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Service Manual

Service Manual Signature, ISX, and QSX15 Volume 2


Cummins Inc.
Box 3005
Columbus, Indiana, U.S.A., 47202 Signature, ISX, and QSX15
Registered Office Volume 2
Cummins Ltd.
Unit 1-B Uniongate, Ridgeway Trading Estate,
Iver,
Buckinghamshire SL0 9HX,
England
Registration 573951 England

Copyright© 2007
Cummins Inc.

Bulletin 3666239
Printed in U.S.A. 09-AUGUST-2007 p41
Service Manual
Signature, ISX, and QSX15
Volume 2

Copyright© 2007 Bulletin 3666239


Cummins Inc. Printed 09-AUGUST-2007
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

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

Component Manufacturers ....................................................................................................................... M

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

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


Signature, ISX, and QSX15 Engi [...]
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
All Applications..............................................................................................................................................6-9
Initial Check......................................................................................................................................................6-6
With Pressurized Fuel Filtering.......................................................................................................................6-6
With Vacuum Fuel Filtering............................................................................................................................6-7
Install................................................................................................................................................................6-9
With Pressurized Fuel Filtering.......................................................................................................................6-9
With Priming Pump...................................................................................................................................... 6-10
Without Priming Pump..................................................................................................................................6-10
Remove............................................................................................................................................................6-8
With Pressurized Fuel Filtering.......................................................................................................................6-8
With Vacuum Fuel Filtering............................................................................................................................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 .............................................................................................................................................................6-13
Assemble........................................................................................................................................................6-21
Oil Seal........................................................................................................................................................6-21
Disassemble................................................................................................................................................... 6-19
Oil Seal........................................................................................................................................................6-19
Finishing Steps...............................................................................................................................................6-24
Inspect for Reuse............................................................................................................................................6-18
Install..............................................................................................................................................................6-23
Leak Test........................................................................................................................................................6-13
Preparatory Steps...........................................................................................................................................6-16
Remove.......................................................................................................................................................... 6-17
Service Tools ....................................................................................................................................................6-1
Injectors and Fuel Lines....................................................................................................................................6-1
Signature, ISX, and QSX15 Engi [...]
Page 6-b Section 6 - Injectors and Fuel Lines - Group 06

This Page Left Intentionally Blank


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

Service Tools
Injectors and Fuel Lines

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.

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 Engi [...]
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 Engi [...] 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 Engi [...]
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 Engi [...] 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 N•m [ 15 ft-lb ]
Install the ECM.
Install and tighten the five ECM mounting capscrews.
Torque Value: 20 N•m [ 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 N•m [ 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 Engi [...]
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
229 MAX 9
If restriction exceeds specifications, inspect the drain lines
for cause of 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 N•m [ 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.

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 run 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 Engi [...] 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 integrated fuel system module to measure
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 vent
line plumbed into the upper location. Refer to the following
procedure 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 Engi [...]
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 Engi [...] 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.
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 ¾ of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.

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 run for two minutes which
will adequately fill the fuel filter. The engine can then be
started.
Fuel Filter (Spin-On Type) Signature, ISX, and QSX15 Engi [...]
Page 6-10 Section 6 - Injectors and Fuel Lines - Group 06

With 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.
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 run for two minutes, which
will adequately fill the 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. Run the pump for two minutes and shut it off.
The engine can then be started.

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.
Apply a thin coating of clean engine oil to the filter gasket
surface and the center seal.
Signature, ISX, and QSX15 Engi [...] Fuel Inlet Restriction
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-11

CAUTION
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
NOTE: If the filter is equipped with a water-in-fuel sensor,
rotate the sensor on the filter to the desired location and
connect the wiring harness.
Fill the filter with clean fuel prior to installation.
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.

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


minutes until the air is out of the system.
Remove the external hex plug on the top of the integrated
fuel system module. Crank the engine until a solid stream
of fuel comes out of the port.
Install the hex plug.
Crank the engine for 20 seconds. If the engine does not
start within 20 seconds, wait two minutes. It will probably
be necessary to remove the filter, fill the filter with clean
fuel, and install the filter.
Repeat these steps until the engine starts.

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.

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 ]
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.
Fuel Inlet Restriction Signature, ISX, and QSX15 Engi [...]
Page 6-12 Section 6 - Injectors and Fuel Lines - Group 06

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.

Hold the vacuum gauge at the same level as the


integrated fuel system module connection.
Signature, ISX, and QSX15 Engi [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-13

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 (006-026)
Leak Test
This test checks for combustion gas leaks back through the injector rail check valve or other failure modes that will
allow 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 fails and 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 failed rail check valve. If a container of water
is used instead of a manometer, bubbles will be seen as air escapes through the failed rail check valve.
Injector Signature, ISX, and QSX15 Engi [...]
Page 6-14 Section 6 - Injectors and Fuel Lines - Group 06

The overhead set marks on the damper are used to identify which cylinder is on the compression stroke and therefore
which injector has failed 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 off the engine.


Signature, ISX, and QSX15 Engi [...] 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. Refer to Procedure 019-110 in the ISX Fuel
System Troubleshooting and Repair Manual, Bulletin
3666259.
Install the Injector Leak Test Kit, Part Number 3164001, in
its place.
Torque Value: 9 N•m [ 80 in-lb ]
Connect the flexible tubing to the hose fitting on the
mounting plate.
Place the flexible tubing into a container of water.

CAUTION
Use the engine barring device. Do not use the starting
motor to bar the engine during this test or engine
damage can result.
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 failure indicator is if bubbles
occur for an extended duration between timing marks.

Note between which two timing marks the bubbles occur.


Determine the failed injector by following the diagram.
If bubbles occur between:
A and B the number 3 injector has failed
B and C then number 1 injector has failed
C and A then number 2 injector has failed.

Remove the mounting plate connected to the port for the


front three cylinders. Install the fuel-metering actuator
removed previously. Refer to Procedure 019-110 in the
ISX Fuel System Troubleshooting and Repair Manual,
Bulletin 3666259.
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.
Place the flexible tubing into a container of water.
Torque Value: 9 N•m [ 80 in-lb ]
Repeat the above procedure the rear three cylinders.
Injector Signature, ISX, and QSX15 Engi [...]
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 then number 4 injector has failed
B and C then number 6 injector has failed
C and A then number 5 injector has failed.

Replace the failed injector(s). Refer to the injector removal


section in this procedure.

Preparatory Steps

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

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Drain coolant to below the cylinder head level. Refer
to Procedure 008-018.
• Remove the rocker lever cover. Refer to Procedure
003-011.
• Disconnect the engine brake solenoid wiring
harness. Refer to Procedure 020-015.
Signature, ISX, and QSX15 Engi [...] 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 injector rocker lever adjusting screws.
Remove six capscrews and injector rocker lever shaft.
Do not let rocker levers come off shaft during removal.

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

Loosen and back off 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 sure 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 Engi [...]
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 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 Engi [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-19

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

Use 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 Engi [...]
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 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
that the barrel is not damaged during oil seal removal.
Use a 3/32 inch punch, place the punch at an upward
angle 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 Engi [...] 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.

Assemble
Oil Seal

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.
Injector Signature, ISX, and QSX15 Engi [...]
Page 6-22 Section 6 - Injectors and Fuel Lines - Group 06

Place the injector holding fixture with injector into 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 shown.
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.

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.


Signature, ISX, and QSX15 Engi [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-23

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.

Install the spring retainer bracket.


Tighten the retainer capscrew.
Torque Value: 30 N•m [ 22 ft-lb ]
Install new injector o-rings.

Install
Use clean 15W-40 lubricating oil. Lubricate the o-rings.
Injector Signature, ISX, and QSX15 Engi [...]
Page 6-24 Section 6 - Injectors and Fuel Lines - Group 06

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 injector clamp, and capscrew with washer.
Tighten the capscrew.
Torque Value: 80 N•m [ 59 ft-lb ]
Install the crossheads.

Finishing Steps
• Install the injector rocker lever and valve rocker lever
assemblies. Refer to Procedure 003-009.
• Connect the engine brake solenoid wiring harness,
if equipped. Refer to Procedure 020-015.
• Adjust the overhead set as needed. Refer to
Procedure 003-004.
• Install the rocker lever cover. Refer to Procedure
003-011.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate 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.
Signature, ISX, and QSX15 Engi [...]
Section 7 - Lubricating Oil System - Group 07 Page 7-a

Section 7 - Lubricating Oil System - Group 07


Section Contents
Page
Centinel™ System ............................................................................................................................................7-55
General Information.........................................................................................................................................7-55
Lubricating Oil and Filter Analysis .................................................................................................................7-55
Inspect............................................................................................................................................................7-55
Lubricating Oil..............................................................................................................................................7-55
Lubricating Oil Filter.....................................................................................................................................7-56
Lubricating Oil Cooler .......................................................................................................................................7-3
Clean and Inspect for Reuse.............................................................................................................................7-5
All Applications..............................................................................................................................................7-5
Finishing Steps.................................................................................................................................................7-9
Automotive with CM870..................................................................................................................................7-9
Automotive, Industrial with CM570 and Power Generation without CM570......................................................7-9
Install................................................................................................................................................................7-8
All Applications..............................................................................................................................................7-8
Leak Test..........................................................................................................................................................7-7
All Applications..............................................................................................................................................7-7
Preparatory Steps.............................................................................................................................................7-3
Automotive with CM870..................................................................................................................................7-3
Automotive, Industrial with CM570 and Power Generation without CM570......................................................7-4
Remove............................................................................................................................................................7-4
All Applications..............................................................................................................................................7-4
Lubricating Oil Cooler Element .........................................................................................................................7-9
Assemble........................................................................................................................................................7-12
Single-Element.............................................................................................................................................7-12
Dual-Element............................................................................................................................................... 7-12
Clean and Inspect for Reuse...........................................................................................................................7-10
Disassemble.....................................................................................................................................................7-9
Single-Element...............................................................................................................................................7-9
Dual-Element............................................................................................................................................... 7-10
Finishing Steps...............................................................................................................................................7-13
Preparatory Steps.............................................................................................................................................7-9
Pressure Test..................................................................................................................................................7-11
Lubricating Oil Dipstick ...................................................................................................................................7-13
Calibrate.........................................................................................................................................................7-13
Lubricating Oil Dipstick Tube .........................................................................................................................7-14
Install..............................................................................................................................................................7-14
Automotive with CM870................................................................................................................................7-14
Automotive With CM871...............................................................................................................................7-15
Remove.......................................................................................................................................................... 7-14
Automotive with CM870................................................................................................................................7-14
Automotive With CM871...............................................................................................................................7-14
Lubricating Oil Fill Tube ................................................................................................................................. 7-49
Clean and Inspect for Reuse...........................................................................................................................7-51
Automotive with CM870................................................................................................................................7-51
Automotive With CM871...............................................................................................................................7-51
Install..............................................................................................................................................................7-52
Automotive with CM870................................................................................................................................7-52
Automotive With CM871...............................................................................................................................7-53
Remove.......................................................................................................................................................... 7-49
Automotive with CM870................................................................................................................................7-49
Automotive With CM871...............................................................................................................................7-50
Lubricating Oil Filter (Spin-On) .......................................................................................................................7-15
General Information.........................................................................................................................................7-15
Lubricating Oil..............................................................................................................................................7-15
Install..............................................................................................................................................................7-16
Remove.......................................................................................................................................................... 7-16
Lubricating Oil Filter Bypass Valve ................................................................................................................7-17
Signature, ISX, and QSX15 Engi [...]
Page 7-b Section 7 - Lubricating Oil System - Group 07

