7 - Lubricating Oil System - Group 07

Measure the end clearance of the external drive gear.

Drive Shaft End Clearance


mm in
0.100 MIN 0.003
0.163 MAX 0.006

Measure the gear backlash by mounting a dial indicator.


Position the dial indicator contact point onto the
lubricating oil pump external idler gear teeth.
With the external drive gear locked into place and the dial
indicator contact in place, rotate the external idler gear
clockwise and counterclockwise to measure the
backlash.
Use the backlash measurement to classify and mark the
pump per the following table.
Lubricating Oil Pump
Gear Backlash
Class mm in
1 0.457 to 0.610 0.018 to 0.024
2 0.152 to 0.305 0.006 to 0.012
3 0.000 to 0.152 0.000 to 0.006
4 0.305 to 0.457 0.012 to 0.018

Install
Align dowels on oil pump with mounting holes in the
cylinder block.
Install the oil pump, shims (if they were removed), and the
four capscrews.
Tighten the capscrews.
Torque Value: 56 Nm [ 41 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-43

Use a dial indicator, check the oil pump idler gear back
lash.

Oil Pump Idler Gear Backlash


mm in
0.18 MIN 0.008
0.46 MAX 0.018
0.32 NOM 0.013

CAUTION
Improper gear lash can cause damage to the gear train
and the lubricating oil pump.
Shims will be available in six different thicknesses in order
to provide correct lash. The various thicknesses are
identified by the color of the shim. Identify the number
stamped on the pump (1) and the letter on the block (2).
Use the following table to determine which shim should be
used according to the stamped number and letter.
Lubricating Oil Pump Signature, ISX, and QSX15 Eng [...]
Page 7-44 Section 7 - Lubricating Oil System - Group 07

If a lube pump or cylinder block is replaced, the block and pump will not be stamped. In that instance, a shim must
be chosen and installed. The oil pump idler gear backlash must be checked. If the backlash is not within the
specification, choose another size shim and recheck the backlash. Do this until the backlash is within specification.
Block
Pump A B C D
1 0.000 mm [0.000 in]-None- 0.45 mm [0.018 in]-Black- 0.55 mm [0.022 in]- 0.35 mm [0.014 in]-
Purple- Yellow-
2 0.45 mm [0.018 in]-Black- 0.65 mm [0.026 in]-Red- 0.75 mm [0.030 in]-Blue- 0.55 mm [0.022 in]-Purple-
3 0.55 mm [0.022 in]-Purple- 0.75 mm [0.030 in]-Blue- 0.85 mm [0.033 in]-Green- 0.65 mm [0.026 in]-Red-
4 0.35 mm [0.014 in]-Yellow- 0.55 mm [0.022 in]- 0.65 mm [0.026 in]-Red- 0.45 mm [0.018 in]-Black-
Purple-
If the lubricating oil pump is not within specifications, the
shims must be changed to proper thickness to give proper
backlash.

Finishing Steps
Install the lubricating oil suction tube. Refer to
Procedure 007-035 in Section 7.
Install the lubricating oil pan. Refer to Procedure
007-025 in Section 7.
Fill the engine with lubricating oil. Refer to Procedure
007-037 in Section 7.
Operate the engine and check for leaks.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Suction Tube (Block-Mounted)
Section 7 - Lubricating Oil System - Group 07 Page 7-45

Lubricating Oil Suction Tube (Block-


Mounted) (007-035)
Preparatory Steps

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
Drain the lubricating oil. Refer to Procedure 007-037.
Remove the lubricating oil pan. Refer to Procedure
007-025.

Remove
Remove the lubricating oil suction tube capscrews,
suction tube, and o-ring. Discard o-ring.

Inspect for Reuse


Inspect the oil suction tube for cracks or damage.
Inspect the o-ring grooves for cavities or damage.
If cracks, damage, or cavities are found, the oil suction
tube must be replaced.
Lubricating Oil Suction Tube (Block-Mounted) Signature, ISX, and QSX15 Eng [...]
Page 7-46 Section 7 - Lubricating Oil System - Group 07

Install
Lubricate the o-ring with clean 15W-40 engine oil.
Install the new o-ring on the oil suction tube.

Install the oil suction tube into the lubricating oil pump.
Install the lubricating oil suction tube capscrews. Tighten
capscrews.
Torque Value: 47 Nm [ 35 ft-lb ]

Finishing Steps
Install the lubricating oil pan. Refer to Procedure 007-025.
Fill engine with oil. Refer to Procedure 007-037.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System
Section 7 - Lubricating Oil System - Group 07 Page 7-47

Lubricating Oil System (007-037)


Drain

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
Operate the engine until the water temperature reaches
60C [140F].
Shut off the engine.
Remove the oil drain plug.
Drain the oil immediately to make sure all the oil and
suspended contaminants are removed from the engine.
If lubricating oil element failure occurs resulting in
contamination of the lubricating oil, the following is
recommended:
Inspect the lubricating oil filter by cutting it open and
inspecting for debris. Refer to Procedure 007-083.
If debris is not found, drain the lubricating oil and
remove the lubricating oil pan. Clean and reinstall
the lubricating oil pan. Refer to Procedure 007-025.
Remove the valve cover and clean the contaminated
lubricating oil from the cylinder head cavities. This
can be done using a siphoning device. Refer to
Procedure 003-011.
If debris is found, refer to the Cummins Warranty
Administration Manual, Bulletin 4021290.

Prime
CAUTION
The lubricating oil system must be primed before
operating the engine after any internal engine repairs
or extended engine storage (beyond 6 months) to
avoid internal component damage.
Bar the engine during oil priming.
Lubricating Oil System Signature, ISX, and QSX15 Eng [...]
Page 7-48 Section 7 - Lubricating Oil System - Group 07

Remove the oil plug from the lubricating oil cooler housing
and install fitting and hose.
Use the coupler, Part Number 3376859, to connect the
priming pump to the coupling.

Connect the priming pump oil supply hose to the


lubricating oil pump coupling. Use clean 15W-40
lubricating oil from a drum or a container to supply oil to
the lubricating oil pump and engine.
Turn the priming pump on.
Allow the oil to flow until the oil pressure gauge indicates
a maximum pressure of 69 to 138 kPa [10 to 20 psi] at the
main oil rifle.
Turn the priming pump off.

Remove the priming pump oil supply hose and fitting.


Install the oil cooler housing plug.
Torque Value: 34 Nm [ 25 ft-lb ]

Check the oil level on the dipstick before adding additional


oil.
If necessary, fill the engine with lubricating oil.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System
Section 7 - Lubricating Oil System - Group 07 Page 7-49

Fill
Fill and install the lubricating oil filter before putting oil into
the engine. Refer to Procedure 007-013.
Add the specified amount of clean 15W-40 oil to fill the oil
pan.
Oil Pan Capacity
Automotive and Industrial Power Generation
41.6 liters [11 gal] 83.3 liters [22 gal]

Check the oil level on the dipstick. It must be filled to the


H (high) mark.
Refer to Procedure 007-009 for dipstick calibration.
Operate the engine until the water temperature reaches
82C [180F], and check for leaks.

Shut off the engine. Wait 15 minutes for the oil to drain
back to the oil pan.
Check the oil level. Add oil as necessary to bring the level
up to the H (high) mark on the dipstick.
Lubricating Oil Thermostat Signature, ISX, and QSX15 Eng [...]
Page 7-50 Section 7 - Lubricating Oil System - Group 07

Lubricating Oil Thermostat (007-039)


Remove

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
Remove the alternator. Refer to Procedure 013-001
(Alternator) in Section 13.
Remove the water pump. Refer to Procedure 008-062
(Water Pump) in Section 8.
Remove the thermostat plug.
Remove the tapered snap ring.
Remove the thermostat from the lubricating oil cooler
housing.

Inspect for Reuse

WARNING
The flash point of new lubricating oil is approximately
221C [430F]. Do not allow the oil temperature in the
container to exceed 149C [300F]. Do not allow
water droplets to enter the container of hot oil. Water
droplets will cause a violent reaction that can cause
personal injury.
Suspend the thermostat and a 127C [260F]
thermometer in a container of new lubricating oil. Do not
allow the thermostat or the thermometer to touch the sides
of the container.
Heat the lubricating oil.

Write down the temperature at which the valve is fully


extended. The valve must be fully extended to at least 6
mm [0.250 in] from the closed position when the
temperature reaches 127C [260F].
Replace the thermostat if it does not operate as
described.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Thermostat
Section 7 - Lubricating Oil System - Group 07 Page 7-51

Inspect the valve for damage. Any damage to the front


face of the valve will allow oil to constantly bypass the oil
cooler.
If cracks are found on the oil thermostat, inspect the oil
cooler housing for the correct seat depth. Refer to
Procedure 007-003 (Lubricating Oil Cooler) in Section 7.

Install
Install the thermostat into lubricating oil cooler housing.
Install the tapered snap ring with the tapered side facing
away from the lubricating oil cooler housing.
Install and tighten the thermostat plug.
Torque Value: 100 Nm [ 74 ft-lb ]
Install the alternator. Refer to Procedure 013-001
(Alternator) in Section 13.
Install the water pump. Refer to Procedure 008-062 (Water
Pump) in Section 8.

Prime the lubricating oil system. Refer to Procedure


007-037 (Lubricating oil System) in Section 7.

Operate the engine to normal operating temperature and


check for leaks.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Eng [...]
Page 7-52 Section 7 - Lubricating Oil System - Group 07

Lubricating Oil Fill Tube (007-065)


Remove
Automotive with CM870

CAUTION
Removal of the oil fill tube without loosening the tube
brace capscrew is likely to cause fill tube thread
breakage.
Loosen the tube brace capscrew (1).
Remove the tube brace capscrew from the gear cover (2).

Remove the oil fill tube (1) and the tube brace (2) from the
oil fill tube connection (3).

A smooth, rounded end bar can be used for leverage to


rotate the oil fill tube connection.
Rotate the oil fill tube connection counterclockwise to
remove.

Remove the ring seals from the oil fill connection, the oil
fill tube, and the oil fill tube cap.
Discard the ring seals.
Ring seals:
1. Oil fill connection ring seal
2. Oil fill tube ring seal
3. Oil fill cap ring seal.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Fill Tube
Section 7 - Lubricating Oil System - Group 07 Page 7-53

Automotive With CM871

CAUTION
Removal of the oil fill tube without loosening the tube
brace capscrew is likely to cause fill tube thread
breakage
Remove the tube brace capscrews from the gear cover.

Remove the oil fill tube from the oil fill tube connection.

Rotate the oil fill tube connection counterclockwise to


remove. A smooth, rounded end, bar can be used for
leverage to rotate the oil fill tube connection.

Remove the ring seals from the oil fill connection, the oil
fill tube, and the oil fill tube cap.
Discard the ring seals.
Ring seals:
1. Oil fill connection ring seal
2. Oil fill tube o-rings
3. Oil fill cap ring seal.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Eng [...]
Page 7-54 Section 7 - Lubricating Oil System - Group 07

Clean and Inspect for Reuse


Automotive with CM870
Clean the oil fill connection and gear cover seal surface.

Inspect the oil fill tube and fill tube threads for cracks or
other damage.
Inspect the oil fill tube sealing surfaces for cracks or other
damage.
Inspect the oil fill tube extrusion for cracks or damage.

Automotive With CM871


Clean the oil fill connection and gear cover seal surface.

Inspect the oil fill tube and fill tube threads for cracks or
other damage.
Inspect the oil fill tube sealing surfaces for cracks or other
damage.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Fill Tube
Section 7 - Lubricating Oil System - Group 07 Page 7-55

Install
Automotive with CM870
Install a new oil fill connection ring seal.
Use clean engine oil to lubricate the oil fill connection ring
seal.

Install the oil fill connection to the lower gear cover.

Install the new ring seals on the bottom of the oil fill tube
(1) and on the oil fill tube cap (2).

Install the oil fill tube cap and the oil fill tube.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Eng [...]
Page 7-56 Section 7 - Lubricating Oil System - Group 07

Install and tighten the tube brace gear cover capscrew (2).
Torque Value: 28 Nm [ 21 ft-lb ]
Tighten the tube brace capscrew (1).

Automotive With CM871


Install a new oil fill connection ring seal.
Use clean engine oil to lubricate the oil fill connection ring
seal.