Clean..............................................................................................................................................................7-18
General Information.........................................................................................................................................7-17
Inspect for Reuse............................................................................................................................................7-18
Install..............................................................................................................................................................7-19
Remove.......................................................................................................................................................... 7-17
Lubricating Oil Filter Head Adapter ................................................................................................................7-20
Clean and Inspect for Reuse...........................................................................................................................7-21
Finishing Steps...............................................................................................................................................7-22
Install..............................................................................................................................................................7-21
Preparatory Steps...........................................................................................................................................7-20
Remove.......................................................................................................................................................... 7-20
Lubricating Oil High Pressure Relief Valve ....................................................................................................7-22
General Information.........................................................................................................................................7-22
Inspect for Reuse............................................................................................................................................7-23
Install..............................................................................................................................................................7-23
Remove.......................................................................................................................................................... 7-22
Lubricating Oil Leaks ......................................................................................................................................7-24
General Information.........................................................................................................................................7-24
Lubricating Oil Pan ..........................................................................................................................................7-26
Clean and Inspect for Reuse...........................................................................................................................7-27
Finishing Steps...............................................................................................................................................7-28
Install..............................................................................................................................................................7-27
Preparatory Steps...........................................................................................................................................7-26
Remove.......................................................................................................................................................... 7-26
Lubricating Oil Pressure Gauge ......................................................................................................................7-28
Test................................................................................................................................................................ 7-28
Lubricating Oil Pump ......................................................................................................................................7-29
Assemble........................................................................................................................................................7-37
Clean and Inspect for Reuse...........................................................................................................................7-31
Disassemble................................................................................................................................................... 7-29
Finishing Steps...............................................................................................................................................7-41
Install..............................................................................................................................................................7-39
Preparatory Steps...........................................................................................................................................7-29
Remove.......................................................................................................................................................... 7-29
Lubricating Oil Suction Tube (Block-Mounted) ..............................................................................................7-42
Finishing Steps...............................................................................................................................................7-43
Inspect for Reuse............................................................................................................................................7-42
Install..............................................................................................................................................................7-43
Preparatory Steps...........................................................................................................................................7-42
Remove.......................................................................................................................................................... 7-42
Lubricating Oil System ....................................................................................................................................7-44
Drain...............................................................................................................................................................7-44
Fill...................................................................................................................................................................7-46
Prime..............................................................................................................................................................7-44
Lubricating Oil Thermostat .............................................................................................................................7-47
Inspect for Reuse............................................................................................................................................7-47
Install..............................................................................................................................................................7-48
Remove.......................................................................................................................................................... 7-47
Service Tools ....................................................................................................................................................7-1
Lubricating Oil System......................................................................................................................................7-1
Signature, ISX, and QSX15 Engi [...] 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 the engine intake manifold pressure.
ST-1273

Oil Filter Wrench


Used to remove spin-on filter.
3397929

Female Quick Connect Coupler


Used to connect the priming pump to the engine.
3376859

Fluorescent Tracer Dye


Added to oil. Used with black light to find leaks.
3376891

Battery Black Light/Lamp (100 Watt)


To be used in conjunction with Part No. 3376891 and Part No.
3163337 3377438, fluorescent tracers, for fuel, oil, and coolant leaks.

Battery Black Light/Lamp (50 Watt)


To be used in conjunction with Part No. 3376891 and Part No.
3163338 3377438, fluorescent tracers, for fuel, oil, and coolant leaks.
Service Tools Signature, ISX, and QSX15 Engi [...]
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

Silicone Sealant
Used for sealing t-joints.
3823494
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Cooler
Section 7 - Lubricating Oil System - Group 07 Page 7-3

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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

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

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.
• Remove the lubricating oil filter. Refer to Procedure
007-013.
• Remove the variable geometry turbocharger. Refer
to Procedure 010-033.
• Remove the EGR valve. Refer to Procedure 011-022.
• Remove the EGR cooler connection. Refer to
Procedure 011-024.
• Remove the EGR cooler. Refer to Procedure
011-019.
Lubricating Oil Cooler Signature, ISX, and QSX15 Engi [...]
Page 7-4 Section 7 - Lubricating Oil System - Group 07

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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

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

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.
• Remove the lubricating oil filter. Refer to Procedure
007-013.
• Remove the turbocharger. This step is not required
with a die cast oil cooler. Refer to Procedure
010-033.
• Remove the alternator. Refer to Procedure 013-001.

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 oil passages.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Cooler
Section 7 - Lubricating Oil System - Group 07 Page 7-5

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

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.
Lubricating Oil Cooler Signature, ISX, and QSX15 Engi [...]
Page 7-6 Section 7 - Lubricating Oil System - Group 07

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.

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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Cooler
Section 7 - Lubricating Oil System - Group 07 Page 7-7

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 7°C [44°F].
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.

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].
Lubricating Oil Cooler Signature, ISX, and QSX15 Engi [...]
Page 7-8 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.
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 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 checked and tightened to the
specified torque.

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 passage.
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 center
out.
Torque Value: 47 N•m [ 35 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Cooler Element
Section 7 - Lubricating Oil System - Group 07 Page 7-9

Finishing Steps
Automotive with CM870
• Install the EGR cooler. Refer to Procedure 011-019.
• Install the EGR cooler connections. Refer to
Procedure 011-024.
• Install the EGR valve. Refer to Procedure 011-022.
• Install the lubricating oil filter. Refer to Procedure
007-013.
• Install the variable geometry turbocharger. Refer to
Procedure 010-033.
• Fill the cooling system. Refer to Procedure 008-018.
• Prime the lubricating oil system. Refer to Procedure
007-037.
• Fill the engine with clean oil.
• Operate engine to normal operating range and check
for oil and coolant leaks.

Automotive, Industrial with CM570 and Power


Generation without CM570
• Install the oil filter. Refer to Procedure 007-013.
• Install the alternator. Refer to Procedure 013-001.
• Install the turbocharger. Refer to Procedure 010-033.
• Fill the cooling system. Refer to Procedure 008-018.
• Prime the lubricating oil system. Refer to Procedure
007-037.
• 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.
Lubricating Oil Cooler Element Signature, ISX, and QSX15 Engi [...]
Page 7-10 Section 7 - Lubricating Oil System - Group 07

Dual-Element
Remove the elements from the lubricating oil filter head.
Remove the oil cooler tube.
Discard the gaskets.

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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Cooler Element
Section 7 - Lubricating Oil System - Group 07 Page 7-11

Inspect the oil cooler tube for cracks. Replace the cooler
tube if cracks are found.

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 N•m [ 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 Engi [...]
Page 7-12 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 N•m [ 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 N•m [ 15 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Dipstick
Section 7 - Lubricating Oil System - Group 07 Page 7-13

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 Engi [...]
Page 7-14 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 N•m [ 52 ft-lb ]
Tighten the clamp.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Filter (Spin-On)
Section 7 - Lubricating Oil System - Group 07 Page 7-15

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 N•m [ 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 20071 and CES 20076
oil classifications for turbocharged engines.
Lubricating Oil Filter (Spin-On) Signature, ISX, and QSX15 Engi [...]
Page 7-16 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 -5°C [23°F]. However,
the continuous use of low-viscosity oils can decrease
engine life.
Tthe accompanying chart to determine the best weight of
oil for the engine operating conditions.

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.
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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Filter Bypass Valve
Section 7 - Lubricating Oil System - Group 07 Page 7-17

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
82°C [180°F].
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.
Lubricating Oil Filter Bypass Valve Signature, ISX, and QSX15 Engi [...]
Page 7-18 Section 7 - Lubricating Oil System - Group 07

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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Filter Bypass Valve
Section 7 - Lubricating Oil System - Group 07 Page 7-19

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 N•m [ 33 ft-lb ]

Prime the lubricating oil system. Refer to Procedure


007-037.

Operate the engine to normal operating temperature and


check for leaks.
Lubricating Oil Filter Head Adapter Signature, ISX, and QSX15 Engi [...]
Page 7-20 Section 7 - Lubricating Oil System - Group 07

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 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.

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.
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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Filter Head Adapter
Section 7 - Lubricating Oil System - Group 07 Page 7-21

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 N•m [ 330 ft-lb ]
Lubricating Oil High Pressure Relief Valve Signature, ISX, and QSX15 Engi [...]
Page 7-22 Section 7 - Lubricating Oil System - Group 07

Finishing Steps
Fill the new oil filter with clean lubricating oil.
Install the lubricating oil filter. Refer to Procedure 007-013.
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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil High Pressure Relief Valve
Section 7 - Lubricating Oil System - Group 07 Page 7-23

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.
Lubricating Oil Leaks Signature, ISX, and QSX15 Engi [...]
Page 7-24 Section 7 - Lubricating Oil System - Group 07

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
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Leaks
Section 7 - Lubricating Oil System - Group 07 Page 7-25

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.
Lubricating Oil Pan Signature, ISX, and QSX15 Engi [...]
Page 7-26 Section 7 - Lubricating Oil System - Group 07

Check for a loose or missing oil dipstick tube, dipstick, or


oil filler cap.

Operate the engine until the water temperature reaches


82°C [180°F]. 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.

Remove
Remove the oil pan mounting capscrews, oil pan, and
gasket.
Discard the oil pan gasket.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pan
Section 7 - Lubricating Oil System - Group 07 Page 7-27

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.

Install a new oil pan gasket.


Install the oil pan onto the cylinder block. Use your fingers
to install one of the 13 mm oil pan mounting capscrews on
each side of the oil pan, halfway between the front and the
rear of the oil pan.
Finger-tighten all the mounting capscrews.
Lubricating Oil Pressure Gauge Signature, ISX, and QSX15 Engi [...]
Page 7-28 Section 7 - Lubricating Oil System - Group 07

Tighten the thirty-two 13 mm capscrews in the sequence


shown.
Torque Value: 55 N•m [ 41 ft-lb ]
Install the oil drain plug.
Torque Value: 47 N•m [ 35 ft-lb ]

Finishing Steps
Fill the lubricating oil pan. Refer to Procedure 007-037.
Operate the engine until the water temperature reaches
82°C [180°F], and check for leaks.

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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-29

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.
• Remove the lubricating oil pan. Refer to Procedure
007-025.
• Remove the lubricating oil suction tube. Refer to
Procedure 007-035.

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.

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.
Lubricating Oil Pump Signature, ISX, and QSX15 Engi [...]
Page 7-30 Section 7 - Lubricating Oil System - Group 07

The external idler gear has a left-handed thread capscrew.


Remove the external idler gear from the lubricating oil
pump.

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.

Remove the high-pressure relief spring and ball.


Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-31

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.

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.
Lubricating Oil Pump Signature, ISX, and QSX15 Engi [...]
Page 7-32 Section 7 - Lubricating Oil System - Group 07

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 lube 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 lube pump cover can be felt with a
fingernail, the part must be replaced.

Measure the regulator spring bore for beat-in.

Spring Beat-In Specification


mm in
186.95 MIN 7.3602
187.45 MAX 7.3799
If the regulator spring bore depth is not within the
specifications, the housing must be replaced.

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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-33

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 29.62
135.3 MAX 30.42
If the regulator spring is not within the specifications, the
spring must be replaced.

Inspect the high pressure relief spring for a broken coil or


rust.
Lubricating Oil Pump Signature, ISX, and QSX15 Engi [...]
Page 7-34 Section 7 - Lubricating Oil System - Group 07

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
281.47 MIN 63.277
298.87 MAX 67.189
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.

Discard the mounting bolt.


Inspect the external idler gear retainer.
Minor retainer scuff is acceptable. If the scuff can be felt
by a fingernail, replace the retainer.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-35

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.

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.
Lubricating Oil Pump Signature, ISX, and QSX15 Engi [...]
Page 7-36 Section 7 - Lubricating Oil System - Group 07

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
unacceptable. 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 0.9792
24.871 MAX 0.9787
If the idler shaft is not within specifications, it must be
replaced.

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 0.9792
24.871 MAX 0.9787
If the drive shaft is not within specifications, it must be
replaced.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-37

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.

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 N•m [ 21 ft-lb ]
Lubricating Oil Pump Signature, ISX, and QSX15 Engi [...]
Page 7-38 Section 7 - Lubricating Oil System - Group 07

Install the external idler gear using a new capscrew.


Insert the external idler gear retainer such that the holes
are at the 3 and 9 o'clock position.
The idler gear retainer has left-handed threads.
Torque Value: 115 N•m [ 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.

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
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-39

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 N•m [ 40 ft-lb ]

Using a dial indicator, check the oil pump idler gear back
lash.

Oil Pump Idler Gear Backlash


mm in
0.241 MIN 0.005
0.267 MAX 0.015
0.254 NOM 0.010
Lubricating Oil Pump Signature, ISX, and QSX15 Engi [...]
Page 7-40 Section 7 - Lubricating Oil System - Group 07

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 block (2). Use the
following table to determine which shim should be used
according to the stamped number.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-41

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]- 0.45 mm [0.018 in]-Black- 0.55 mm [0.022 in]- 0.35 mm [0.014 in]-
None- Purple- Yellow-
2 0.45 mm [0.018 in]- 0.65 mm [0.026 in]-Red- 0.75 mm [0.030 in]-Blue- 0.55 mm [0.022 in]-
Black- Purple-
3 0.55 mm [0.022 in]- 0.75 mm [0.030 in]-Blue- 0.85 mm [0.033 in]- 0.65 mm [0.026 in]-Red-
Purple- Green-
4 0.35 mm [0.014 in]- 0.55 mm [0.022 in]- 0.65 mm [0.026 in]-Red- 0.45 mm [0.018 in]-Black-
Yellow- Purple-

Check the oil pump idler gear backlash.

Oil Pump Idler Gear Backlash


mm in
0.254 NOMINAL 0.010
±0.13 TOLERANCE ±0.005

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.
• Install the lubricating oil pan. Refer to Procedure
007-025.
• Fill the engine with lubricating oil. Refer to Procedure
007-037.
Lubricating Oil Suction Tube (Block-Mounted) Signature, ISX, and QSX15 Engi [...]
Page 7-42 Section 7 - Lubricating Oil System - Group 07

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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Suction Tube (Block-Mounted)
Section 7 - Lubricating Oil System - Group 07 Page 7-43

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 N•m [ 35 ft-lb ]

Finishing Steps
Install the lubricating oil pan. Refer to Procedure 007-025.
Fill engine with oil. Refer to Procedure 007-037.
Lubricating Oil System Signature, ISX, and QSX15 Engi [...]
Page 7-44 Section 7 - Lubricating Oil System - Group 07

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
60°C [140°F].
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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil System
Section 7 - Lubricating Oil System - Group 07 Page 7-45

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 N•m [ 25 ft-lb ]

Check the oil level on the dipstick before adding additional


oil.
If necessary, fill the engine with lubricating oil.
Lubricating Oil System Signature, ISX, and QSX15 Engi [...]
Page 7-46 Section 7 - Lubricating Oil System - Group 07

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
82°C [180°F], 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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Thermostat
Section 7 - Lubricating Oil System - Group 07 Page 7-47

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.
Remove the water pump. Refer to Procedure 008-062.
Remove the thermostat plug.
Remove the tapered snap ring.
Remove the thermostat from lubricating oil cooler
housing.

Inspect for Reuse

WARNING
The flash point of new lubricating oil is approximately
221°C [430°F]. Do not allow the oil temperature in the
container to exceed 149°C [300°F]. 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 127°C [260°F]
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 127°C [260°F].
Replace the thermostat if it does not operate as
described.
Lubricating Oil Thermostat Signature, ISX, and QSX15 Engi [...]
Page 7-48 Section 7 - Lubricating Oil System - Group 07

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 007-039.

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 N•m [ 74 ft-lb ]
Install the alternator. Refer to Procedure 013-001.
Install the water pump. Refer to Procedure 008-062.

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 Engi [...] Lubricating Oil Fill Tube
Section 7 - Lubricating Oil System - Group 07 Page 7-49

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.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Engi [...]
Page 7-50 Section 7 - Lubricating Oil System - Group 07

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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Fill Tube
Section 7 - Lubricating Oil System - Group 07 Page 7-51

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.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Engi [...]
Page 7-52 Section 7 - Lubricating Oil System - Group 07

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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Fill Tube
Section 7 - Lubricating Oil System - Group 07 Page 7-53

Install and tighten the tube brace gear cover capscrew (2).
Torque Value: 28 N•m [ 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.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Engi [...]
Page 7-54 Section 7 - Lubricating Oil System - Group 07

Install the oil fill tube cap and the oil fill tube.

Install and tighten the tube brace gear cover capscrews.


Torque Value: 28 N•m [ 21 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Lubricating Oil and Filter Analysis
Section 7 - Lubricating Oil System - Group 07 Page 7-55

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.
Lubricating Oil and Filter Analysis Signature, ISX, and QSX15 Engi [...]
Page 7-56 Section 7 - Lubricating Oil System - Group 07

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
Signature, ISX, and QSX15 Engi [...]
Section 8 - Cooling System - Group 08 Page 8-a

Section 8 - Cooling System - Group 08


Section Contents
Page
Belt Tensioner, Automatic (Water Pump) .......................................................................................................8-61
Clean and Inspect for Reuse...........................................................................................................................8-64
All Applications.............................................................................................................................................8-64
CM570.........................................................................................................................................................8-65
Finishing Steps...............................................................................................................................................8-67
Drives Alternator.......................................................................................................................................... 8-67
Initial Check....................................................................................................................................................8-61
All Applications.............................................................................................................................................8-61
Install..............................................................................................................................................................8-66
Drives Alternator.......................................................................................................................................... 8-66
Automotive Applications...............................................................................................................................8-66
Industrial and Power Generation...................................................................................................................8-66
Preparatory Steps...........................................................................................................................................8-62
Drives Alternator.......................................................................................................................................... 8-62
Remove.......................................................................................................................................................... 8-62
Drives Alternator.......................................................................................................................................... 8-62
Automotive Applications...............................................................................................................................8-63
Industrial and Power Generation...................................................................................................................8-63
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 Engi [...]
Page 8-b Section 8 - Cooling System - Group 08

Drain...............................................................................................................................................................8-23
Fill...................................................................................................................................................................8-26
Flush...............................................................................................................................................................8-24
Pressure Test..................................................................................................................................................8-29
Cooling System - Air or Combustion Gas Test ..............................................................................................8-30
Initial Check....................................................................................................................................................8-30
Air in Cooling System...................................................................................................................................8-30
Leak Test........................................................................................................................................................8-31
Fan, Shutter, or Heater Air Control Valve......................................................................................................8-31
Air Compressor............................................................................................................................................8-32
Overflow Method..........................................................................................................................................8-33
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 ..........................................................................................................................................8-34
Initial Check....................................................................................................................................................8-34
With Low Temperature Fan-On Control.........................................................................................................8-34
With High Temperature Fan On....................................................................................................................8-35
Fan, Cooling ....................................................................................................................................................8-41
Inspect for Reuse............................................................................................................................................8-41
Install..............................................................................................................................................................8-42
Remove.......................................................................................................................................................... 8-41
Fan Hub, Belt Driven .......................................................................................................................................8-36
Clean and Inspect for Reuse...........................................................................................................................8-38
Automotive with CM870................................................................................................................................8-38
Automotive, Industrial with CM570 and Power Generation without CM570....................................................8-38
Finishing Steps...............................................................................................................................................8-40
Automotive with CM870................................................................................................................................8-40
Automotive with CM570................................................................................................................................8-40
Industrial CM570 and Power Generation without CM570...............................................................................8-40
Install..............................................................................................................................................................8-39
Automotive with CM870................................................................................................................................8-39
Automotive with CM570................................................................................................................................8-39
Industrial CM570 and Power Generation without CM570...............................................................................8-39
Preparatory Steps...........................................................................................................................................8-36
Automotive with CM870................................................................................................................................8-36
Automotive with CM570................................................................................................................................8-36
Industrial CM570 and Power Generation without CM570...............................................................................8-37
Remove.......................................................................................................................................................... 8-37
Automotive with CM870................................................................................................................................8-37
Automotive with CM570................................................................................................................................8-37
Industrial CM570 and Power Generation without CM570...............................................................................8-37
Fan Pulley ........................................................................................................................................................8-72
Inspect for Reuse............................................................................................................................................8-72
Install..............................................................................................................................................................8-73
Industrial and Power Generation...................................................................................................................8-73
Remove.......................................................................................................................................................... 8-72
Industrial and Power Generation...................................................................................................................8-72
Fan Shroud Assembly .....................................................................................................................................8-40
Initial Check....................................................................................................................................................8-40
Fan Support .....................................................................................................................................................8-69
Finishing Steps...............................................................................................................................................8-71
Industrial and Power Generation...................................................................................................................8-71
Install..............................................................................................................................................................8-70
Signature, ISX, and QSX15 Engi [...]
Section 8 - Cooling System - Group 08 Page 8-c

Industrial and Power Generation...................................................................................................................8-70