Install the oil fill connection to the lower gear cover.

Install the new o-rings on the bottom of the oil fill tube and
a new ring seal on the oil fill tube cap.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Fill Tube
Section 7 - Lubricating Oil System - Group 07 Page 7-57

Install the oil fill tube cap and the oil fill tube.

Install and tighten the tube brace gear cover capscrews.


Torque Value: 28 Nm [ 21 ft-lb ]
Lubricating Oil and Filter Analysis Signature, ISX, and QSX15 Eng [...]
Page 7-58 Section 7 - Lubricating Oil System - Group 07

Centinel System (007-075)


General Information
NOTE: Fleetguard Extended Service (ES) System
lubrication oil and fuel filters are required with Centinel.
These filters provide the filtration performance needed for
extended service intervals.
Centinel is an onboard continuous oil replenishment
system that operates as a function of fuel rate. The
Centinel valve is controlled by the ECM and is actuated
proportional to the amount of fuel consumed. The oil burn
rate has been designed for continued reliability and
durability of the engine. The continuous oil replenishment
process stabilizes engine oil quality and allows extended
oil and filter change intervals. The extended intervals are
a 844,907 km [525,000 mi] oil drain interval and 160,935
km [100,000 mi] oil filter change interval. The calibration
setting is a 0.33-percent blend rate. This rate uses 3.8
liters [1 gal] of oil for every 1136 liters [300 gal] of fuel
consumed (3.8/1136 = 1/300 = 0.33 percent).
The basic Centinel system can operate on vehicles
whose engines are equipped with either 12- or 24-VDC
electrical systems. Though the Centinel control valve
operates on 12-VDC, the valve is compatible with either
12- or 24-VDC engines because both engine ECMs (12- or
24-VDC) provide 12-VDC to the valve.
In addition to the valve and mounting hardware, it is
necessary to obtain an oil makeup tank and plumbing.
Tanks are available through Cummins Inc. with a capacity
between the high and low mark of 15.142 liter [4 gal], or
24.605 liters [6.5 gal].
Refer to Centinel Master Repair Manual, Bulletin
3666231, for detailed repair procedures on Centinel
equipped engines.

Lubricating Oil and Filter Analysis


(007-083)
Inspect
Lubricating Oil
An analysis of used oil can help diagnose internal engine
damage and determine if it was caused by one of the
following:
Intake air filter malfunction
Coolant leaks
Oil diluted with fuel
Metal particles causing wear.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil and Filter Analysis
Section 7 - Lubricating Oil System - Group 07 Page 7-59

For additional oil analysis information, refer to Cummins


Engine Oil Recommendations, Bulletin 3810340.
NOTE: Do not disassemble an engine for repair based
only on the results of an oil analysis. The oil filter must
also be inspected. If the oil filter shows evidence of
internal damage, find the source of the problem and repair
the damage. Refer to the appropriate procedure(s) based
on the following oil filter inspection.

Lubricating Oil Filter

WARNING
Carefully cut open the upper section of the
combination filter. The filter element spring is under
compression and can cause personal injury.
Use the tube cutter, Part Number 3376579, to open the
upper section of the combination filter.

Inspect the filter element for evidence of moisture or metal


particles.

Metal Probable Source


Copper Bearings and bushings
Chromium Piston rings
Iron Cylinder liners
Lead Bearing overlay material
Aluminum Piston wear or scuffing
Lubricating Oil and Filter Analysis Signature, ISX, and QSX15 Eng [...]
Page 7-60 Section 7 - Lubricating Oil System - Group 07

Notes
Signature, ISX, and QSX15 Eng [...]
Section 8 - Cooling System - Group 08 Page 8-a

Section 8 - Cooling System - Group 08


Section Contents
Page
Belt Tensioner, Automatic (Water Pump) .......................................................................................................8-68
Clean and Inspect for Reuse...........................................................................................................................8-71
All Applications.............................................................................................................................................8-71
CM570.........................................................................................................................................................8-72
Finishing Steps...............................................................................................................................................8-74
Drives Alternator.......................................................................................................................................... 8-74
Initial Check....................................................................................................................................................8-68
All Applications.............................................................................................................................................8-68
Install..............................................................................................................................................................8-72
Drives Alternator.......................................................................................................................................... 8-72
Automotive Applications...............................................................................................................................8-72
Industrial and Power Generation...................................................................................................................8-73
Preparatory Steps...........................................................................................................................................8-69
Drives Alternator.......................................................................................................................................... 8-69
Remove.......................................................................................................................................................... 8-69
Drives Alternator.......................................................................................................................................... 8-69
Automotive Applications...............................................................................................................................8-69
Industrial and Power Generation...................................................................................................................8-70
Coolant Filter .....................................................................................................................................................8-5
General Information..........................................................................................................................................8-5
Install................................................................................................................................................................8-6
Remove............................................................................................................................................................8-6
Coolant Filter Valve ...........................................................................................................................................8-7
Clean................................................................................................................................................................8-8
Inspect for Reuse..............................................................................................................................................8-8
Install................................................................................................................................................................8-8
Remove............................................................................................................................................................8-7
Coolant Thermostat ..........................................................................................................................................8-9
Finishing Steps...............................................................................................................................................8-14
Inspect for Reuse............................................................................................................................................8-12
Out-of-Chassis Opening Temperature Test...................................................................................................8-12
Install..............................................................................................................................................................8-13
Leak Test..........................................................................................................................................................8-9
In-Chassis Opening Temperature Test..........................................................................................................8-11
Preparatory Steps...........................................................................................................................................8-11
Remove.......................................................................................................................................................... 8-11
Coolant Thermostat Housing ..........................................................................................................................8-15
Finishing Steps...............................................................................................................................................8-21
Inspect for Reuse............................................................................................................................................8-18
Install..............................................................................................................................................................8-18
Single Thermostat........................................................................................................................................8-18
Dual Thermostat...........................................................................................................................................8-19
Preparatory Steps...........................................................................................................................................8-15
Remove.......................................................................................................................................................... 8-16
Single Thermostat........................................................................................................................................8-16
Dual Thermostat...........................................................................................................................................8-16
Coolant Thermostat Seal ................................................................................................................................ 8-21
Inspect for Reuse............................................................................................................................................8-22
Install..............................................................................................................................................................8-22
Single Seal...................................................................................................................................................8-22
Dual Seal.....................................................................................................................................................8-22
Remove.......................................................................................................................................................... 8-21
Single Seal...................................................................................................................................................8-21
Dual Seal.....................................................................................................................................................8-22
Coolant Vent Lines ..........................................................................................................................................8-23
Initial Check....................................................................................................................................................8-23
Cooling System ...............................................................................................................................................8-23
Signature, ISX, and QSX15 Eng [...]
Page 8-b Section 8 - Cooling System - Group 08

Drain...............................................................................................................................................................8-23
Fill...................................................................................................................................................................8-26
Flush...............................................................................................................................................................8-24
Pressure Test..................................................................................................................................................8-31
Cooling System - Air or Combustion Gas Test ..............................................................................................8-32
Initial Check....................................................................................................................................................8-32
Air in Cooling System...................................................................................................................................8-32
Leak Test........................................................................................................................................................8-34
Fan, Shutter, or Heater Air Control Valve......................................................................................................8-34
Air Compressor............................................................................................................................................8-34
Combustion Gas Leak..................................................................................................................................8-35
Overflow Method..........................................................................................................................................8-38
Drive Belt, Cooling Fan .....................................................................................................................................8-3
Clean and Inspect for Reuse.............................................................................................................................8-3
Drives Alternator............................................................................................................................................8-3
Install................................................................................................................................................................8-3
Drives Alternator............................................................................................................................................8-3
Remove............................................................................................................................................................8-3
Drives Alternator............................................................................................................................................8-3
Drive Belt, Water Pump ....................................................................................................................................8-4
Adjust...............................................................................................................................................................8-5
Inspect for Reuse..............................................................................................................................................8-4
Install................................................................................................................................................................8-5
Remove............................................................................................................................................................8-4
Fan Clutch, On-Off ..........................................................................................................................................8-39
Initial Check....................................................................................................................................................8-39
With Low Temperature Fan-On Control.........................................................................................................8-39
With High Temperature Fan On....................................................................................................................8-40
Fan Drive Idler Pulley Assembly .....................................................................................................................8-42
Finishing Steps...............................................................................................................................................8-43
Install..............................................................................................................................................................8-42
Preparatory Steps...........................................................................................................................................8-42
Remove.......................................................................................................................................................... 8-42
Fan Hub, Belt Driven .......................................................................................................................................8-43
Clean and Inspect for Reuse...........................................................................................................................8-44
Automotive with CM870................................................................................................................................8-44
Automotive, Industrial with CM570 and Power Generation without CM570....................................................8-45
Finishing Steps...............................................................................................................................................8-46
Automotive with CM870................................................................................................................................8-46
Automotive with CM570................................................................................................................................8-47
Industrial CM570 and Power Generation without CM570...............................................................................8-47
Install..............................................................................................................................................................8-45
Automotive with CM870................................................................................................................................8-45
Automotive with CM570................................................................................................................................8-46
Industrial CM570 and Power Generation without CM570...............................................................................8-46
Preparatory Steps...........................................................................................................................................8-43
Automotive with CM870................................................................................................................................8-43
Automotive with CM570................................................................................................................................8-43
Industrial CM570 and Power Generation without CM570...............................................................................8-43
Remove.......................................................................................................................................................... 8-44
Automotive with CM870................................................................................................................................8-44
Automotive with CM570................................................................................................................................8-44
Industrial CM570 and Power Generation without CM570...............................................................................8-44
Fan Pulley ........................................................................................................................................................8-78
Inspect for Reuse............................................................................................................................................8-79
Install..............................................................................................................................................................8-79
Industrial and Power Generation...................................................................................................................8-79
Remove.......................................................................................................................................................... 8-78
Industrial and Power Generation...................................................................................................................8-78
Fan Shroud Assembly .....................................................................................................................................8-47
Initial Check....................................................................................................................................................8-47
Fan Support .....................................................................................................................................................8-75
Finishing Steps...............................................................................................................................................8-78
Signature, ISX, and QSX15 Eng [...]
Section 8 - Cooling System - Group 08 Page 8-c

Industrial and Power Generation...................................................................................................................8-78


Install..............................................................................................................................................................8-76
Industrial and Power Generation...................................................................................................................8-76
Preparatory Steps...........................................................................................................................................8-75
Industrial and Power Generation...................................................................................................................8-75
Remove..........................................................................................................................................................8-76
Industrial and Power Generation...................................................................................................................8-76
Fan, Cooling ....................................................................................................................................................8-48
Inspect for Reuse............................................................................................................................................8-48
Install..............................................................................................................................................................8-49
Remove..........................................................................................................................................................8-48
Radiator ...........................................................................................................................................................8-49
Initial Check....................................................................................................................................................8-49
Radiator Hoses ................................................................................................................................................8-50
Inspect for Reuse............................................................................................................................................8-50
Radiator Pressure Cap ....................................................................................................................................8-50
Inspect for Reuse............................................................................................................................................8-50
....................................................................................................................................................................8-50
Radiator Shutter Assembly .............................................................................................................................8-51
General Information.........................................................................................................................................8-51
Service Tools ....................................................................................................................................................8-1
Cooling System.................................................................................................................................................8-1
Water Inlet Connection ...................................................................................................................................8-74
Finishing Steps...............................................................................................................................................8-75
Install..............................................................................................................................................................8-75
Preparatory Steps...........................................................................................................................................8-74
Remove..........................................................................................................................................................8-75
Water Pump .....................................................................................................................................................8-51
Assemble........................................................................................................................................................8-60
Clean..............................................................................................................................................................8-55
Automotive With CM871...............................................................................................................................8-55
Clean and Inspect for Reuse...........................................................................................................................8-57
Disassemble...................................................................................................................................................8-56
Finishing Steps...............................................................................................................................................8-67
Automotive with CM870................................................................................................................................8-67
Automotive with CM570................................................................................................................................8-67
Industrial CM570 and Power Generation without CM570...............................................................................8-67
Automotive With CM871...............................................................................................................................8-67
Install..............................................................................................................................................................8-63
Automotive with CM870................................................................................................................................8-63
Automotive with CM570................................................................................................................................8-63
Industrial CM570 and Power Generation without CM570...............................................................................8-65
Automotive With CM871...............................................................................................................................8-66
Measure..........................................................................................................................................................8-59
Preparatory Steps...........................................................................................................................................8-51
Automotive with CM870................................................................................................................................8-51
Automotive with CM570................................................................................................................................8-52
Industrial CM570 and Power Generation without CM570...............................................................................8-52
Automotive with CM871................................................................................................................................8-53
Remove..........................................................................................................................................................8-53
Automotive with CM870................................................................................................................................8-53
Automotive with CM570................................................................................................................................8-54
Industrial CM570 and Power Generation without CM570...............................................................................8-54
Automotive With CM871...............................................................................................................................8-54
Water Pump Cartridge .....................................................................................................................................8-80
Clean and Inspect for Reuse...........................................................................................................................8-81
Finishing Steps...............................................................................................................................................8-81
Install..............................................................................................................................................................8-81
Preparatory Steps...........................................................................................................................................8-80
Automotive With CM871...............................................................................................................................8-80
Remove..........................................................................................................................................................8-80
Signature, ISX, and QSX15 Eng [...]
Page 8-d Section 8 - Cooling System - Group 08

This Page Left Intentionally Blank


Signature, ISX, and QSX15 Eng [...] Service Tools
Section 8 - Cooling System - Group 08 Page 8-1

Service Tools
Cooling System

The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.

Tool No. Tool Description Tool Illustration


Pulley Alignment Tool
Used to align pulleys.
3163524

Thermostat Seal Driver


Used to install the thermostat seal in the thermostat housing to the
3164350 correct specification.

Fluorescent Tracer
Used with black light, Part Number 3824754, to find coolant leaks.
3377438

Optical Tachometer
Used to measure engine rpm using reflective tape, Part Number
3377462 3377464.

Reflective Tape (for optical tachometer, Part Number 3377462)


Used with optical tachometer, Part Number 3377462, to measure
3377464 rpm.

Fluke Digital Temperature Measuring Instrument Kit


Used to measure temperatures for the fuel pump and injector test
3822666 stands.
Service Tools Signature, ISX, and QSX15 Eng [...]
Page 8-2 Section 8 - Cooling System - Group 08

Tool No. Tool Description Tool Illustration


Combustion Gas Leak Test Kit
Used to detect combustion gas leaks. Includes test fluid, Part
3822985 Number 3822986, adapter, Part Number 3822987, and instructions,
Part Number 3877612.

Thermocouple Extension Wire Kit


Used with fluke digital temperature measuring instrument kit.
3822988 Includes adapter, Part Number 3822989, thermocouple, Part Number
3822990, thermocouple wire assembly, Part Number 3822991, and
bushing (1/8 NPT), Part Number 3822992.

Cooling System Test Kit - Fleetguard


Used to measure supplemental coolant additive (SCA) concentration.
CC-2602

Refractometer
Used to measure glycol (antifreeze) concentration.
CC-2800
Signature, ISX, and QSX15 Eng [...] Drive Belt, Cooling Fan
Section 8 - Cooling System - Group 08 Page 8-3

Drive Belt, Cooling Fan (008-002)


Remove
Drives Alternator

CAUTION
The belt tensioner is spring loaded and must be
pivoted away from the drive belt. Pivoting in the
wrong direction can result in damage to the belt
tensioner or cause personal injury.
Pivot the automatic tensioner down to relieve tension on
the belt.
Remove the belt.

Clean and Inspect for Reuse


Drives Alternator
Inspect the alternator pulley, the water pump pulley, the
fan clutch pulley, and the crankshaft pulley for cracks,
burrs, and broken or deformed grooves.
Use a wire brush to clean debris found in the pulley
grooves.

Inspect the belt for cracks, glazing, tears or cuts, and


excessive wear.
Replace the belt if necessary.

Install
Drives Alternator

CAUTION
The belt tensioner is spring loaded and must be
pivoted away from the drive belt. Pivoting in the
wrong direction can result in damage to the belt
tensioner or cause personal injury.
Pivot and hold the belt tensioner.
Install the drive belt and release the tensioner.
Drive Belt, Water Pump Signature, ISX, and QSX15 Eng [...]
Page 8-4 Section 8 - Cooling System - Group 08

Drive Belt, Water Pump (008-003)


Remove
CAUTION
The belt tensioner is spring-loaded and must be
pivoted away from the drive belt. Pivoting in the
wrong direction can result in damage to the belt
tensioner.
Using a 1/2-inch square drive, lift the tensioner to relieve
tension in the belt and remove the belt.

Inspect for Reuse


Inspect the idler and the water pump pulley for cracks or
broken grooves. Replace if necessary.

Inspect and replace the belt for the following


characteristics:
Cracks
Glazing
Tears or cuts
Excessive wear.

Inspect the pulley alignment. Pulley misalignment must


not exceed 0.5 mm per cm [0.0625 in per ft] of distance
between the pulley centers.
Replace the water pump if the pulleys are not in
alignment. Refer to Procedure 008-062.
Signature, ISX, and QSX15 Eng [...] Coolant Filter
Section 8 - Cooling System - Group 08 Page 8-5

Install
CAUTION
The belt tensioner is spring-loaded and must be
pivoted away from the drive belt. Pivoting in the
wrong direction can result in damage to the belt
tensioner.
Using a 1/2-inch square drive lift and hold the belt
tensioner. Install the drive belt and release the tensioner.

Adjust
Belt drive systems equipped with an automatic belt
tensioner can not be adjusted. A belt tension gauge will
not give an accurate measure of the belt tension. The
automatic belt tensioner is designed to maintain proper
belt tension over the life of the belt. Only inspection of the
tensioner is required.
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops when the belt
length and geometry are correct.
If the tensioner is hitting either of the limits during
operation, check the mounting brackets and the belt
length. Loose brackets, bracket failure, alternator
movement, incorrect belt length, or belt failure can cause
the tensioner to hit the limits.

Coolant Filter (008-006)


General Information
Refer to the Coolant Recommendations and Specification,
Procedure 018-004 in the Operation and Maintenance
Manual Signature and ISX Engines, Bulletin 3666251, the
Operation and Maintenance Manual Industrial and Power
Generation QSX15 Engines, Bulletin 3666423, or the
Operation and Maintenance Manual Signature and ISX
Engines, Bulletin 3666311.
Coolant Filter Signature, ISX, and QSX15 Eng [...]
Page 8-6 Section 8 - Cooling System - Group 08

An on/off valve is provided to prevent coolant leakage


while changing the coolant filter.
With the valve in the ON position (1), the coolant flows to
and from the coolant filter. In the OFF position (2), the
coolant flow is cut off to and from the coolant filter.

Remove

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Remove the cooling system pressure cap.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Turn the coolant on/off valve to the OFF position.
Do not use force to open or close the on/off valve. If the
valve does not turn freely, refer to Procedure 008-082.
Remove and discard the coolant filter. Clean the gasket
surface on the filter head.

Install
CAUTION
Mechanical overtightening can distort the threads or
damage the filter head.
Apply a thin film of clean engine oil, or its equivalent, to
the coolant filter gasket sealing surface before installing
the coolant filter.
Tighten the coolant filter to of a turn after initial
gasket contact, or as specified by the manufacturer.
Turn the coolant on/off valve to the ON position.
Signature, ISX, and QSX15 Eng [...] Coolant Filter Valve
Section 8 - Cooling System - Group 08 Page 8-7

Install the radiator pressure cap.

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Operate the engine until the coolant temperature is above
82C [180F], and check for coolant leaks.
After the air has been purged from the system, check the
coolant level again.

Coolant Filter Valve (008-009)


Remove
Drain the coolant. Refer to Procedure 008-018.

Remove the coolant valve retaining capscrew and large


flat washer.
Coolant Filter Valve Signature, ISX, and QSX15 Eng [...]
Page 8-8 Section 8 - Cooling System - Group 08

Remove the coolant filter valve and o-ring.

Clean

WARNING
Use skin and eye protection when handling caustic
solutions to reduce the possibility of personal injury.
Clean the coolant filter valve and valve bore in the water
inlet connection with a filter brush and solvent.

Inspect for Reuse


Inspect the valve for corrosion or other damage. Replace
if necessary.

Install
Install a new o-ring onto the valve.
Install the valve into the water inlet connection.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat
Section 8 - Cooling System - Group 08 Page 8-9

Install the retaining capscrew and flat washer. Make sure


the flat washer fits in the notch in the valve.
While pushing the flat washer into the groove, tighten the
retaining capscrew.
Torque Value: 7 Nm [ 60 in-lb ]

Turn the valve to the ON position.

Fill the cooling system. Refer to Procedure 008-018.


Operate engine and check for leaks.

Coolant Thermostat (008-013)


Leak Test
Signature, ISX, and QSX engines use two engine coolant
thermostats.
The engine thermostat and thermostat seal must operate
properly in order for the engine to operate in the most
efficient heat range. Overheating or overcooling will
shorten engine life.
Refer to Procedure 008-016 to inspect the thermostat seal.
Coolant Thermostat Signature, ISX, and QSX15 Eng [...]
Page 8-10 Section 8 - Cooling System - Group 08

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the coolant to a level below the vent line in the
thermostat housing.
Disconnect and plug the vent line hose. Refer to
Procedure 008-017.
Remove the radiator hose from the radiator top tank.

The radiator hose must be at the point of overflowing


before the engine is run. Small amounts of leakage will
not be detected if the hose is not pre-filled.
Fill the radiator hose with coolant until coolant is just about
ready to flow out of the hose.
Place a dry container under the end of the hose.

Operate the engine at rated rpm for three minutes.


Shut off the engine and measure the amount of coolant
collected in the container.
The amount of coolant collected must not be more than
100 cc [3.3 fl oz].

If more than 100 cc ]3.3 fl oz] of coolant is collected, the


thermostat or thermostat seal is leaking.
Remove the thermostats and test their operation as
described in the Out-of-Chassis Opening Temperature
Test in this procedure.
Refer to Procedure 008-016 for thermostat seal
inspection.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat
Section 8 - Cooling System - Group 08 Page 8-11

In-Chassis Opening Temperature Test


NOTE: An electronic service tool can also be used to
monitor the thermostat opening temperature without
removing the radiator hose.
Remove the coolant temperature sensor and install a
thermocouple or temperature gauge, which is known to be
accurate, on the engine side of the thermostat housing.

Complete the following test in-chassis to test the


thermostat opening temperature.
Start the engine and monitor the water temperature and
the container.

Thermostat Initial Opening Temperature


C F
81 MIN 178
83 MAX 182
Shut off the engine when the coolant starts to flow.
If coolant does not start flowing into the container during
the initial opening temperature range, the thermostat
must be replaced.

Preparatory Steps

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. If not reused, dispose of in
accordance with local environmental regulations.
Drain the cooling system. Refer to Procedure 008-018.

Remove
Remove the upper radiator hose from the thermostat
housing cover.
Coolant Thermostat Signature, ISX, and QSX15 Eng [...]
Page 8-12 Section 8 - Cooling System - Group 08

Disconnect vent line.


Disconnect the coolant sensor connector.

Remove the four capscrews that attach the thermostat


housing cover to the thermostat housing.
Remove the thermostat housing cover and gasket from
the thermostat housing. Discard the gasket.

Remove the thermostats from the thermostat housing


cover.

Inspect for Reuse


Out-of-Chassis Opening Temperature Test
Inspect the thermostat for damage.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat
Section 8 - Cooling System - Group 08 Page 8-13

Suspend the thermostat and a 100C [212F]


thermometer into a container of water. Do not allow the
thermostat or the thermometer to touch the sides of the
container.
Heat the water.
Record the temperatures at which the thermostat begins
to open and when it is fully open.

The nominal operating temperature is stamped on the


thermostat.
The thermostat must begin to open within 1C [2F]
of nominal temperature.
The thermostat must be fully open to at least 11 mm
[0.435 in] within 12C [22F] above nominal
temperature.
Replace the thermostat if it does not operate as
described.

Install
Install the two thermostats into the thermostat housing
cover by pushing on the outer rims.