Preparatory Steps...........................................................................................................................................8-69
Industrial and Power Generation...................................................................................................................8-69
Remove..........................................................................................................................................................8-69
Industrial and Power Generation...................................................................................................................8-69
Radiator ...........................................................................................................................................................8-42
Initial Check....................................................................................................................................................8-42
Radiator Hoses ................................................................................................................................................8-43
Inspect for Reuse............................................................................................................................................8-43
Radiator Pressure Cap ....................................................................................................................................8-43
Inspect for Reuse............................................................................................................................................8-43
....................................................................................................................................................................8-43
Radiator Shutter Assembly .............................................................................................................................8-44
General Information.........................................................................................................................................8-44
Service Tools ....................................................................................................................................................8-1
Cooling System.................................................................................................................................................8-1
Water Inlet Connection ...................................................................................................................................8-68
Finishing Steps...............................................................................................................................................8-69
Install..............................................................................................................................................................8-68
Preparatory Steps...........................................................................................................................................8-68
Remove..........................................................................................................................................................8-68
Water Pump .....................................................................................................................................................8-45
Assemble........................................................................................................................................................8-53
Clean..............................................................................................................................................................8-48
Automotive With CM871...............................................................................................................................8-48
Clean and Inspect for Reuse...........................................................................................................................8-51
Disassemble...................................................................................................................................................8-49
Finishing Steps...............................................................................................................................................8-60
Automotive with CM870................................................................................................................................8-60
Automotive with CM570................................................................................................................................8-60
Industrial CM570 and Power Generation without CM570...............................................................................8-61
Automotive With CM871...............................................................................................................................8-61
Install..............................................................................................................................................................8-56
Automotive with CM870................................................................................................................................8-56
Automotive with CM570................................................................................................................................8-57
Industrial CM570 and Power Generation without CM570...............................................................................8-58
Automotive With CM871...............................................................................................................................8-60
Measure..........................................................................................................................................................8-52
Preparatory Steps...........................................................................................................................................8-45
Automotive with CM870................................................................................................................................8-45
Automotive with CM570................................................................................................................................8-45
Industrial CM570 and Power Generation without CM570...............................................................................8-46
Automotive with CM871................................................................................................................................8-46
Remove..........................................................................................................................................................8-46
Automotive with CM870................................................................................................................................8-46
Automotive with CM570................................................................................................................................8-47
Industrial CM570 and Power Generation without CM570...............................................................................8-47
Automotive With CM871...............................................................................................................................8-48
Water Pump Cartridge .....................................................................................................................................8-74
Finishing Steps...............................................................................................................................................8-74
Preparatory Steps...........................................................................................................................................8-74
Automotive With CM871...............................................................................................................................8-74
Signature, ISX, and QSX15 Engi [...]
Page 8-d Section 8 - Cooling System - Group 08

This Page Left Intentionally Blank


Signature, ISX, and QSX15 Engi [...] 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 Engi [...]
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 Engi [...] 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 Engi [...]
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 Engi [...] 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 Engi [...]
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 50°C
[120°F] 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 ½ to ¾ 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 Engi [...] 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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Operate the engine until the coolant temperature is above
82°C [180°F], 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 Engi [...]
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 Engi [...] 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 N•m [ 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 Engi [...]
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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the 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 Engi [...] 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 50°C
[120°F] 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 Engi [...]
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 Engi [...] Coolant Thermostat
Section 8 - Cooling System - Group 08 Page 8-13

Suspend the thermostat and a 100°C [212°F]


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 1°C [2°F]
of nominal temperature.
• The thermostat must be fully open to at least 11 mm
[0.435 in] within 12°C [22°F] 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 34 N•m [ 25 ft-lb ]
Capscrews
Long 56 N•m [ 41 ft-lb ]
Capscrews
Coolant Thermostat Signature, ISX, and QSX15 Engi [...]
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 N•m [ 20 ft-lb ]

Install the upper radiator hose. Tighten the hose clamp.


Torque Value: 5 N•m [ 40 in-lb ]

Finishing Steps
Fill the cooling system. Refer to Procedure 008-018.
Operate the engine until the coolant temperature reaches
70°C [160°F]. Check for leaks.
Signature, ISX, and QSX15 Engi [...] 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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Drain the 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 Engi [...]
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 Engi [...] 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 Engi [...]
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 N•m [ 33 ft-lb ]
Signature, ISX, and QSX15 Engi [...] 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 N•m [ 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 N•m [ 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 Engi [...]
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 34 N•m [ 25 ft-lb ]
capscrews
Long 56 N•m [ 41 ft-lb ]
capscrews

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 N•m [ 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 N•m [ 20 ft-lb ]
Automotive has a similar design with connector for
transmission cooler.
Signature, ISX, and QSX15 Engi [...] 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 70°C [158°F] 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 Engi [...]
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 Engi [...] 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 Engi [...]
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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Remove the radiator cap after the engine is cool.

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 container must be free
of oil and dirt. Before pouring coolant back into the engine,
it must be tested for SCA concentration. Refer to
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.
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 Engi [...] 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,
or 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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Operate the engine at normal operating temperatures, at
least 85°C [185°F] 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 Engi [...]
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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Operate the engine at high idle for five minutes with the
coolant temperature above 85°C [185°F].
Shut off the engine and drain the cooling system.
If the water being drained is still dirty, the system must be
continually 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. Refer to 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.

Fill
Close the radiator draincocks.
Install the lower radiator hose(s).
Tighten the hose clamps.
Torque Value: 5 N•m [ 40 in-lb ]
Signature, ISX, and QSX15 Engi [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-27

Cummins Inc. recommends using 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 using Fleetguard®


COMPLEAT ES. 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. Refer to 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, for the correct filter.
Cooling System Signature, ISX, and QSX15 Engi [...]
Page 8-28 Section 8 - Cooling System - Group 08

NOTE: Some radiators have two fill locations, both of


which must be filled when the cooling system is 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 [180°F], and check for leaks.

Shut off the engine and allow to cool.

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

CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50°C [120°F] 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.
Signature, ISX, and QSX15 Engi [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-29

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.

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 per
Procedure 008-047 and replace, if necessary.
Cooling System - Air or Combustion Gas Test Signature, ISX, and QSX15 Engi [...]
Page 8-30 Section 8 - Cooling System - Group 08

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 50°C
[120°F] 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 Coolant
Recommendations and Specifications in Section V of this
manual and Service Bulletin 3810340 for a description.

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 82°C
[180°F].
Check for a continuous flow of air bubbles from the hose
into the water container.
Signature, ISX, and QSX15 Engi [...] Cooling System - Air or Combustion Gas Test
Section 8 - Cooling System - Group 08 Page 8-31

A continuous flow of air bubbles can be caused by one of


the following:
• An air compressor cylinder head leak. Refer to Leak
Test - Air Compressor in this procedure.
• Fan, shutter, or heater air control thermostat valve
leaking air. Refer to Leak Test - Fan, Shutter, or
Heater Air Control Valve in this procedure.
• A cracked cylinder head. Refer to Cylinder Head
Crack Detection Test in Procedure 002-004.
• A cylinder head gasket combustion leak. Refer to
Combustion Gas Leak - Overlfow 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 80°C [180°F],
and check for coolant leaks.

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 [212°F] 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.
Cooling System - Air or Combustion Gas Test Signature, ISX, and QSX15 Engi [...]
Page 8-32 Section 8 - Cooling System - Group 08

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.

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.
Signature, ISX, and QSX15 Engi [...] Cooling System - Air or Combustion Gas Test
Section 8 - Cooling System - Group 08 Page 8-33

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.

Overflow Method

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

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 82°C [180°F].
Check for a continuous flow of air bubbles from the hose
in the water container.
Fan Clutch, On-Off Signature, ISX, and QSX15 Engi [...]
Page 8-34 Section 8 - Cooling System - Group 08

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.

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 99°C
[210°F], 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.
Signature, ISX, and QSX15 Engi [...] Fan Clutch, On-Off
Section 8 - Cooling System - Group 08 Page 8-35

The fan clutch must disengage when the coolant


temperature drops to 96°C [205°F].
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.

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 110°C
[215°F], 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.
Fan Hub, Belt Driven Signature, ISX, and QSX15 Engi [...]
Page 8-36 Section 8 - Cooling System - Group 08

Return the engine to idle and remove the radiator air


restriction.

The fan clutch must disengage before the coolant


temperature drops to 93°C [200°F]. Cummins Inc.
recommends that the fan disengage at 3°C [6°F] below
the temperature stamped on the temperature sensor.
NOTE: The temperature given for fan disengagement is
for fans controlled by the ECM.

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.
Signature, ISX, and QSX15 Engi [...] Fan Hub, Belt Driven
Section 8 - Cooling System - Group 08 Page 8-37

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.

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.
Fan Hub, Belt Driven Signature, ISX, and QSX15 Engi [...]
Page 8-38 Section 8 - Cooling System - Group 08

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.

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
Signature, ISX, and QSX15 Engi [...] Fan Hub, Belt Driven
Section 8 - Cooling System - Group 08 Page 8-39

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 N•m [ 83 ft-lb ]

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 N•m [ 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 N•m [ 66 ft-lb ]
Fan Shroud Assembly Signature, ISX, and QSX15 Engi [...]
Page 8-40 Section 8 - Cooling System - Group 08

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.

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.
Signature, ISX, and QSX15 Engi [...] Fan, Cooling
Section 8 - Cooling System - Group 08 Page 8-41

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 (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.
Radiator Signature, ISX, and QSX15 Engi [...]
Page 8-42 Section 8 - Cooling System - Group 08

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.

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.
Signature, ISX, and QSX15 Engi [...] Radiator Pressure Cap
Section 8 - Cooling System - Group 08 Page 8-43

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.

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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Remove the radiator pressure cap.
Radiator Shutter Assembly Signature, ISX, and QSX15 Engi [...]
Page 8-44 Section 8 - Cooling System - Group 08

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.

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.
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-45

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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

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

Automotive with CM570

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

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Drain the 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.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-46 Section 8 - Cooling System - Group 08

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 50°C
[120°F] 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.

Automotive with CM871

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

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Drain the 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.
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-47

Remove the remaining three capscrews, the water pump,


and the o-ring seal.
Discard the o-ring seal.

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.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-48 Section 8 - Cooling System - Group 08

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.

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.
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-49

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.

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.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-50 Section 8 - Cooling System - Group 08

Position the water pump with the pulley end facing up.
Remove the bearing bore retaining clip.

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).
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-51

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.

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.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-52 Section 8 - Cooling System - Group 08

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.

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.
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-53

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.

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.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-54 Section 8 - Cooling System - Group 08

Install the retaining clip with the beveled side of the clip
facing away from the bearing.

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.
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-55

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.

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.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-56 Section 8 - Cooling System - Group 08

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.

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 N•m [ 53 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-57

Automotive with 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.
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.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-58 Section 8 - Cooling System - Group 08

Tighten the water pump mounting capscrews in the


sequence and values shown.
Torque Value:
Capscrews 1, 58 N•m [ 43 ft-lb ]
2, and 3
Capscrews 4 72 N•m [ 53 ft-lb ]
and 5
All Capscrews, 72 N•m [ 53 ft-lb ]
Engines
Without Belt
Tensioner
Bracket

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.
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-59

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.