Install the thermostat housing cover, gasket, and four


capscrews on the cylinder head.
Tighten the capscrews to the values shown.
Torque Value:
Short Capscrews 34 Nm [ 25 ft-lb ]
Long Capscrews 56 Nm [ 41 ft-lb ]
Coolant Thermostat Signature, ISX, and QSX15 Eng [...]
Page 8-14 Section 8 - Cooling System - Group 08

Connect the vent line. Refer to the OEM instructions.


Connect the coolant sensor connector.

Industrial engines use a thermostat housing cover with


either a cover plate or a water connection.
If removed, tighten the capscrews to the following
specification.
Torque Value: 28 Nm [ 20 ft-lb ]

Install the upper radiator hose. Tighten the hose clamp.


Torque Value: 5 Nm [ 40 in-lb ]

Finishing Steps
Fill the cooling system. Refer to Procedure 008-018.
Operate the engine until the coolant temperature reaches
70C [160F]. Check for leaks.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat Housing
Section 8 - Cooling System - Group 08 Page 8-15

Coolant Thermostat Housing (008-014)


Preparatory Steps

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the cooling system. Refer to Procedure
008-018.
Remove the air intake piping. Refer to the OEM
service manual.
Remove the charge air cooler piping. Refer to
Procedure 010-027.
Remove the upper radiator hose. Refer to the OEM
service manual.
Remove the vent line. Refer to the OEM service
manual.
Remove the engine coolant temperature sensor.
Refer to Procedure 019-019 in the ISX CM871 and
ISM CM876 Electronic Control System
Troubleshooting and Repair Manual, Bulletin
4021560.
Remove the turbocharger coolant return line. Refer
to Procedure 010-041.
Remove the OEM coolant sensor(s). Refer to the
OEM service manual.
Remove the exhaust gas pressure sensor. Refer to
019-376 in the ISX CM871 and ISM CM876
Electronic Control System Troubleshooting and
Repair Manual, Bulletin 4021560
Remove the turbocharger actuator air line, if
required. Refer to Procedure 010-113.
Remove the heat shield, if required. Refer to
Procedure 011-032.
Remove the EGR valve. Refer to Procedure 011-022.
Remove the EGR cooler connection tube, if required.
Refer to Procedure 011-024.
Remove the EGR cooler coolant return tube, if
required. Refer to Procedure 011-031.
Remove the refrigerant compressor. Refer to
Procedure 009-051.
Remove the refrigerant compressor mounting
bracket. Refer to Procedure 009-055.
Coolant Thermostat Housing Signature, ISX, and QSX15 Eng [...]
Page 8-16 Section 8 - Cooling System - Group 08

Remove
Single Thermostat
Remove the four thermostat housing cover capscrews.
Remove the thermostat cover and gasket.
Discard the gasket.

Remove the thermostat from the thermostat housing


cover.

Remove the three thermostat housing capscrews.


Remove the thermostat housing and gasket.
Discard the gasket.

Dual Thermostat
Remove the upper radiator hose from the thermostat
housing cover.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat Housing
Section 8 - Cooling System - Group 08 Page 8-17

Disconnect vent line, if required.


Disconnect the coolant sensor connector.

Remove the four capscrews that attach the thermostat


housing cover to the thermostat housing.
Remove the thermostat housing cover and gasket from
the thermostat housing.
Discard the gasket.

Remove the thermostats from the thermostat housing


cover.

Remove the two capscrews that attach the thermostat


housing to the cylinder head.
Remove the thermostat housing and gasket from the
cylinder head.
Discard the gasket.
Coolant Thermostat Housing Signature, ISX, and QSX15 Eng [...]
Page 8-18 Section 8 - Cooling System - Group 08

Inspect for Reuse


Inspect the thermostat housing and thermostat cover for
cracks.

Inspect the bottom of the thermostat bores in thermostat


cover for corrosion, pitting, or erosion that would cause
leakage past the thermostats when they are in the open
position.
Replace the thermostat seals, if damaged. Refer to
Procedure 008-016.

Inspect the thermostats. Refer to Procedure 008-013.

Install
Single Thermostat
To reduce the possibility of a coolant leak, the 90-degree
elbow on the thermostat housing must be positioned
appropriately and tightened before the thermostat housing
is installed on the cylinder head.
Use two thermostat housing capscrews to align the
thermostat housing.
Install the thermostat housing, gasket, and three
capscrews to the cylinder block.
Tighten the three thermostat housing mounting
capscrews.
Torque Value: 45 Nm [ 33 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat Housing
Section 8 - Cooling System - Group 08 Page 8-19

Install the thermostat into the thermostat housing cover by


pushing on the outer rim.

Install the thermostat housing cover, gasket, and four


capscrews.
Tighten the capscrews.
Torque Value: 45 Nm [ 33 ft-lb ]

Dual Thermostat
Use two thermostat housing cover capscrews to align the
thermostat housing.
Install the thermostat housing, gasket, and two capscrews
on the cylinder head.
Tighten the two thermostat housing capscrews.
Torque Value: 56 Nm [ 41 ft-lb ]
Remove the two thermostat housing cover capscrews
used as guides.

Install the two thermostats into the thermostat housing


cover by pushing on the outer rims.
Coolant Thermostat Housing Signature, ISX, and QSX15 Eng [...]
Page 8-20 Section 8 - Cooling System - Group 08

Install the thermostat housing cover, gasket, and four


capscrews on the cylinder head.
Tighten the capscrews.
Torque Value:
Short capscrews 34 Nm [ 25 ft-lb ]
Long capscrews 56 Nm [ 41 ft-lb ]

Connect the vent line. Refer to the OEM instructions.


Connect the coolant sensor connector.

Install the upper radiator hose.


Tighten the hose clamp.
Torque Value: 5 Nm [ 40 in-lb ]

Industrial engines use a thermostat housing cover with


either a cover plate or a water connection.
Install the thermostat cover if removed.
Tighten the capscrews.
Torque Value: 28 Nm [ 20 ft-lb ]
Automotive has a similar design with connector for
transmission cooler.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat Seal
Section 8 - Cooling System - Group 08 Page 8-21

Finishing Steps
Install the refrigerant compressor mounting bracket.
Refer to Procedure 009-055.
Install the refrigerant compressor. Refer to
Procedure 009-051.
Install the EGR cooler coolant return tube, if
required. Refer to Procedure 011-031.
Install the EGR cooler connection tube, if required.
Refer to Procedure 011-024.
Install the EGR valve, if required. Refer to Procedure
011-022.
Install the heat shield, If required. Refer to Procedure
011-032.
Install the turbocharger actuator air line. Refer to
Procedure 010-113.
Install the exhaust gas pressure sensor. Refer to
Procedure 019-376 in the ISX CM871 and ISM
CM876 Electronic Control System Troubleshooting
and Repair Manual, Bulletin 4021560.
Install the turbocharger coolant return line. Refer to
Procedure 010-041.
Install the vent line. Refer to the OEM service
manual.
Install the OEM coolant sensor(s). Refer to the OEM
service manual.
Install the engine coolant temperature sensor. Refer
to Procedure 019-019 in the ISX CM871 and ISM
CM876 Electronic Control System Troubleshooting
and Repair Manual, Bulletin 4021560.
Install the upper radiator hose. Refer to the OEM
service manual.
Install the charge air cooler piping. Refer to
Procedure 010-027.
Install the air intake piping. Refer to the OEM service
manual.
Fill the cooling system. Refer to Procedure 008-018.
Operate the engine until the coolant temperature
reaches 70C [158F] and check for leaks.

Coolant Thermostat Seal (008-016)


Remove
Single Seal
Remove the thermostat seal. Do not damage the
thermostat cover.
Coolant Thermostat Seal Signature, ISX, and QSX15 Eng [...]
Page 8-22 Section 8 - Cooling System - Group 08

Dual Seal
NOTE: The Signature, ISX, and QSX engines have two
engine coolant thermostats.
Remove the thermostat housing cover. Refer to Procedure
008-014.
Remove the thermostat seal. Do not damage the
thermostat cover.

Inspect for Reuse


NOTE: The Signature, ISX, and QSX engines have two
engine coolant thermostats.
Inspect the thermostat seal for cracks, corrosion, or other
damage. Replace if necessary.

Install
Single Seal
NOTE: When installing a new seal, the flat side of the seal
must be toward the mandrel for correct installation.
Use thermostat seal mandrel, Part Number 3824716, and
a lead hammer to install the seal.
A counterbore in the housing bore locates the seal.

Dual Seal
NOTE: The Signature, ISX, and QSX engines have two
engine coolant thermostats.
NOTE: When installing a new seal, the flat side of the seal
must be toward the mandrel for correct installation.
Use thermostat seal mandrel, Part Number 3164350, and
a lead hammer to install the seal.
A counterbore in the housing bore locates the seal.
Install the thermostat housing cover. Refer to Procedure
008-014.
Signature, ISX, and QSX15 Eng [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-23

Coolant Vent Lines (008-017)


Initial Check
The cooling system must be designed to allow air to
escape while filling the coolant system.

During engine operation, coolant will continuously flow


through the engine vent line to remove air from the
coolant.

Engine Vent Line


The cooling system vent line is plumbed from a special
connection located on the top of the thermostat cover. The
line then goes to the radiator fill tank or auxiliary tank
above the coolant level.

Cooling System (008-018)


Drain
Position the equipment on level ground.
Cooling System Signature, ISX, and QSX15 Eng [...]
Page 8-24 Section 8 - Cooling System - Group 08

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Remove the radiator cap after the engine has cooled down
ad adequately.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Do not allow the cooling system to dry out.
If the coolant is to be reused, the holding container must
be free of oil and dirt. Before pouring coolant back into the
engine, it must be tested for SCA (Supplemental Coolant
Additive) concentration.
For automotive applications, use the Signature and ISX
Operation and Maintenance Manual, Bulletin 3666251.
Refer to Procedure 018-004 in Section V.
For industrial applications, use the Industrial and Power
Generation QSX15 Engines Operation and Maintenance
Manual, Bulletin 3666423. Refer to Procedure 018-004 in
Section V.
Open the radiator draincocks.
Remove the lower radiator hose(s).
Do not remove the coolant filter.

Flush
CAUTION
Do not use caustic cleaners in the cooling system.
Aluminum components will be damaged.
The cooling system must be clean to work correctly and
to eliminate buildup of harmful chemicals.
Signature, ISX, and QSX15 Eng [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-25

Restore is a heavy-duty cooling system cleaner that


removes corrosion, silica gel, and other deposits. The
performance of Restore is dependent on time,
temperature, and concentration levels. An extremely
scaled or flow-restricted system, for example, can require
higher concentrations of cleaners, higher temperatures,
longer cleaning times, or the use of Restore Plus. Up to
twice the recommended concentration levels of Restore
can be used safely. Restore Plus must be used only at
its recommended concentration level. Extremely scaled or
fouled systems can require more than one cleaning.

CAUTION
Fleetguard Restore contains no antifreeze. Do not
allow the cooling system to freeze during the cleaning
operation.
After draining the coolant, immediately add 3.8 liters [1
gal] of Fleetguard Restore, Restore Plus, or
equivalent, for each 38 to 57 liters [10 to 15 gal] of cooling
system capacity, and fill the system with plain water.
Turn the cab heater temperature switch to high to allow
maximum coolant flow through the heater core. The
blower does not have to be on.

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Operate the engine at normal operating temperatures, at
least 85C [185F], for one to one and a half hours.
Shut off the engine and drain the cooling system.

Fill the cooling system with clean water.


Cooling System Signature, ISX, and QSX15 Eng [...]
Page 8-26 Section 8 - Cooling System - Group 08

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Operate the engine at high idle for 5 minutes with the
coolant temperature above 85C [185F].
Shut off the engine and drain the cooling system.
If the water being drained is still dirty, the system must be
repeatedly flushed until the water is clean.

CAUTION
To reduce the possibility of engine damage, do not
add coolant while the engine is hot.
Fill the cooling system with fully-formulated coolant or a
50/50 mixture of fully-formulated antifreeze and good-
quality water. Use a service filter to bring the coolant to
the correct SCA concentration level.
For automotive applications, use the Signature and ISX
Operation and Maintenance Manual, Bulletin 3666251.
Refer to Procedure 018-004 in Section V.
For industrial applications use the Industrial and Power
Generation QSX15 Engines Operation and Maintenance
Manual, Bulletin 3666423. Refer to Procedure 018-004 in
Section V.

Fill
CM570
Close the radiator draincocks.
Install the lower radiator hose(s).
Tighten the hose clamps.
Torque Value: 5 Nm [ 44 in-lb ]
Signature, ISX, and QSX15 Eng [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-27

Cummins Inc. recommends the use of either a 50/50


mixture of good-quality water and fully-formulated
antifreeze, or fully-formulated coolant when filling the
cooling system. The fully-formulated antifreeze or coolant
must meet TMC RP329 or TMC RP330 specifications.
Good-quality water is important for cooling system
performance. Excessive levels of calcium and magnesium
contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Water Quality
Calcium Magnesium Maximum 170 ppm as (CaCO3 +
(Hardness) MgCO3)
Chloride 40 ppm as (CI)
Sulfate 100 ppm as (SO4)

Cummins Inc. recommends the use of Fleetguard ES


COMPLEAT. It is available in glycol forms (ethylene and
propylene) and complies with TMC RP329 and RP330
standards.

Fill the cooling system with heavy-duty coolant and install


the correct service filter.
Identify the correct filter. For automotive applications, use
the Signature and ISX Operation and Maintenance
Manual, Bulletin 3666251.Refer to Procedure 018-004 in
Section V.
For industrial applications, use the Industrial and Power
Generation QSX15 Engines Operation and Maintenance
Manual, Bulletin 3666423. Refer to Procedure 018-004 in
Section V.
Cooling System Signature, ISX, and QSX15 Eng [...]
Page 8-28 Section 8 - Cooling System - Group 08

CAUTION
Opening the manual bleed valve or removing the pipe
plug on applicable installations is critical. Failure to
do so can result in engine damage.
NOTE: Some applications can have a manual bleed valve
or pipe plug that is required to be opened to properly fill
the system. The upper radiator pipe is a common location.
NOTE: Some applications can have a pipe plug installed
in place of the manual bleed valve.
If applicable, open the manual bleed valve or remove the
pipe plug before filling the cooling system.
Once filled, close the manual bleed valve or install the pipe
plug. For the torque specification, refer to the OEM service
manual.

NOTE: Some radiators have two fill locations, both of


which must be filled when the cooling system has been
drained.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.

Install the radiator or expansion tank fill cap.


Operate the engine until it reaches a temperature of 82
C [180F], and check for leaks.

Shut off the engine and allow it to cool.


Signature, ISX, and QSX15 Eng [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-29

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50C [120F] before adding coolant.
Remove the radiator or fill cap and check the coolant level
according to the operator equipment manual
recommendations. Add coolant if necessary. Do not
overfill.

Automotive with CM870 and CM871


Close the radiator draincocks.
Install the lower radiator hose(s).
Tighten the hose clamps.
Torque Value: 5 Nm [ 44 in-lb ]

Cummins Inc. recommends the use of either a 50/50


mixture of good-quality water and fully-formulated
antifreeze, or fully-formulated coolant when filling the
cooling system. The fully-formulated antifreeze or coolant
must meet TMC RP329 or TMC RP330 specifications.
Good-quality water is important for cooling system
performance. Excessive levels of calcium and magnesium
contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Water Quality
Calcium Magnesium Maximum 170 ppm as (CaCO3 +
(Hardness) MgCO3)
Chloride 40 ppm as (CI)
Sulfate 100 ppm as (SO4)
Cooling System Signature, ISX, and QSX15 Eng [...]
Page 8-30 Section 8 - Cooling System - Group 08

Cummins Inc. recommends the use of Fleetguard ES


COMPLEAT. It is available in glycol forms (ethylene and
propylene) and complies with TMC RP329 and RP330
standards.

Fill the cooling system with heavy-duty coolant and install


the correct service filter.
Identify the correct filter. For automotive applications, use
the Signature and ISX Operation and Maintenance
Manual, Bulletin 3666251.Refer to Procedure 018-004 in
Section V.
For industrial applications, use the Industrial and Power
Generation QSX15 Engines Operation and Maintenance
Manual, Bulletin 3666423. Refer to Procedure 018-004 in
Section V.

CAUTION
Opening the manual bleed valve or removing the pipe
plug on applicable installations is critical. Failure to
do so can result in engine damage.
NOTE: Some applications can have a manual bleed valve
or pipe plug that is required to be opened to properly fill
the system. The upper radiator pipe is a common location.
NOTE: Some applications can have a pipe plug installed
in place of the manual bleed valve.
If applicable, open the manual bleed valve or remove the
pipe plug before filling the cooling system.
Once filled, close the manual bleed valve or install the pipe
plug. For the torque specification, refer to the OEM service
manual.

NOTE: Some radiators have two fill locations, both of


which must be filled when the cooling system has been
drained.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.
Signature, ISX, and QSX15 Eng [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-31

Without installing the coolant pressure cap, operate the


engine until the thermostat opens.
Shut off the engine.

CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50C [120F] before adding coolant.
Check the coolant level according to the operator
equipment manual recommendations. Add coolant, if
necessary. Do not overfill.

Pressure Test
Connect the air line in place of a vent line on the surge
tank.
Install an air regulator (2) between the ball valve (1) of the
air line and the surge tank connection.
Attach a hose to the radiator overflow connection (3).

Place the free end of the hose below the water level in a
container of water.
Cooling System - Air or Combustion Gas Test Signature, ISX, and QSX15 Eng [...]
Page 8-32 Section 8 - Cooling System - Group 08

CAUTION
Do not apply more than 140 kPa [20 psi] air pressure
to the cooling system. The water pump seal can be
damaged.
Pressurize the cooling system slowly to the rated radiator
cap pressure until bubbles can be seen in the overflow
bottle.

If the bubbles start at a lower pressure than the minimum


recommended cap pressure (See Cooling System
Specifications), inspect the radiator pressure cap. Refer
to Procedure 008-047 in Section 8. Replace the radiator
pressure cap, if necessary.

Cooling System - Air or Combustion


Gas Test (008-019)
Initial Check
Air in Cooling System

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Allow the engine to cool and remove the radiator cap.

Check the coolant level according to the operator's


equipment manual recommendations and fill, if
necessary.
Add heavy-duty coolant. Refer to Procedure 018-004
(Coolant Recommendations and Specifications) in
Section V, in the Signature and ISX Operation and
Maintenance Manual, Bulletin 3666251. Refer to Service
Bulletin 3810340 for a description of heavy-duty coolants.
Signature, ISX, and QSX15 Eng [...] Cooling System - Air or Combustion Gas Test
Section 8 - Cooling System - Group 08 Page 8-33

The pressure cap must be tightly sealed in the top of the


radiator fill neck.
Place the radiator cap back on and attach a rubber hose
to the radiator overflow connection.
Place the free end of the hose below the water level in a
container of water.

The engine coolant temperature must be stable to


perform this test. An increasing coolant temperature will
give a false indication of air due to expansion of the
coolant in the system.
Operate the engine at rated rpm until it reaches 82C
[180F].
Check for a continuous flow of air bubbles from the hose
into the water container.

A continuous flow of air bubbles can be caused by one of


the following:
An air compressor cylinder head leak. See the Leak
Test - Air Compressor in this procedure.
Fan, shutter, or heater air control thermostat valve
leaking air. See the Leak Test - Fan, Shutter, or
Heater Air Control Valve in this procedure.
A cracked cylinder head. Refer to Procedure
002-004 (Cylinder Head) in Section 2.
A cylinder head gasket combustion leak. See the
Combustion Gas Leak - Overflow Method in this
procedure.

If no air is found in the cooling system, do the following:


Remove the test equipment.
Operate the engine until it reaches 80C [180F],
and check for coolant leaks.
Cooling System - Air or Combustion Gas Test Signature, ISX, and QSX15 Eng [...]
Page 8-34 Section 8 - Cooling System - Group 08

Leak Test
Fan, Shutter, or Heater Air Control Valve

CAUTION
The engine can overheat with the fan control or the
shutter air control valve disconnected. Monitor the
engine coolant temperature while performing this
test. The coolant temperature must not exceed 100
C [212F] or engine damage can occur.

Disconnect the vehicle air supply hose from the fan, the
shutter, and the heater air control valve.
Install a plug into the air supply hose.
If the vehicle is equipped with more than one air control
valve, check only one valve at a time.

Start the engine and run for five minutes before testing for
air in the coolant. This will allow any trapped air to purge
from the system.
Repeat the test for air in the cooling system, as previously
described.
If no air is found in the cooling system with the air control
valve(s) isolated, install a new control valve.

Air Compressor

CAUTION
The air compressor discharge line must be
disconnected at the compressor to allow the
compressor to discharge air to the atmosphere during
this next test to prevent the compressor from
overheating. Do not run the engine over 5 minutes
with components isolated from the cooling system.
Component damage can occur.
Signature, ISX, and QSX15 Eng [...] Cooling System - Air or Combustion Gas Test
Section 8 - Cooling System - Group 08 Page 8-35

Disconnect the coolant supply and the return tubes from


the air compressor.
Use a short piece of hose to connect the tubes together to
prevent coolant loss during engine operation.

Drain the air tanks completely to reduce the possibility of


air entering the cooling system through the cab heater
control valve.

Repeat the test for air in the cooling system as previously


described in this procedure.
If no air is found in the cooling system with the air
compressor isolated, repair or replace the air compressor.

Combustion Gas Leak


Use combustion gas tester, Part Number 3822985 or its
equivalent, to test for combustion gases in the cooling
system.
A 50 percent antifreeze and 50 percent water mixture
must be used in the cooling system when performing the
combustion gas leak test.
Cooling System - Air or Combustion Gas Test Signature, ISX, and QSX15 Eng [...]
Page 8-36 Section 8 - Cooling System - Group 08

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
NOTE: Coolant that gets into the combustion analyzer will
stop the color change and render the test ineffective.
Drain the coolant level down approximately 75 mm [3 in]
below the radiator cap seal ledge in the radiator fill neck.

Pour the test fluid into the combustion gas leak test
instrument until it is up to the yellow fill line on the
instrument.

Insert the rubber tip of the combustion gas leak test


instrument into the radiator fill neck. Hold the instrument
down firmly and turn back and forth to make sure that an
airtight seal is formed between the tester and the radiator
fill neck.

Start the engine and run at high idle for approximately 30


minutes. Monitor the engine temperature and color of the
test fluid during engine operation. Do not allow the engine
temperature to exceed 100C [212F] during the test.
A flow of bubbles will occur as the engine warms up and
coolant expands.
Bubbles in the combustion analyzer is not a sign of a
combustion leak.
Signature, ISX, and QSX15 Eng [...] Cooling System - Air or Combustion Gas Test
Section 8 - Cooling System - Group 08 Page 8-37

If the color of the test fluid changes from blue to green or


yellow any time during the test, combustion gases are
leaking into the cooling system. Discontinue the test if the
color of test fluid changes from blue to green or yellow.

If the color of the test fluid does not change from blue to
green or yellow during the 30-minute test period, return
the engine to low idle.

Check the test instrument to make sure it is firmly sealed


in the radiator fill neck.

Insert the tip of the rubber ball into the hole in the top of
the test instrument. Squeeze the rubber ball 2 to 3 minutes
to draw air from the radiator through the test fluid.
If the color of the test fluid remains blue, combustion
gases are not entering the cooling system. If the color of
the test fluid changes from blue to green or yellow,
combustion gases are entering the cooling system and
further investigation is required to determine the source of
the combustion leak.
Cooling System - Air or Combustion Gas Test Signature, ISX, and QSX15 Eng [...]
Page 8-38 Section 8 - Cooling System - Group 08

As the cooling system warms up to operating temperature,


air will be expelled through the combustion gas tester in
the form of bubbles in the test fluid. This is due to normal
expansion of the coolant. Do not mistake the presence of
air bubbles in the tester as combustion gases or air leaks
into the cooling system. A change in the color of the test
fluid from blue to green or yellow is the only indication of
combustion gas in the cooling system.