Tighten the water pump mounting capscrews in the


sequence and values shown.
Torque Value:
Capscrews 1, 58 N•m [ 43 ft-lb ]
2, and 3
Capscrews 4 72 N•m [ 53 ft-lb ]
and 5
All Capscrews, 72 N•m [ 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 N•m [ 25 ft-lb ]
Install the dust seal.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-60 Section 8 - Cooling System - Group 08

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 N•m [ 53 ft-lb ]
Install the two bracket capscrews.
Tighten the capscrews.
Torque Value: 30 N•m [ 25 ft-lb ]
Install the EGR tube outlet capscrew.
Tighten the capscrew.
Torque Value: 30 N•m [ 25 ft-lb ]

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.
Signature, ISX, and QSX15 Engi [...] Belt Tensioner, Automatic (Water Pump)
Section 8 - Cooling System - Group 08 Page 8-61

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) (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.
Belt Tensioner, Automatic (Water Pump) Signature, ISX, and QSX15 Engi [...]
Page 8-62 Section 8 - Cooling System - Group 08

Using a ½ 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.

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.
Signature, ISX, and QSX15 Engi [...] Belt Tensioner, Automatic (Water Pump)
Section 8 - Cooling System - Group 08 Page 8-63

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.

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.
Belt Tensioner, Automatic (Water Pump) Signature, ISX, and QSX15 Engi [...]
Page 8-64 Section 8 - Cooling System - Group 08

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.

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.
Signature, ISX, and QSX15 Engi [...] Belt Tensioner, Automatic (Water Pump)
Section 8 - Cooling System - Group 08 Page 8-65

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.

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.
Belt Tensioner, Automatic (Water Pump) Signature, ISX, and QSX15 Engi [...]
Page 8-66 Section 8 - Cooling System - Group 08

Install
Drives Alternator
Install the belt tensioner and mounting capscrew.
Tighten the capscrew.
Torque Value: 50 N•m [ 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 N•m [ 25 ft-lb ]
Install the belt tensioner and capscrew.
Torque Value: 34 N•m [ 25 ft-lb ]

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 N•m [ 41 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Belt Tensioner, Automatic (Water Pump)
Section 8 - Cooling System - Group 08 Page 8-67

Install the belt tensioner.


Torque Value: 56 N•m [ 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 N•m [ 41 ft-lb ]

Install the belt tensioner.


Torque Value: 56 N•m [ 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 Signature, ISX, and QSX15 Engi [...]
Page 8-68 Section 8 - Cooling System - Group 08

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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

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

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 N•m [ 41 ft-lb ]
Install the coolant hoses.
Signature, ISX, and QSX15 Engi [...] Fan Support
Section 8 - Cooling System - Group 08 Page 8-69

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.

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.
Fan Support Signature, ISX, and QSX15 Engi [...]
Page 8-70 Section 8 - Cooling System - Group 08

Remove the fan support and guide studs.

Install
Industrial and Power Generation
Install two guide studs into the upper gear cover.

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 N•m [ 41 ft-lb ]

Install the belt tensioner support bracket to the engine and


fan support.
Tighten all eight capscrews finger tight.
Signature, ISX, and QSX15 Engi [...] Fan Support
Section 8 - Cooling System - Group 08 Page 8-71

Tighten capscrew numbers 1 and 2 finger tight to mate the


surfaces of the belt tensioner support bracket to the fan
support.

Tighten capscrew numbers 3, 4, 5, and 6.


Torque Value: 90 N•m [ 66 ft-lb ]

Tighten capscrew numbers 1, 2, 7, and 8.


Torque Value: 56 N•m [ 41 ft-lb ]

Finishing Steps
Industrial and Power Generation
• Install the fan pulley. Refer to Procedure 008-089.
• Install the alternator belt tensioner bracket. Refer to
Procedure 013-040.
• Install the alternator drive belt. Refer to Procedure
013-005.
• Install the fan and water pump drive belt. Refer to
Procedure 008-003.
Fan Pulley Signature, ISX, and QSX15 Engi [...]
Page 8-72 Section 8 - Cooling System - Group 08

Fan Pulley (008-089)


Remove
Industrial and Power Generation
Remove the fan and water pump belt. Refer to Procedure
008-003.

Remove the alternator drive belt. Refer to Procedure


013-005.

Remove six capscrews and the pulley from the fan


support.

Inspect for Reuse


Inspect the pulley for cracks, excessive wear in the belt
grooves, or other damage.
Signature, ISX, and QSX15 Engi [...] Fan Pulley
Section 8 - Cooling System - Group 08 Page 8-73

Install
Industrial and Power Generation
Install the fan pulley using six capscrews.
Tighten the capscrews in a star pattern.
Torque Value: 95 N•m [ 70 ft-lb ]

Install the alternator drive belt. Refer to Procedure


013-005.

Install the fan and water pump drive belt. Refer to


Procedure 008-003.
Water Pump Cartridge Signature, ISX, and QSX15 Engi [...]
Page 8-74 Section 8 - Cooling System - Group 08

Water Pump Cartridge (008-102)


Preparatory Steps
Automotive With CM871

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

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

Finishing Steps
• 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.
Signature, ISX, and QSX15 Engi [...]
Section 9 - Drive Units - Group 09 Page 9-a

Section 9 - Drive Units - Group 09


Section Contents
Page
Alternator/Refrigerant Compressor Mounting Bracket .................................................................................. 9-13
Finishing Steps...............................................................................................................................................9-16
Automotive with CM870................................................................................................................................9-16
Automotive with CM570................................................................................................................................9-16
Inspect for Reuse............................................................................................................................................9-14
Automotive with CM870................................................................................................................................9-14
Automotive with CM570................................................................................................................................9-14
Install..............................................................................................................................................................9-15
Automotive with CM870................................................................................................................................9-15
Automotive with CM570................................................................................................................................9-15
Preparatory Steps...........................................................................................................................................9-13
Automotive with CM870................................................................................................................................9-13
Automotive with CM570................................................................................................................................9-13
Remove.......................................................................................................................................................... 9-13
Automotive with CM870................................................................................................................................9-13
Automotive with CM570................................................................................................................................9-14
Belt Tensioner, Refrigerant Compressor, Automatic .......................................................................................9-5
Finishing Steps.................................................................................................................................................9-6
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-6
Initial Check......................................................................................................................................................9-5
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-5
Install................................................................................................................................................................9-6
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-6
Preparatory Steps.............................................................................................................................................9-6
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-6
Remove............................................................................................................................................................9-6
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-6
Drive Belt, Refrigerant Compressor .................................................................................................................9-3
Clean and Inspect for Reuse.............................................................................................................................9-3
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-3
Finishing Steps.................................................................................................................................................9-4
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-4
Install................................................................................................................................................................9-4
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-4
Preparatory Steps.............................................................................................................................................9-3
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-3
Remove............................................................................................................................................................9-3
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-3
Idler Pulley, Refrigerant Compressor ...............................................................................................................9-7
Finishing Steps.................................................................................................................................................9-8
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-8
Inspect for Reuse..............................................................................................................................................9-7
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-7
Install................................................................................................................................................................9-7
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-7
Preparatory Steps.............................................................................................................................................9-7
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-7
Remove............................................................................................................................................................9-7
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-7
Refrigerant Compressor ....................................................................................................................................9-1
Clean and Inspect for Reuse.............................................................................................................................9-2
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-2
Climate Control Incorporated..........................................................................................................................9-2
Finishing Steps.................................................................................................................................................9-3
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-3
Install................................................................................................................................................................9-2
Sanden..........................................................................................................................................................9-2
Signature, ISX, and QSX15 Engi [...]
Page 9-b Section 9 - Drive Units - Group 09

Climate Control Incorporated..........................................................................................................................9-2


Preparatory Steps.............................................................................................................................................9-1
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-1
Remove............................................................................................................................................................9-1
Sanden..........................................................................................................................................................9-1
Climate Control Incorporated..........................................................................................................................9-1
Refrigerant Compressor Mounting Bracket ......................................................................................................9-8
Clean and Inspect for Reuse...........................................................................................................................9-10
Automotive with CM870................................................................................................................................9-10
Automotive, Industrial with CM570 and Power Generation without CM570....................................................9-10
Finishing Steps...............................................................................................................................................9-12
Automotive with CM870................................................................................................................................9-12
Automotive, Industrial with CM570 and Power Generation without CM570....................................................9-12
Install..............................................................................................................................................................9-11
Sanden........................................................................................................................................................9-11
Climate Control Incorporated........................................................................................................................9-11
Automotive, Industrial with CM570 and Power Generation without CM570....................................................9-11
Preparatory Steps.............................................................................................................................................9-8
Automotive with CM870..................................................................................................................................9-8
Automotive, Industrial with CM570 and Power Generation without CM570......................................................9-8
Remove............................................................................................................................................................9-9
Sanden..........................................................................................................................................................9-9
Climate Control Incorporated..........................................................................................................................9-9
Automotive, Industrial with CM570 and Power Generation without CM570......................................................9-9
Signature, ISX, and QSX15 Engi [...] Refrigerant Compressor
Section 9 - Drive Units - Group 09 Page 9-1

Refrigerant Compressor (009-051)


Preparatory Steps
With Water Pump and Refrigerant Compressor Belt
Routing

WARNING
To protect the environment, liquid refrigerant systems
must be properly emptied and filled using equipment
that prevents the release of refrigerant gas into the
atmosphere. Federal law requires capturing and
recycling the refrigerant.
NOTE: If the refrigerant compressor is only being
removed to access other components, refrigerant system
depressurization is not required. Leave hoses connected
and properly support the refrigerant compressor to other
vehicle components.
• Depressurize the refrigerant system, only if
complete removal of the refrigerant compressor is
required. Refer to the OEM service manual for the
proper procedure.
• Remove the cooling fan drive belt. Refer to
Procedure 008-002.
• Refrigerant compressor belt. Refer to Procedure
009-052.

Remove
Sanden
Remove the four refrigerant compressor mounting
capscrews.
Remove the refrigerant compressor.

Climate Control Incorporated


Remove the four refrigerant compressor mounting
capscrews.
Remove the refrigerant compressor and bracket
assembly.
Refrigerant Compressor Signature, ISX, and QSX15 Engi [...]
Page 9-2 Section 9 - Drive Units - Group 09

Clean and Inspect for Reuse


With Water Pump and Refrigerant Compressor Belt
Routing
Inspect the refrigerant compressor pulley, for cracks or
broken grooves. Replace refrigerant compressor if
damaged.
Refer to the OEM service manual for proper compressor
inspection on the various types and configurations
available.

Climate Control Incorporated


Inspect the refrigerant compressor bracket for cracks.
Replace bracket if cracked.
Inspect the roll pins. The roll pins must not be loose or
have any damage. Replace the refrigerant compressor
mounting brackets, if the roll pin are loose or damaged.