A positive result from the combustion gas leak tester


indicates the following:
Injector sleeve leakage. Be sure that the injector
hold-down torque is correct. Refer to Procedure
006-026 (Injector) in Section 6.
Cylinder liner protrusion not correct. Refer to
Procedure 001-028 (Cylinder Liner) in Section 1.
Cylinder head gasket or cylinder head casting
leakage. Refer to Procedure 002-004 (Cylinder
Head) in Section 2.
Cracked cylinder liner. Refer to Procedure 001-028
(Cylinder Liner) in Section 1.
NOTE: Discard the tester fluid if it has indicated positive.

A negative result from the combustion gas leak tester,


coupled with a continuous flow of air bubbles from the
previous test, indicates the following:
Defective fan, shutter, or heater air control valve.
Air compressor head or head gasket leakage.
Air entrained due to a bad radiator check valve or
incorrect fill.

Overflow Method

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Allow the engine to cool and remove the radiator cap.
Signature, ISX, and QSX15 Eng [...] Fan Clutch, On-Off
Section 8 - Cooling System - Group 08 Page 8-39

Install a radiator pressure cap that has had the spring and
the pressure relief valve removed to allow free flow from
the overflow tube.
The pressure cap must be tightly sealed in the top of the
radiator fill neck.
Attach a rubber hose to the radiator overflow connection.
Put the free end of the hose below the water level in a
container of water.

The engine coolant temperature must be stable to


perform this test. An increasing coolant temperature will
give a false indication of air due to expansion of the
coolant in the system.
Operate the engine at rated rpm until it reaches a
temperature of 82C [180F].
Check for a continuous flow of air bubbles from the hose
in the water container.

Fan Clutch, On-Off (008-027)


Initial Check
With Low Temperature Fan-On Control

CAUTION
If the fan clutch logic is not set correctly, the ECM will
not be able to engage the fan for engine cooling and
engine protection. The engine can overheat and
damage is possible.
The fan clutches can be controlled by the ECM. The ECM
can be programmed for either 12 volts, fan ON or 12 volts,
fan OFF. Check the ECM program using INSITE.

Restrict the air flow to the radiator.


Operate the engine at rated rpm.
Fan Clutch, On-Off Signature, ISX, and QSX15 Eng [...]
Page 8-40 Section 8 - Cooling System - Group 08

If the vehicle is air conditioned, make sure the air


conditioning is turned off to prevent continuous operation
of the fan. When the coolant temperature reaches 99C
[210F], check for fan engagement.
NOTE: The temperature given for fan engagement is for
fans controlled by the ECM.
NOTE: Fan noise and airflow will increase when the fan
clutch engages.

Return the engine to idle and remove the radiator air flow
restriction.

The fan clutch must disengage when the coolant


temperature drops to 96C [205F].
NOTE: The temperature given for fan disengagement is
for fans controlled by the ECM.

With High Temperature Fan On


On Signature, ISX, and QSX engines, the fan clutches can
be controlled by the ECM. The ECM is programmed to turn
the fan clutch on and off.
Signature, ISX, and QSX15 Eng [...] Fan Clutch, On-Off
Section 8 - Cooling System - Group 08 Page 8-41

Restrict the radiator airflow.


Operate the engine at rated rpm.

If the vehicle is air conditioned, make sure the air


conditioning is turned off to prevent continuous operation
of the fan. When the coolant temperature reaches 110C
[215F], check for fan engagement.
NOTE: The temperature given for fan engagement is for
fans controlled by the ECM.
NOTE: Fan noise and airflow will increase when the fan
clutch engages.

Return the engine to idle and remove the radiator air


restriction.

The fan clutch must disengage before the coolant


temperature drops to 93C [200F]. Cummins Inc.
recommends that the fan disengage at 3C [6F] below
the temperature stamped on the temperature sensor.
NOTE: The temperature given for fan disengagement is
for fans controlled by the ECM.
Fan Drive Idler Pulley Assembly Signature, ISX, and QSX15 Eng [...]
Page 8-42 Section 8 - Cooling System - Group 08

Fan Drive Idler Pulley Assembly


(008-030)
Preparatory Steps
Remove the fan drive belt. Refer to Procedure
008-002 in Section 8.

Remove
On initial installation, remove the three capscrews
indicated in the illustration from the lower front cover.

Install
Install the bracket on the engine with the three spacers
and three capscrews.
Tighten the capscrews.
Torque Value:
Fan drive idler 18 Nm [ 159 in-lb ]
pulley bracket
capscrew
M8x60mm

Mount the fan drive idler pulley assembly to the fan drive
idler pulley bracket and tighten the capscrew. Make sure
the washer is centered on the idler pulley.
Torque Value:
Fan drive idler 54 Nm [ 40 ft-lb ]
pulley assembly
capscrew
M10x80mm
Install the dust shield by pressing on the outside diameter
of the shield to prevent damage to the dust shield.
Use an appropriate size driver or other suitable tool.
Signature, ISX, and QSX15 Eng [...] Fan Hub, Belt Driven
Section 8 - Cooling System - Group 08 Page 8-43

Finishing Steps
Install the drive belt. Refer to Procedure 008-002 in
Section 8.

Fan Hub, Belt Driven (008-036)


Preparatory Steps
Automotive with CM870
Remove the cooling fan. Refer to Procedure
008-040.
Remove the cooling fan drive belt. Refer to
Procedure 008-002.
Remove the automatic belt tensioner (water pump).
Refer to Procedure 008-080.

Automotive with CM570


Remove the cooling fan. Refer to Procedure
008-040.
Remove the water pump belt. Refer to Procedure
008-003.
Remove the alternator belt Refer to Procedure
013-005.

Industrial CM570 and Power Generation without


CM570
Remove the cooling fan. Refer to Procedure
008-040.
Remove the fan and water pump belt. Refer to
Procedure 008-003.
Remove the alternator drive belt. Refer to Procedure
013-005.
Remove the fan hub and the fan hub support. Refer
to Procedure 008-088.
Fan Hub, Belt Driven Signature, ISX, and QSX15 Eng [...]
Page 8-44 Section 8 - Cooling System - Group 08

Remove
Automotive with CM870

WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Remove the mounting capscrews and the fan hub
assembly.

Automotive with CM570

WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce
the possibility of personal injury, use a hoist or get
assistance to lift this assembly.
Remove alternator belt tensioner and bracket.
Remove the capscrews and the fan hub assembly.

Industrial CM570 and Power Generation without


CM570
Remove the fan hub mounting capscrews.
Remove the fan hub from the fan support.

Clean and Inspect for Reuse


Automotive with CM870
Inspect the fan hub for the following:
Freedom of rotation
Cracks
Grease seal leakage.
Repair or replace the fan hub if the fan hub does not rotate
freely or if there is evidence of cracks or grease seal
leakage.
Refer to the OEM service literature for repair of the fan
hub.
Signature, ISX, and QSX15 Eng [...] Fan Hub, Belt Driven
Section 8 - Cooling System - Group 08 Page 8-45

Measure the fan hub end clearance play. The end


clearance is dependent upon the fan hub style.
Replace the fan hub if the end clearance is not within the
manufacturer's specifications.
Refer to OEM service manual for additional inspection
steps.

Automotive, Industrial with CM570 and Power


Generation without CM570
Inspect the fan hub for the following:
Freedom of rotation
Cracks
Grease seal leakage.
Repair or replace the fan hub if the fan hub does not rotate
freely or if there is evidence of cracks or grease seal
leakage.

Measure the fan hub end clearance. The end clearance is


dependent upon the fan hub style.
Replace the fan hub if the end clearance is not within
specifications.

Fan Hub End Clearance


mm in
0.08 MIN 0.003
0.25 MAX 0.009

Install
Automotive with CM870

WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce
the possibility of personal injury, use a hoist or get
assistance to lift this assembly.
Install the fan hub assembly and the capscrews.
Tighten the capscrews.
Torque Value: 113 Nm [ 83 ft-lb ]
Fan Hub, Belt Driven Signature, ISX, and QSX15 Eng [...]
Page 8-46 Section 8 - Cooling System - Group 08

Automotive with CM570

WARNING
This assembly weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift
this assembly.
Install the fan hub and the capscrews.
Tighten the capscrews.
Torque Value: 90 Nm [ 66 ft-lb ]
Install the belt tensioner bracket.

Industrial CM570 and Power Generation without


CM570
The fan hub must be installed in the correct location on
the fan support to allow proper clearance between the fan
and fan shroud. Refer to the OEM service manual.

Make certain the correct fan center is used for the


application.
Install the fan hub on the fan support using four capscrews
and washers.
Tighten the capscrews.
Torque Value: 90 Nm [ 66 ft-lb ]

Finishing Steps
Automotive with CM870
Install the automatic belt tensioner (water pump).
Refer to Procedure 008-080.
Install the cooling fan drive belt. Refer to Procedure
008-002.
Install the cooling fan. Refer to Procedure 008-040.
Signature, ISX, and QSX15 Eng [...] Fan Shroud Assembly
Section 8 - Cooling System - Group 08 Page 8-47

Automotive with CM570


Install the alternator belt. Refer to Procedure
013-005.
Install the water pump belt. Refer to Procedure
008-003.
Install the cooling fan. Refer to Procedure 008-040.

Industrial CM570 and Power Generation without


CM570
Install the fan hub and fan hub support. Refer to
Procedure 008-088.
Install the alternator drive belt. Refer to Procedure
013-005.
Install the fan and water pump belt. Refer to
Procedure 008-003.
Install the cooling fan. Refer to Procedure 008-040.

Fan Shroud Assembly (008-038)


Initial Check
CAUTION
The fan shroud must be installed correctly and be in
good condition. The shroud-to-fan clearance must be
within the manufacturer's specifications to maintain
proper air flow through the radiator to provide
adequate engine cooling, or engine damage can
occur.
Inspect the fan shroud for proper fan clearance, cracks,
air leaks, or damage. Replace if necessary. Refer to the
manufacturer's instructions.

Cummins Inc. recommends fan clearance be 5.08 to 10.16


cm [2 to 4 in] from the radiator core. Refer to the
equipment manufacturer for alternative positions.
Fan, Cooling Signature, ISX, and QSX15 Eng [...]
Page 8-48 Section 8 - Cooling System - Group 08

Fan, Cooling (008-040)


Remove

WARNING
Disconnect the batteries or air supply line to the air
starter to prevent accidental engine starting and
personal injury.

CAUTION
Do not pry or pull on the fan. The fan blades can be
damaged.
Remove the fan.

Inspect for Reuse

WARNING
Do not straighten a bent fan blade or continue to use
a damaged fan. A bent or damaged fan blade can fail
during operation and cause personal injury or
property damage.

Replace the original equipment fan with a fan of the


identical part number. Cummins Inc. must approve any
other fan changes.

An inspection of the cooling fan is required daily.


Check for cracks, loose rivets, bent or loose blades, and
for contact between the fan blade tips and the fan shroud.
Check the fan to make sure it is securely mounted.
Tighten the capscrews, if necessary. Refer to the vehicle
manufacturer's specifications for fan capscrew torque
value.
Replace any fan that is damaged.
Signature, ISX, and QSX15 Eng [...] Radiator
Section 8 - Cooling System - Group 08 Page 8-49

Install
NOTE: Replace the original equipment fan with a fan of
the identical part number. Cummins Inc. must approve
any fan changes.

Install the fan.


Tighten the mounting capscrews. Refer to OEM
specifications.
Connect the batteries or air starter supply line.

Radiator (008-042)
Initial Check
Inspect the radiator for plugged radiator fins.
Use 550-kPa [80-psi] air pressure to blow the dirt and
debris from the fins. Blow the air in the opposite direction
of the fan airflow.
Inspect the CAC and the clearance between the CAC and
the radiator for trapped debris. Remove the CAC if
necessary.
Remove any debris found.

Inspect the radiator for bent or broken fins.


NOTE: The radiator must be replaced due to bent or
broken fins that can cause the engine to overheat. Refer
to the manufacturer's replacement procedures.
Inspect the radiator for core and gasket leaks.
Radiator Pressure Cap Signature, ISX, and QSX15 Eng [...]
Page 8-50 Section 8 - Cooling System - Group 08

WARNING
If a liquid refrigerant system must be removed before
removing the radiator, wear eye and face protection.
For environmental protection, federal law requires
that Freon be recycled and not vented into the
atmosphere. Wrap a cloth around the fittings before
removing. Liquid refrigerant can cause serious eye
and skin injury.

Radiator Hoses (008-045)


Inspect for Reuse
Inspect all hoses for cracks, cuts, or collapsing.
NOTE: The silicone engine coolant hose will exhibit
swelling due to the elasticity of the hose.

Radiator Pressure Cap (008-047)


Inspect for Reuse

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Remove the radiator pressure cap.

Inspect the rubber inner seal and the brass outer seal of
the pressure cap for damage.
Inspect the radiator or expansion tank fill neck for cracks
or other damage.
Refer to the radiator manufacturer's or vehicle
manufacturer's instructions if the fill neck is damaged.
Make sure the correct pressure cap is used. Refer to the
Cooling System Specifications.
Signature, ISX, and QSX15 Eng [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-51

Pressure-test the radiator cap to the rated cap pressure.

Radiator Shutter Assembly (008-049)


General Information
NOTE: Shutters and fan clutch must be set to operate in
the same temperature range as the thermostat with which
they are used.
Check the shutters and the fan clutch every 1500 hours.
Every 192,000 km [120,000 mi], 3000 hours, or 2 years,
whichever comes first, check the shutters and the fan
clutch.
Check the shutters in the closed position to be sure they
are completely closed.
NOTE: If the shutters are not closed, refer to the
manufacturer's instructions.
Be sure the shutters open completely at the desired
temperature setting.
NOTE: If the shutters are closed, refer to the
manufacturer's instructions.

Water Pump (008-062)


Preparatory Steps
Automotive with CM870

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the cooling system. Refer to Procedure
008-018.
Remove the water pump drive belt and tensioner.
Refer to Procedure 008-080.
Remove the refrigerant compressor drive belt. Refer
to Procedure 009-052.
Water Pump Signature, ISX, and QSX15 Eng [...]
Page 8-52 Section 8 - Cooling System - Group 08

Automotive with CM570

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the cooling system. Refer to Procedure
008-018.
Remove the water pump and fan drive belt. Refer to
Procedure 008-003.
Remove the alternator drive belt. Refer to Procedure
013-005.
Remove the alternator. Refer to Procedure 013-001.
Remove the water pump belt tensioner bracket and
belt tensioner. Refer to Procedure 008-080.
If necessary, remove the vibration dampers. Refer to
Procedure 001-052.

Industrial CM570 and Power Generation without


CM570

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep children and pets away. If the
coolant is not going to be reused, dispose of it in
accordance with local environmental regulations.
Drain the cooling system. Refer to Procedure
008-018.
Remove the cooling fan and water pump belt. Refer
to Procedure 008-003.
Remove the alternator drive belt. Refer to Procedure
013-005.
Remove the alternator. Refer to Procedure 013-001.
If required, remove the damper assembly. Refer to
Procedure 001-052.
Signature, ISX, and QSX15 Eng [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-53

Automotive with CM871

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the cooling system. Refer to Procedure
008-018.
Remove the water pump drive belt and tensioner.
Refer to Procedure 008-080.
Remove the refrigerant compressor drive belt. Refer
to Procedure 009-052.
Remove the water pump cartridge. Refer to
Procedure 008-102.

Remove
Automotive with CM870
Remove two water pump mounting capscrews and install
two guide studs.

Remove the remaining three capscrews, the water pump,


and the o-ring seal.
Discard the o-ring seal.
Water Pump Signature, ISX, and QSX15 Eng [...]
Page 8-54 Section 8 - Cooling System - Group 08

Automotive with CM570


Remove two water pump capscrews and install guide
studs.
Remove remaining three capscrews, water pump, and
water inlet o-ring seal.
Discard the o-ring seal.

Industrial CM570 and Power Generation without


CM570
Remove the pulley (1), pilot adapter (2), and belt tensioner
bracket (3).

Remove the remaining water pump capscrews, and water


inlet o-rings.
Discard the o-ring seals.

Automotive With CM871


Remove the five water pump housing mounting
capscrews.
Remove the two bracket mounting capscrews
Remove the EGR tube outlet capscrew.
Remove the water pump housing and o-ring seals.
Discard the water inlet o-ring seal and EGR tube inlet and
outlet o-ring seal.
Signature, ISX, and QSX15 Eng [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-55

Clean
Clean the water pump and the water inlet connections.

Inspect the water pump housing for cracks.


Inspect the water pump weep hole for indication of leaks.
A streak or chemical buildup at the weep hole is not
justification for water pump replacement. If a steady flow
of coolant or oil is observed, recondition the existing water
pump or replace the water pump with a new or rebuilt unit.

Automotive With CM871

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the water pump components with solvent and dry
with compressed air.

Inspect the water pump housing for cracks and damage.


Inspect the water pump inlet tube for out of roundness,
damage, or leaks.
If the water pump housing is damaged, it must be
replaced.
Continuous pitting deeper than 0.635 mm [0.025 in] or
individual pits deeper than 2.54 mm [0.100 inch] are not
acceptable.
Replace the water pump housing if not within
specifications.
Water Pump Signature, ISX, and QSX15 Eng [...]
Page 8-56 Section 8 - Cooling System - Group 08

Disassemble

WARNING
The retaining clip contains extreme amounts of
potential energy. To reduce the possibility of personal
injury from the clip slipping, place the water pump in
a box prior to removing the retaining clip.
Place the water pump in a box.
Remove the retaining clip securing the impeller cover.
Remove and discard the water pump outlet o-ring.

Use a heel bar to remove the impeller cover from the


pump.
Discard the o-ring.

Support the water pump housing pulley in a press with the


pulley facing up.
Press the pulley off of the water pump and shaft assembly.

Position the water pump with the pulley end facing up.
Remove the bearing bore retaining clip.
Signature, ISX, and QSX15 Eng [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-57

Support the water pump in a press with the impeller facing


up.
Press the shaft out of the impeller and through the pump
housing.
Remove the impeller from the housing.
Discard a phenolic impeller, retain a cast iron impeller.

Support the water pump in a press with the pulley end


facing up.
Press the seal out of the housing.

NOTE: Disassemble the shaft and bearings only if the


seal is leaking or the bearing is damaged.
Remove the retaining ring (1).
Use the water pump bearing separator, Part Number
3375326 to remove the:
Front bearing (2)
Rear bearing (3).

Clean and Inspect for Reuse

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

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the water pump components with solvent and dry
with compressed air.
Water Pump Signature, ISX, and QSX15 Eng [...]
Page 8-58 Section 8 - Cooling System - Group 08

Inspect the water pump housing for cracks and damage.


If the water pump housing is damaged, it must be
replaced.

Inspect the cast iron impeller for cracks, pitting and other
damage.
Continuous pitting deeper than 0.635 mm [0.025 in] or
individual pits deeper than 2.54 mm [0.100 in] are not
acceptable.
Replace the impeller if damaged or if pits are not within
specifications.

The water pump bearings are sealed bearings.


Spin the bearings to check for roughness.
Inspect the bearings for signs of grease purge.
If the bearing seals show signs of grease purge or the
bearing does not spin smoothly, it must be replaced.

Inspect the impeller cover for cracks and other damage.


Scratching on the inside face is acceptable.
If there is any damage to the outer o-ring area, the impeller
cover must be replaced.
Signature, ISX, and QSX15 Eng [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-59

Inspect the impeller cover retaining clip.


If the retaining clip is rusted or pitted, it must be replaced.

Inspect the pulley for cracks, wear, and damage.


Inspect the mating surface and pulley bore areas for
damage.
If the pulley is damaged, it must be replaced.

Measure
Measure the inside diameter of the water pump housing
large bearing bore.

Water Pump Housing Large Bearing Bore Inside


Diameter
mm in
71.988 MIN 2.834
72.018 MAX 2.835
If the water pump housing large bearing bore inside
diameter is not within specifications, the water pump
housing must be replaced.

Measure the inside diameter of the cast iron impeller.

Cast Iron Impeller Inside Diameter


mm in
15.850 MIN 0.624
15.875 MAX 0.625
If the cast iron impeller inside diameter is not within
specifications, it must be replaced.
Water Pump Signature, ISX, and QSX15 Eng [...]
Page 8-60 Section 8 - Cooling System - Group 08

Measure the outside diameter of the water pump shaft.

Water Pump Shaft Diameter


mm in
Small End 25.015 MIN 0.9848
25.002 MAX 0.9843
Large End 29.015 MIN 1.1423
29.002 MAX 1.1418
Measure the outside diameter of the larger end of the
shaft.
If the shaft is not within specifications, it must be
replaced.

Measure the inside diameter of the pulley bore.

Pulley Bore Inside Diameter


mm in
28.936 MIN 1.139
29.964 MAX 1.140
If the pulley bore is not within specifications, the pulley
must be replaced.

Assemble
CAUTION
The mandrel must make contact on the inner race of
the bearing to prevent damage to the bearing.
Support the shaft in an arbor press.
Use an arbor press with water pump mandrel, Part
Number ST-658 (4), or equivalent to install the bearings.

Install the retaining clip with the beveled side of the clip
facing away from the bearing.
Signature, ISX, and QSX15 Eng [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-61

Support the water pump housing on a table with the pulley


end facing up.
Install the shaft and bearing assembly into the bearing
bore with the smaller bearing end of the assembly entering
first.
If the shaft does not drop into position from its weight, the
assembly can be pressed into place.

Install the retaining clip with the beveled side of the clip
facing away from the bearing.

CAUTION
To reduce the possibility of damage to the water pump
housing, make sure the impeller end of the shaft is
supported before pressing on the pulley.
Support the impeller end of the shaft in a press.
Press on the pulley until it is flush with the end of the shaft.
Make sure the pulley rotates freely.

Press the water pump seal onto the shaft.


Measure the water pump seal installed height.

Water Pump Seal Installed Height


mm in
10.919 MIN 0.430
11.679 MAX 0.460
If the water pump seal installed height is not within
specifications, the seal must be removed and installed
again.
Water Pump Signature, ISX, and QSX15 Eng [...]
Page 8-62 Section 8 - Cooling System - Group 08

Support the water pump in a press with the pulley down.


Press the impeller, vane side up, onto the shaft until it is
flush with the end of the shaft.

CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.

CAUTION
Make sure the o-ring is seated properly. If the o-ring
is not seated properly it can be damaged during
impeller cover installation.
Lubricate the impeller cover o-ring with soapy water.
Install the cover o-ring into the water pump housing.

CAUTION
Do not use petroleum lubricant on the impeller cover,
o-ring damage can result from the use of petroleum
lubricant.
Lubricate the outside diameter of the impeller cover and
the o-ring bore with soapy water.
Support the water pump in a press.
Press the impeller cover into the bore until seated.

WARNING
The retaining clip contains extreme amounts of
potential energy. To reduce the possibility of personal
injury from the clip slipping, place the water pump in
a box prior to installing the retaining clip.
Place the water pump in a box.
Install the retaining clip.
Signature, ISX, and QSX15 Eng [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-63

Measure the impeller clearance between the impeller and


impeller cover with a feeler gauge.

Impeller Clearance
mm in
0.29 MIN 0.011
1.24 MAX 0.049

Install
Automotive with CM870

CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.
Lubricate and install the new o-ring seal.
Install the two guide studs.
Install the water pump and three capscrews.

Remove the two guide studs and install the remaining


mounting capscrews.
Tighten the capscrews.
Torque Value: 72 Nm [ 53 ft-lb ]

Automotive with CM570


Install a new o-ring seal in the water inlet.
Install the two guide studs.
Water Pump Signature, ISX, and QSX15 Eng [...]
Page 8-64 Section 8 - Cooling System - Group 08

CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.
Install a new o-ring seal in the water pump outlet groove.
Apply a thin layer of non-petroleum-based lubricant, such
as vegetable oil, to both o-ring seals.

Use clean engine oil to lubricate the threads and bottom


of the capscrew heads of all the water pump capscrews.
Install the water pump and two lower capscrews.
Tighten the capscrews to hold the pump in place.

NOTE: Some configurations do not use the middle


aluminum belt tensioner bracket shown. Refer to
Procedure 008-088 for the appropriate tensioner bracket
installation.
Install the belt tensioner bracket, if equipped, and
capscrews in the location shown.
Finger tighten all capscrews.