Install
Sanden
Install the four mounting capscrews through the
refrigerant compressor and refrigerant compressor
bracket.
Tighten the capscrews.
Torque Value: 18 N•m [ 115 in-lb ]

Climate Control Incorporated


Install the four mounting capscrews through the
refrigerant compressor to the alternator/refrigerant
compressor mounting bracket. Make sure the roll pins
align properly.
Tighten the capscrews.
Torque Value: 36 N•m [ 27 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Drive Belt, Refrigerant Compressor
Section 9 - Drive Units - Group 09 Page 9-3

Finishing Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Install the refrigerant compressor belt. Refer to
Procedure 009-052.
• Install the fan drive belt. Refer to Procedure 008-002.
• Fill the refrigerant system, if depressurized. Refer to
the OEM service manual.

Drive Belt, Refrigerant Compressor


(009-052)
Preparatory Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Remove the cooling fan drive belt. Refer to
Procedure 008-002.

Remove
With Water Pump and Refrigerant Compressor Belt
Routing

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 counterclockwise to
relieve tension on the belt.
Remove the belt.

Clean and Inspect for Reuse


With Water Pump and Refrigerant Compressor Belt
Routing
Inspect the refrigerant compressor pulley for cracks or
broken grooves. Replace compressor if damaged.
Drive Belt, Refrigerant Compressor Signature, ISX, and QSX15 Engi [...]
Page 9-4 Section 9 - Drive Units - Group 09

Inspect belt for cracks, glazing, tears or cuts, and


excessive wear. Replace belt, if necessary.

Install
With Water Pump and Refrigerant Compressor Belt
Routing

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 counterclockwise and hold the belt tensioner.
Install the drive belt and relieve the tensioner.

Finishing Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Install the cooling fan drive belt. Refer to Procedure
008-002.
Signature, ISX, and QSX15 Engi [...] Belt Tensioner, Refrigerant Compressor, Automatic
Section 9 - Drive Units - Group 09 Page 9-5

Belt Tensioner, Refrigerant


Compressor, Automatic (009-053)
Initial Check
With Water Pump and Refrigerant Compressor Belt
Routing

WARNING
Tensioner is spring loaded. Do not attempt to
disassemble the tensioner. Severe bodily injury can
result.
With the tensioner installed on the engine, pivot the
tensioner through the full range of motion. Tensioner
must move with resistance while pivoting the tensioner
away from the belt. If no resistance, replace tensioner.
If this check is okay, check the belt part number. Make
sure that the belt is correct for this refrigerant compressor
option.

Check the tensioner pulley and body for cracks. If cracks


are found, replace the tensioner.

Spin the tensioner pulley. The pulley must spin freely. If


not, replace the tensioner.
Belt Tensioner, Refrigerant Compressor, Automatic Signature, ISX, and QSX15 Engi [...]
Page 9-6 Section 9 - Drive Units - Group 09

Preparatory Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Remove the fan drive belt. Refer to Procedure
008-002.
• Remove the refrigerant compressor belt. Refer to
Procedure 009-052.

Remove
With Water Pump and Refrigerant Compressor Belt
Routing
Remove the mounting capscrew and the refrigerant
compressor belt tensioner from the bracket.

Install
With Water Pump and Refrigerant Compressor Belt
Routing
Install the refrigerant compressor belt tensioner.
Install and tighten capscrew.
Torque Value: 45 N•m [ 33 ft-lb ]

Finishing Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Install the refrigerant compressor belt. Refer to
Procedure 009-052.
• Install the fan drive belt. Refer to Procedure 008-002.
Signature, ISX, and QSX15 Engi [...] Idler Pulley, Refrigerant Compressor
Section 9 - Drive Units - Group 09 Page 9-7

Idler Pulley, Refrigerant Compressor


(009-054)
Preparatory Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Remove the cooling fan drive belt. Refer to
Procedure 008-002.
• Remove the refrigerant compressor belt. Refer to
Procedure 009-051.

Remove
With Water Pump and Refrigerant Compressor Belt
Routing
Remove the pulley mounting capscrew.
Remove the refrigerant compressor idler pulley.

Inspect for Reuse


With Water Pump and Refrigerant Compressor Belt
Routing
Inspect the refrigerant compressor idler pulley for cracks
or broken grooves. Replace idler pulley if damage is
found.
Spin the refrigerant compressor idler pulley.
The refrigerant compressor idler pulley must rotate freely
when installed.

Install
With Water Pump and Refrigerant Compressor Belt
Routing
Install the refrigerant compressor idler pulley and the
mounting capscrew.
Torque Value: 36 N•m [ 27 ft-lb ]
NOTE: A special alignment procedure is not required for
the refrigerant compressor idler pulley to the alternator/
refrigerant compressor mounting bracket.
Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Engi [...]
Page 9-8 Section 9 - Drive Units - Group 09

Finishing Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Install the refrigerant compressor belt. Refer to
Procedure 009-051.
• Install the cooling fan drive belt. Refer to Procedure
008-002.

Refrigerant Compressor Mounting


Bracket (009-055)
Preparatory Steps
Automotive with CM870

WARNING
To protect the environment, liquid refrigerant systems
must be properly emptied and filled using equipment
that prevents the release of refrigerant gas into the
atmosphere. Federal law requires capturing and
recycling the refrigerant.
• Remove the cooling fan drive belt. Refer to
Procedure 008-002.
• Remove the refrigerant compressor belt. Refer to
Procedure 009-052.
• Remove the refrigerant compressor. Refer to
Procedure 009-051.

Automotive, Industrial with CM570 and Power


Generation without CM570

WARNING
To protect the environment, liquid refrigerant systems
must be properly emptied and filled using equipment
that prevents the release of refrigerant gas into the
atmosphere. Federal law requires capturing and
recycling the refrigerant.
• Remove the refrigerant compressor and alternator
belt. Refer to Procedure 013-005.
• Remove the refrigerant compressor. Refer to
Procedure 009-051.
Signature, ISX, and QSX15 Engi [...] Refrigerant Compressor Mounting Bracket
Section 9 - Drive Units - Group 09 Page 9-9

Remove
Sanden
Remove the mounting capscrew from each refrigerant
compressor bracket.
Remove the refrigerant compressor brackets.

Climate Control Incorporated


Remove the four mounting capscrews from the refrigerant
compressor bracket.
Remove the refrigerant compressor bracket from the
refrigerant compressor.

Automotive, Industrial with CM570 and Power


Generation without CM570
Remove the two bracket mounting capscrews and the
bracket.
Remove the support links from the bracket.
Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Engi [...]
Page 9-10 Section 9 - Drive Units - Group 09

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 protect 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 refrigerant compressor mounting brackets with
solvents.
Dry with compressed air.
Inspect the refrigerant compressor mounting brackets.
Replace the refrigerant compressor mounting brackets if
cracked or damaged.

Inspect the roll pins. The roll pins must not be loose or
have any damage. Replace the refrigerant compressor
mounting brackets, if the roll pins are loose or damaged.

Automotive, Industrial with CM570 and Power


Generation without CM570

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 bracket, links, and mounting capscrews with
solvent.
Dry the parts with compressed air.
Signature, ISX, and QSX15 Engi [...] Refrigerant Compressor Mounting Bracket
Section 9 - Drive Units - Group 09 Page 9-11

Inspect the bracket and links for cracks.


Replace the bracket or links if damage is found.

Install
Sanden
Install the two mounting capscrews and the refrigerant
compressor mounting bracket.
Tighten the capscrews.
Torque Value: 7 N•m [ 62 in-lb ]

Climate Control Incorporated


Install the refrigerant compressor mounting bracket to the
refrigerant compressor. The refrigerant compressor is
positioned on top of the bracket ledge.
Install the four mounting capscrews and the refrigerant
compressor bracket.
Tighten the capscrews.
Torque Value: 41 N•m [ 30 ft-lb ]

Automotive, Industrial with CM570 and Power


Generation without CM570
Before installation, inspect the refrigerant compressor
bracket to make sure the mounting spacers are installed
properly.
Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Engi [...]
Page 9-12 Section 9 - Drive Units - Group 09

Install the refrigerant compressor bracket on the gear


housing with two long capscrews.
Tighten the capscrews.
Torque Value: 56 N•m [ 41 ft-lb ]

Position both links in the assembly with the part number


facing outward.
Insert one capscrew through the elongated hole in the
long link and attach the long link to the left side of the
refrigerant compressor bracket.
Insert one capscrew through the small hole in the short
link and attach the short link to the right side of the
refrigerant compressor bracket.

Finishing Steps
Automotive with CM870
• Install the refrigerant compressor. Refer to
Procedure 009-051.
• Install the refrigerant compressor belt. Refer to
Procedure 009-052.
• Install the fan drive belt. Refer to Procedure 008-002.

Automotive, Industrial with CM570 and Power


Generation without CM570
• Install the refrigerant compressor. Refer to
Procedure 009-051.
• Install the refrigerant compressor and alternator belt.
Refer to Procedure 013-005.
Signature, ISX, and QSX15 Engi [...] Alternator/Refrigerant Compressor Mounting Bracket
Section 9 - Drive Units - Group 09 Page 9-13

Alternator/Refrigerant Compressor
Mounting Bracket (009-056)
Preparatory Steps
Automotive with CM870
• Remove the turbocharger control valve. Refer to
Procedure 019-388 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
• Remove the alternator drive belt. Refer to Procedure
013-005.
• Remove the alternator. Refer to Procedure 013-001.
• Remove the alternator spacers. Refer to Procedure
013-036.
• Remove the refrigerant compressor drive belt. Refer
to Procedure 009-052.
• Remove the refrigerant compressor. Refer to
Procedure 009-051.
• Remove the refrigerant compressor mounting
bracket. Refer to Procedure 009-055.
• Remove the refrigerant compressor belt tensioner.
Refer to Procedure 009-053.
• Remove the refrigerant idler pulley. Refer to
Procedure 009-054.
• Remove the water pump belt tensioner. Refer to
Procedure 008-080.

Automotive with CM570


• Remove the refrigerant compressor and alternator
belt. Refer to Procedure 013-005.
• Remove the refrigerant compressor. Refer to the
OEM service manual.
• Remove the upper belt tensioner. Refer to Procedure
013-021.
• Remove the lower belt tensioner. Refer to Procedure
008-080.

Remove
Automotive with CM870
Disconnect the wire harness jumper from the EGR valve
motor, EGR valve position sensor and the main engine
wire harness.
Remove the five mounting capscrews from the alternator/
refrigerant compressor mounting bracket.
Gently pry out the bracket from the gear housing.
The split washers will create a slight friction fit between
the bracket and the gear housing.
Remove the wire harness jumper from the alternator/
refrigerant compressor mounting bracket.
Alternator/Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Engi [...]
Page 9-14 Section 9 - Drive Units - Group 09

Automotive with CM570


Remove the six mounting capscrews from the alternator/
refrigerant compressor mounting bracket.
Gently pry out the bracket from the gear housing.
The split washers will create a slight friction between the
bracket and the gear housing.

Inspect for Reuse


Automotive with CM870
Inspect the alternator/refrigerant compressor mounting
bracket for cracks.
Replace the bracket if necessary.
Inspect underneath the refrigerant compressor, alternator
spacer, water pump belt tensioner, and refrigerant
compressor belt tensioner for wear.
If wear is found, replace the alternator bracket.

Automotive with CM570


Inspect the alternator/refrigerant compressor mounting
bracket for cracks.
Replace the bracket if necessary.

Inspect belt tensioners for excessive wear.


If worn excessively, replace the belt tensioners.
Signature, ISX, and QSX15 Engi [...] Alternator/Refrigerant Compressor Mounting Bracket
Section 9 - Drive Units - Group 09 Page 9-15

Install
Automotive with CM870
Install the wire harness jumper to the alternator/refrigerant
compressor mounting bracket.
Torque Value: 18 N•m [ 14 ft-lb ]
Tap the split washers out slightly. This will ease the
installation.
Install the alternator/refrigerant compressor mounting
bracket to the gear housing.

Install the five mounting capscrews.


Tighten the capscrews in the sequence shown.
Torque Value:
(1, 2 3 and 4) 36 N•m [ 27 ft-lb ]
(5) 56 N•m [ 41 ft-lb ]

Automotive with CM570


The alternator/refrigerant compressor mounting bracket
mounts to the gear housing at the top and the water pump
at the bottom.
Install the bracket and six mounting capscrews.
Tighten the capscrew that threads into the gear housing.
Torque Value: 56 N•m [ 41 ft-lb ]

Tighten the short capscrew (1).


Tighten the remaining capscrews (2, 3, 4, and 5).
Torque Value:
(1, 2, 3, 4, and 34 N•m [ 25 ft-lb ]
5)
Alternator/Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Engi [...]
Page 9-16 Section 9 - Drive Units - Group 09

Finishing Steps
Automotive with CM870
• Install the water pump belt tensioner. Refer to
Procedure 008-080.
• Install the refrigerant compressor idler pulley. Refer
to Procedure 009-054.
• Install the refrigerant compressor belt tensioner
Refer to Procedure 009-053.
• Install the refrigerant compressor mounting bracket.
Refer to Procedure 009-055.
• Install the refrigerant compressor. Refer to
Procedure 009-051.
• Install the refrigerant compressor drive belt. Refer to
Procedure 009-052.
• Install the alternator spacers. Refer to Procedure
013-036.
• Install the alternator. Refer to Procedure 013-001.
• Install the alternator drive belt. Refer to Procedure
013-005.
• Install the turbocharger control valve. Refer to
Procedure 019-388 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.

Automotive with CM570


• Install the upper belt tensioner. Refer to Procedure
013-021.
• Installl the lower belt tensioner. Refer to Procedure
008-080.
• Install the refrigerant compressor. Refer to the OEM
service manual.
• Install the refrigerant compressor and alternator
drive belt. Refer to Procedure 013-005.
Signature, ISX, and QSX15 Engi [...]
Section 10 - Air Intake System - Group 10 Page 10-a

Section 10 - Air Intake System - Group 10


Section Contents
Page
Air Intake Connection ....................................................................................................................................10-54
Clean and Inspect for Reuse......................................................................................................................... 10-55
All Applications...........................................................................................................................................10-55
Finishing Steps............................................................................................................................................. 10-57
Automotive, Industrial with CM570 and Power Generation without CM570.................................................. 10-57
Automotive with CM870..............................................................................................................................10-57
Automotive With CM871.............................................................................................................................10-58
Install............................................................................................................................................................10-56
Automotive, Industrial with CM570 and Power Generation without CM570.................................................. 10-56
Automotive with CM870..............................................................................................................................10-57
Automotive With CM871.............................................................................................................................10-57
Preparatory Steps......................................................................................................................................... 10-54
Automotive, Industrial with CM570 and Power Generation without CM570.................................................. 10-54
Automotive with CM870..............................................................................................................................10-54
Automotive With CM871.............................................................................................................................10-54
Remove.........................................................................................................................................................10-55
Automotive with CM870..............................................................................................................................10-55
Automotive With CM871.............................................................................................................................10-55
Automotive, Industrial with CM570 and Power Generation without CM570.................................................. 10-55
Air Intake Restriction .................................................................................................................................... 10-13
Measure........................................................................................................................................................10-13
Air Leaks, Air Intake and Exhaust Systems ...................................................................................................10-3
Initial Check....................................................................................................................................................10-3
Automotive With CM871...............................................................................................................................10-5
Charge-Air Cooler ............................................................................................................................................10-9
Clean..............................................................................................................................................................10-9
Inspect for Reuse............................................................................................................................................10-9
Leak Test......................................................................................................................................................10-10
Pressure Differential Test..............................................................................................................................10-12
Temperature Differential Test........................................................................................................................10-11
Intake Manifold Pressure .............................................................................................................................. 10-53
Measure........................................................................................................................................................10-53
Service Tools ...................................................................................................................................................10-1
Air Intake System............................................................................................................................................10-1
Turbocharger .................................................................................................................................................10-15
Assemble......................................................................................................................................................10-30
Clean............................................................................................................................................................10-24
Disassemble..................................................................................................................................................10-23
Finishing Steps............................................................................................................................................. 10-36
Automotive, Industrial with CM570 and Power Generation without CM570.................................................. 10-36
Automotive with CM870..............................................................................................................................10-37
Automotive With CM871.............................................................................................................................10-38
Initial Check..................................................................................................................................................10-15
Automotive with CM870 and CM871...........................................................................................................10-15
Inspect for Reuse..........................................................................................................................................10-25
Automotive with CM870..............................................................................................................................10-28
Automotive With CM871.............................................................................................................................10-29
Install............................................................................................................................................................10-30
Automotive, Industrial with CM570 and Power Generation without CM570.................................................. 10-30
Automotive with CM870..............................................................................................................................10-33
Automotive With CM871.............................................................................................................................10-35
Leak Test......................................................................................................................................................10-17
All Applications...........................................................................................................................................10-17
Automotive with CM870..............................................................................................................................10-18
Preparatory Steps......................................................................................................................................... 10-19
Automotive, Industrial with CM570 and Power Generation without CM570.................................................. 10-19
Automotive with CM870..............................................................................................................................10-19
Signature, ISX, and QSX15 Engi [...]
Page 10-b Section 10 - Air Intake System - Group 10

Automotive With CM871.............................................................................................................................10-20


Remove.........................................................................................................................................................10-20
Automotive, Industrial with CM570 and Power Generation without CM570.................................................. 10-20
Automotive with CM870..............................................................................................................................10-21
Automotive With CM871.............................................................................................................................10-23
Test...............................................................................................................................................................10-17
Flourescent Tracer Dye Test.......................................................................................................................10-17
Turbocharger Air Shutoff Valve Filter ..........................................................................................................10-64
Clean and Inspect for Reuse......................................................................................................................... 10-65
Variable Geometry......................................................................................................................................10-65
Finishing Steps............................................................................................................................................. 10-65
Variable Geometry......................................................................................................................................10-65
Install............................................................................................................................................................10-65
Variable Geometry......................................................................................................................................10-65
Preparatory Steps......................................................................................................................................... 10-64
Variable Geometry......................................................................................................................................10-64
Remove.........................................................................................................................................................10-64
Variable Geometry......................................................................................................................................10-64
Turbocharger Control Shutoff Valve Filter Head ..........................................................................................10-66
Clean and Inspect for Reuse......................................................................................................................... 10-67
Variable Geometry......................................................................................................................................10-67
Finishing Steps............................................................................................................................................. 10-68
Variable Geometry......................................................................................................................................10-68
Install............................................................................................................................................................10-67
Variable Geometry......................................................................................................................................10-67
Preparatory Steps......................................................................................................................................... 10-66
Variable Geometry......................................................................................................................................10-66
Remove.........................................................................................................................................................10-66
Variable Geometry......................................................................................................................................10-66
Turbocharger Coolant Hoses ........................................................................................................................10-38
Clean and Inspect for Reuse......................................................................................................................... 10-40
Finishing Steps............................................................................................................................................. 10-43
Automotive with CM870..............................................................................................................................10-43
Automotive With CM871.............................................................................................................................10-44
Install............................................................................................................................................................10-41
Automotive with CM870..............................................................................................................................10-41
Automotive With CM871.............................................................................................................................10-42
Preparatory Steps......................................................................................................................................... 10-38
Automotive with CM870..............................................................................................................................10-38
Automotive With CM871.............................................................................................................................10-39
Remove.........................................................................................................................................................10-39
Automotive with CM870..............................................................................................................................10-39
Automotive With CM871.............................................................................................................................10-40
Turbocharger Wastegate Actuator ............................................................................................................... 10-44
Adjust............................................................................................................................................................10-49
Finishing Steps............................................................................................................................................. 10-52
Initial Check..................................................................................................................................................10-44
Inspect..........................................................................................................................................................10-47
Inspect for Reuse..........................................................................................................................................10-48
Install............................................................................................................................................................10-50
Preparatory Steps......................................................................................................................................... 10-46
Remove.........................................................................................................................................................10-47
Turbocharger Wastegate Controller .............................................................................................................10-58
Inspect for Reuse..........................................................................................................................................10-59
Install............................................................................................................................................................10-59
Remove.........................................................................................................................................................10-58
Turbocharger Wastegate Valve Body ...........................................................................................................10-52
Inspect for Reuse..........................................................................................................................................10-52
Turbocharger, Variable Geometry Actuator Air Supply Line .......................................................................10-68
Inspect for Reuse..........................................................................................................................................10-69
Install............................................................................................................................................................10-69
Remove.........................................................................................................................................................10-68
Turbocharger, Variable Geometry Control Valve Air Supply Line ...............................................................10-70
Signature, ISX, and QSX15 Engi [...]
Section 10 - Air Intake System - Group 10 Page 10-c

Inspect for Reuse..........................................................................................................................................10-70


Install............................................................................................................................................................10-71
Remove.........................................................................................................................................................10-70
Variable Geometry Turbocharger Actuator, Electric ....................................................................................10-71
Calibrate.......................................................................................................................................................10-77
Finishing Steps.............................................................................................................................................10-77
General Information.......................................................................................................................................10-71
Inspect for Reuse..........................................................................................................................................10-72
Install............................................................................................................................................................10-76
Preparatory Steps.........................................................................................................................................10-72
Remove.........................................................................................................................................................10-72
Time..............................................................................................................................................................10-74
Turbocharger, Variable Geometry Actuator .................................................................................................10-60
Finishing Steps.............................................................................................................................................10-64
Variable Geometry......................................................................................................................................10-64
General Information.......................................................................................................................................10-60
Variable Geometry......................................................................................................................................10-60
Inspect for Reuse..........................................................................................................................................10-62
Variable Geometry......................................................................................................................................10-62
Install............................................................................................................................................................10-63
Variable Geometry......................................................................................................................................10-63
Preparatory Steps.........................................................................................................................................10-61
Variable Geometry......................................................................................................................................10-61
Remove.........................................................................................................................................................10-61
Variable Geometry......................................................................................................................................10-61
Test...............................................................................................................................................................10-63
Variable Geometry......................................................................................................................................10-63
Signature, ISX, and QSX15 Engi [...]
Page 10-d Section 10 - Air Intake System - Group 10