Tighten the water pump mounting capscrews in the


sequence and values shown.
Torque Value:
Capscrews 1, 2, 58 Nm [ 43 ft-lb ]
and 3
Capscrews 4 and 72 Nm [ 53 ft-lb ]
5
All Capscrews, 72 Nm [ 53 ft-lb ]
Engines Without
Belt Tensioner
Bracket
Signature, ISX, and QSX15 Eng [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-65

Industrial CM570 and Power Generation without


CM570
Install a new o-ring seal in the water inlet.
Install the two guide studs.

CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.
Install a new o-ring seal in the water pump outlet groove.
Apply a thin layer of non-petroleum-based lubricant, such
as vegetable oil, to both o-ring seals.

Use clean engine oil to lubricate the threads and bottom


of the capscrew heads of all the water pump capscrews.
Position the water pump on the engine.
Install the bottom two capscrews finger tight.

NOTE: Some configurations do not use the middle


aluminum belt tensioner bracket. Refer to Procedure
008-088 for the appropriate tensioner bracket installation.
NOTE: Early engines that did not have a slotted hole on
the middle aluminum belt tensioner idler bracket required
the vibration dampers to be removed to remove and install
the water pump.
Install the belt tensioner bracket, if equipped, and the
capscrews in the locations shown.
Finger tighten all capscrews.
Water Pump Signature, ISX, and QSX15 Eng [...]
Page 8-66 Section 8 - Cooling System - Group 08

Tighten the water pump mounting capscrews in the


sequence and values shown.
Torque Value:
Capscrews 1, 2, 58 Nm [ 43 ft-lb ]
and 3
Capscrews 4 and 72 Nm [ 53 ft-lb ]
5
All Capscrews, 72 Nm [ 53 ft-lb ]
Engines Without
Belt Tensioner
Bracket

Align the idler pulley (1) and the shaft of the pilot adapter
(2) with the belt tensioner bracket (3) using the guide pin
on the pilot adapter (4), if equipped.
Install the belt idler pulley and shaft on the belt idler
bracket using one washer and capscrew.
Tighten the capscrew.
Torque Value: 30 Nm [ 25 ft-lb ]
Install the dust seal.

Automotive With CM871

CAUTION
Do not use petroleum based lubricants, petroleum
based lubricants cause the o-ring to crack or swell,
leading to a coolant leak.
Install a new water pump inlet o-ring seal and a new EGR
tube outlet o-ring seal.
Install the five water pump housing capscrews.
Tighten the capscrews.
Torque Value: 72 Nm [ 53 ft-lb ]
Install the two bracket capscrews.
Tighten the capscrews.
Torque Value: 30 Nm [ 25 ft-lb ]
Install the EGR tube outlet capscrew.
Tighten the capscrew.
Torque Value: 30 Nm [ 25 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-67

Finishing Steps
Automotive with CM870
Fill the cooling system. Refer to Procedure 008-018.
Install the water pump drive belt and tensioner. Refer
to Procedure 008-080.
Install the refrigerant compressor drive belt. Refer to
Procedure 009-052.

Automotive with CM570


Install the vibration dampers, if removed. Refer to
Procedure 001-052.
Install the alternator. Refer to Procedure 013-001.
Install the water pump belt tensioner bracket and belt
tensioner. Refer to Procedure 008-080.
Install the alternator drive belt. Refer to Procedure
013-005.
Install the water pump drive belt. Refer to Procedure
008-003.
Fill the engine with heavy-duty coolant. Refer to
Procedure 008-018.
Start the engine and check for leaks.

Industrial CM570 and Power Generation without


CM570
Install the damper assembly, if removed. Refer to
Procedure 001-052.
Install the alternator. Refer to Procedure 013-001.
Install the alternator drive belt. Refer to Procedure
013-005.
Install the fan and water pump drive belt. Refer to
procedure 008-003.
Fill the engine with heavy-duty coolant. Refer to
Procedure 008-018.
Start the engine and check for leaks.

Automotive With CM871


Install the water pump cartridge. Refer to Procedure
008-102.
Install the refrigerant compressor drive belt. Refer to
Procedure 009-052.
Install the water pump drive belt and tensioner. Refer
to Procedure 008-080.
Fill the cooling system. Refer to Procedure 008-018.
Operate the engine and check for leaks.
Belt Tensioner, Automatic (Water Pump) Signature, ISX, and QSX15 Eng [...]
Page 8-68 Section 8 - Cooling System - Group 08

Belt Tensioner, Automatic (Water


Pump) (008-080)
Initial Check
All Applications
With the engine turned off and with the water pump/fan
belt installed, check that neither the top nor bottom
tensioner arm stop is touching the cast boss on the
tensioner body. If either of the stops is touching a boss,
the water pump/fan belt must be replaced. Check to make
sure the correct belt part number is being used if either
condition exists.

Check the tensioner pulley and body for cracks. If any


cracks are noticed, the tensioner must be replaced.

Using a inch square drive, lift belt tensioner to relieve


tension on the belt.
Remove the water pump/fan belt.
The belt tensioner is spring-loaded and must be pivoted
away from the drive belt. Pivoting in the wrong direction
can result in damage to the belt tensioner.
If the tensioner pulley touches the accessory drive pulley
after the tensioner has been fully relaxed, the bottom
tensioner arm stop boss has broken and the tensioner
must be replaced.

Make sure the bottom tensioner arm stop is in contact with


the bottom tensioner arm stop boss on the tensioner body.
If these two are not contacting, the tensioner must be
replaced.
Signature, ISX, and QSX15 Eng [...] Belt Tensioner, Automatic (Water Pump)
Section 8 - Cooling System - Group 08 Page 8-69

Preparatory Steps
Drives Alternator

CAUTION
The belt tensioner is spring loaded and must be
pivoted away from the drive belt. Pivoting in the
wrong direction can result in damage to the belt
tensioner or personal injury.
Remove the cooling fan belt. Refer to Procedure
008-002.

Remove
Drives Alternator
Remove the mounting capscrew and the belt tensioner
from the bracket.

Automotive Applications
NOTE: Different engine configurations utilize different belt
tensioner bracket and belt tensioner arrangements.
For the low-mount belt tensioner:
Remove the belt tensioner mounting capscrew and belt
tensioner from the bracket.
Remove the belt tensioner bracket from the water pump.

For the mid-mount belt tensioner:


Remove the belt tensioner mounting capscrew and the
belt tensioner from the bracket.
The mid-mount aluminum belt tensioner/idler bracket is
part of the water pump removal and installation because
of common capscrew usage. Refer to Procedure 008-062.
Belt Tensioner, Automatic (Water Pump) Signature, ISX, and QSX15 Eng [...]
Page 8-70 Section 8 - Cooling System - Group 08

Industrial and Power Generation


For the low-mount (small version) belt tensioner:
Remove the belt tensioner mounting capscrew and belt
tensioner from the bracket.

Remove the belt tensioner bracket from the front engine


support.

For the low-mount (large version) belt tensioner:


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

Remove the belt tensioner bracket from the front engine


support.
Signature, ISX, and QSX15 Eng [...] Belt Tensioner, Automatic (Water Pump)
Section 8 - Cooling System - Group 08 Page 8-71

Clean and Inspect for Reuse


All Applications

WARNING
The belt tensioner is spring loaded. Do not attempt to
disassemble the tensioner. Severe personal injury can
result.

WARNING
When using solvents, acids or alkaline materials for
cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
Check the tensioner for dirt buildup. If the tensioner has
dirt buildup, remove and clean with safety solvent.

Pivot the tensioner through the full range of motion.


Tensioner must move with resistance while pivoting the
tensioner down. If not, replace the tensioner.
Check and make sure the correct belt part number is being
used.

Check the belt tensioner pulley and body for cracks or


damage. If any are found, replace the tensioner.
Inspect the tensioner arm stop bosses, for cracks or
damage. If cracks or damage is found, replace the
tensioner.

Spin the tensioner pulley. If pulley does not spin freely,


replace the tensioner.
Belt Tensioner, Automatic (Water Pump) Signature, ISX, and QSX15 Eng [...]
Page 8-72 Section 8 - Cooling System - Group 08

CM570

WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Check the tensioner for dirt buildup. If this condition
exists, the tensioner must be removed and steam-
cleaned.

Inspect the tensioner for evidence of the pivoting


tensioner arm contacting the stationary circular base. If
there is evidence of these two areas contacting, the pivot
tube bushing has failed and the tensioner must be
replaced.

Install
Drives Alternator
Install the belt tensioner and mounting capscrew.
Tighten the capscrew.
Torque Value: 50 Nm [ 37 ft-lb ]

Automotive Applications
For the low-mount belt tensioner:
Install the belt tensioner bracket to the water pump.
Tighten capscrew.
Torque Value: 34 Nm [ 25 ft-lb ]
Install the belt tensioner and capscrew.
Torque Value: 34 Nm [ 25 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Belt Tensioner, Automatic (Water Pump)
Section 8 - Cooling System - Group 08 Page 8-73

For the mid-mount belt tensioner:


Install the belt tensioner mounting capscrew and the belt
tensioner from the bracket.
The mid-mount aluminum belt tensioner/idler bracket is
part of the water pump removal and installation due to
common capscrew usage. Refer to Procedure 008-062.

Industrial and Power Generation


For the low-mount (small tensioner):
Install the belt tensioner bracket to the front engine
support with three mounting capscrews.
Torque Value: 56 Nm [ 41 ft-lb ]

Install the belt tensioner.


Torque Value: 56 Nm [ 41 ft-lb ]

For the low-mount (large tensioner):


Install the belt tensioner bracket to the front engine
support with three mounting capscrews.
Torque Value: 56 Nm [ 41 ft-lb ]
Water Inlet Connection Signature, ISX, and QSX15 Eng [...]
Page 8-74 Section 8 - Cooling System - Group 08

Install the belt tensioner.


Torque Value: 56 Nm [ 41 ft-lb ]

Finishing Steps
Drives Alternator

CAUTION
The belt tensioner is spring loaded and must be
pivoted away from the drive belt. Pivoting in the
wrong direction can result in damage to the belt
tensioner or personal injury.
Install the drive belt. Refer to Procedure 008-002.

Water Inlet Connection (008-082)


Preparatory Steps

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the cooling system. Refer to Procedure
008-018.
Remove the coolant filter. Refer to Procedure
008-006.
Remove the water pump. Refer to Procedure
008-062.
Signature, ISX, and QSX15 Eng [...] Fan Support
Section 8 - Cooling System - Group 08 Page 8-75

Remove
Remove the coolant hoses.
Remove the four capscrews, water inlet connection,
gasket, and o-ring.

Install
Replace the o-ring and gasket.
Install the gasket, water inlet connection, and the four
capscrews.
Tighten the capscrews.
Torque Value: 56 Nm [ 41 ft-lb ]
Install the coolant hoses.

Finishing Steps
Install the water pump. Refer to Procedure 008-062.
Install the coolant filter. Refer to Procedure 008-006.
Fill the engine with heavy-duty coolant. Refer to
Procedure 008-018.
Start the engine and check for leaks.

Fan Support (008-088)


Preparatory Steps
Industrial and Power Generation
Remove the fan and water pump drive belt. Refer to
Procedure 008-003.
Remove the alternator drive belt. Refer to Procedure
013-005.
Remove the alternator belt tensioner bracket. Refer
to Procedure 013-040.
Remove the fan pulley. Refer to Procedure 008-089.
Fan Support Signature, ISX, and QSX15 Eng [...]
Page 8-76 Section 8 - Cooling System - Group 08

Remove
Industrial and Power Generation
Remove the belt tensioner support bracket from the fan
support.

Remove two capscrews and install two guide studs.


Remove the remaining six capscrews.

Remove the fan support and guide studs.

Install
Industrial and Power Generation
Install two guide studs into the upper gear cover.
Signature, ISX, and QSX15 Eng [...] Fan Support
Section 8 - Cooling System - Group 08 Page 8-77

Use clean 15W40 oil to lubricate the capscrew threads.


Install six capscrews.
Remove the two guide studs and install the remaining two
capscrews.
Tighten the eight capscrews in the sequence shown.
Torque Value: 56 Nm [ 41 ft-lb ]

Install the belt tensioner support bracket to the engine and


fan support.
Tighten all eight capscrews finger tight.

Tighten cap