This Page Left Intentionally Blank


Signature, ISX, and QSX15 Engi [...] Service Tools
Section 10 - Air Intake System - Group 10 Page 10-1

Service Tools
Air Intake 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


Fluorescent Tracer
Added to oil and used with black light to find oil leaks.
3376891

Black Light (100 watt)


Used to inspect for oil or fuel leak.
3163337

Black Light (50 watt)


Used to inspect for oil or fuel leak.
3163338

Fluke Digital Thermometer


Used to measure intake air temperature.
3822666

Thermocouple Wire Kit


Used with fluke digital thermometer.
3822988

Slack Tube Manometer


Used to measure pressure differential.
ST-1111-3
Service Tools Signature, ISX, and QSX15 Engi [...]
Page 10-2 Section 10 - Air Intake System - Group 10

Tool No. Tool Description Tool Illustration


Charge-Air Cooler Tester
Used to pressure-test charge air coolers.
3824556
Signature, ISX, and QSX15 Engi [...] Air Leaks, Air Intake and Exhaust Systems
Section 10 - Air Intake System - Group 10 Page 10-3

Air Leaks, Air Intake and Exhaust


Systems (010-024)
Initial Check
CAUTION
Engine intake air must be filtered to prevent dirt and
debris from entering the engine. If intake air piping is
damaged or loose, unfiltered air will enter the engine
and cause premature wear.
Inspect for loose clamps or damage between the intake
air piping, air cleaner, turbocharger, charge-air cooler,
and intake manifold.
Check for corrosion of the intake system piping under the
clamps and hoses. Corrosion can allow corrosive products
and dirt to enter the intake system. Disassemble and clean
as required.
Replace damaged pipes and tighten loose clamps.

Excessive back pressure can cause exhaust leaks. Verify


the exhaust back pressure is within specified limits. Refer
to Procedure 011-009.
Operate the engine at full throttle and maximum load, and
check for air leaks. Listen for a whistling noise caused by
high-pressure air leaks.

CAUTION
Do not use air tools to remove or install the nut on the
v-band clamp. Use of these tools can seriously
damage the threads or the bolt and cause the clamp
to not be able to be reused.
The noise can be caused by an air leak from the following:
Turbocharger-to-charge-air cooler elbow connection.
• Inspect the connection and o-ring for damage.
• Tighten the v-band clamps.
Torque Value: 9 N•m [ 80 in-lb ]
Air Leaks, Air Intake and Exhaust Systems Signature, ISX, and QSX15 Engi [...]
Page 10-4 Section 10 - Air Intake System - Group 10

Any charge-air cooler piping or connecting hose.


• Inspect the hose and piping for damage.
• Tighten the hose clamps.
Torque Value: 9 N•m [ 80 in-lb ]

Turbocharger-to-exhaust-manifold mounting gasket.


• Replace the gasket.
Refer to Procedure 010-033 for turbocharger removal and
installation.

CAUTION
Do not use air tools to remove or install the nut on the
v-band clamp. Use of these tools can seriously
damage the threads or the bolt and cause the clamp
to not be able to be used.
Turbine housing sealing surface air leak.
• Tighten the v-band clamp.
Torque Value: 14 N•m [ 124 in-lb ]
• Check for an air leak.
• If an air leak is still present, remove and replace the
turbocharger.

Compressor housing sealing surface air leak.


• Tighten the v-band.
Torque Value: 9 N•m [ 80 in-lb ]
• Check for an air leak.
• If an air leak is still present, remove and replace the
turbocharger.
Signature, ISX, and QSX15 Engi [...] Air Leaks, Air Intake and Exhaust Systems
Section 10 - Air Intake System - Group 10 Page 10-5

Check for soot streaks from the EGR connection tubes


and hoses.
• Tighten the hose clamps. Refer to Procedure
011-025.
• Check for an exhaust leak. If an exhaust leak is still
present, remove and replace the EGR crossover
tube or hose.

Check for leakage from the EGR valve weep hole.


• Soot leakage at the EGR valve weep hole is normal
and is expected. Do not replace the EGR valve if
soot streaks are found at the EGR valve weep hole.

Automotive With CM871


Check for soot streaks from the EGR connection tubes
and hoses.
• Tighten the hose clamps. Refer to Procedure
011-025. Check for an exhaust leak. If an exhaust
leak is still present, remove and replace the EGR
crossover tube or hose.

Check for soot streaks from the EGR valve gasket and
seal rings.
• Inspect for signs of leakage such as soot streaks. If
signs of leakage are present, replace the EGR valve
gaskets. Refer to Procedure 011-022.
Air Leaks, Air Intake and Exhaust Systems Signature, ISX, and QSX15 Engi [...]
Page 10-6 Section 10 - Air Intake System - Group 10

Check for leakage from the EGR valve weep hole.


• Soot leakage at the EGR valve weep hole is normal
and is expected. Do not replace the EGR valve if
soot streaks are found at the EGR valve weep hole.

Check for leakage from the EGR cooler bellows.


• Inspect for signs of leakage such as soot streaks. If
signs of leakage are present, replace the EGR cooler
or gaskets. Refer to Procedure 011-019.

Check for soot leakage at the EGR differential pressure


sensing tubes.
• Inspect for signs of leakage such as soot streaks
which may appear yellowish brown or black. If signs
of leakage are present, replace the EGR differential
pressure tubes. Refer to Procedure 011-026.

Check for soot leakage on the exhaust adapter pipe.


• Inspect for signs of leakage such as soot streaks
which may appear yellowish brown or black. If signs
of leakage are present, replace the gasket and v-
band clamp. Refer to Procedure 011-007 for the
bellows and Procedure 011-019 for the exhaust
manifold.
Clean all soot stains and paint the components in order to
detect future leaks.
Signature, ISX, and QSX15 Engi [...] Air Leaks, Air Intake and Exhaust Systems
Section 10 - Air Intake System - Group 10 Page 10-7

Check the aftertreatment adapter pipe.


• Inspect for visible soot streaks at the v-band joint.
If soot streaks are found, tighten the v-band clamp. Refer
to Procedure 011-043.
Operate the engine at full throttle and check for leakage
at full throttle condition.
If a leak is still present, remove and replace the gasket
with a new gasket and a new v-band clamp.

Check the aftertreatment inlet connection.


• Inspect for visible soot streaks at the torca clamp or
v-band clamp joint. Also inspect for loose or
damaged insulation wrapping (if applicable).
If soot streaks are found, tighten the v-band or torca
clamp. Refer to Procedure 011-041.
Operate the engine at full throttle and check for leakage
at full throttle condition.
If a leak is still present, remove and replace the clamp with
a new torca clamp or v-band clamp.

Check the inlet to catalyst connection.


• Inspect for visible soot streaks at the v-band joint.
If soot streaks are found, check for fault codes relating to
high differential pressure in the aftertreatment system. If
no fault codes are found, tighten the v-band clamp. Refer
to Procedure 011-050.
Operate the engine at full throttle and check for leakage
at full throttle condition.
If a leak is still present, remove and replace with a new
gasket and v-band clamp.

Check the catalyst to aftertreatment particulate trap


connection.
• Inspect for visible soot streaks at the v-band joint.
If soot streaks are found, check for fault codes relating to
high differential pressure in the aftertreatment system. If
no fault codes are found, tighten the v-band clamp. Refer
to Procedure 011-049.
Operate the engine at full throttle and check for leakage
at full throttle condition.
If a leak is still present, remove and replace the gasket
with a new gasket and v-band clamp.
Air Leaks, Air Intake and Exhaust Systems Signature, ISX, and QSX15 Engi [...]
Page 10-8 Section 10 - Air Intake System - Group 10

Check the aftertreatment diesel particulate filter to outlet


connection.
• Inspect for visible soot streaks at the v-band joint.
If soot streaks are found, check for fault codes relating to
high differential pressure in the aftertreatment system. If
no fault codes are found, tighten the v-band clamp. Refer
to Procedure 011-041.
Operate the engine at full throttle and check for leakage
at full throttle condition.
If a leak is still present, remove and replace with a new
gasket and v-band clamp.

Check the aftertreatment outlet connection.


• Inspect for visible soot streaks at the v-band joint.
If soot streaks are found, check for fault codes relating to
high differential pressure in the aftertreatment system. If
no fault codes are found, tighten the v-band clamp. Refer
to Procedure 011-041.
Operate the engine at full throttle and check for leakage
at full throttle condition.
If a leak is still present, remove and replace with a new
gasket and v-band clamp.

Check the aftertreatment diesel particulate filter


differential pressure sensor tube connections.
• Inspect for visible soot streaks at the threaded
bosses or hose connections.
If soot streaks are found at the threaded boss, loosen the
differential pressure sensor tube nut, apply a coating of
anti-seize compound, and tighten the differential pressure
sensor tube nut. Refer to Procedure 011-047.
If soot streaks are found at the hose connections, remove
and connect hose. Refer to Procedure 011-047.
Operate the engine at full throttle and check for leakage
at full throttle condition.
If a leak is still present at the threaded boss, remove and
replace the differential pressure sensor tube.
If a leak is still present at the hose connection, replace the
differential pressure sensor tube or differential pressure
sensor, depending on which component the hose is
permanently attached to.
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.
Signature, ISX, and QSX15 Engi [...] Charge-Air Cooler
Section 10 - Air Intake System - Group 10 Page 10-9

Charge-Air Cooler (010-027)


Clean
If the engine experiences a turbocharger failure or any
other occasion where oil or debris is put into the charge-
air cooler, the charge-air cooler must be cleaned.
Remove the charge-air cooler piping and charge-air cooler
from the vehicle. Refer to the manufacturer's instructions.

CAUTION
Do not use caustic cleaners to clean the charge-air
cooler. Damage to the charge-air cooler will result.
Flush the charge-air cooler internally with solvent in the
opposite direction of normal airflow. Shake the charge-air
cooler and lightly tap on the end tanks with a rubber mallet
to dislodge trapped debris. Continue flushing until all
debris or oil is removed.
NOTE: Be sure the tubes are in the vertical direction when
flushing.
If the debris can not be totally removed from the charge-
air cooler, the charge-air cooler must be replaced.

CAUTION
The charge-air cooler must be rinsed, dried, and free
of solvent, oil, and debris or engine damage will
result.
After the charge-air cooler has been thoroughly cleaned
of all oil and debris with solvent, wash the charge-air
cooler internally with hot soapy water to remove the
remaining solvent. Rinse thoroughly with clean water.
Blow compressed air through the inside of the charge-air
cooler in the opposite direction of normal air flow until the
charge-air cooler is dry internally.

Inspect for Reuse


Inspect the charge-air cooler for cracks, holes, or damage.
Inspect the tubes, fins, and welds for tears, breaks, or
other damage. If any damage causes the charge-air cooler
to fail the air leak check, the charge-air cooler must be
replaced.
Install the charge-air cooler on the vehicle.
Charge-Air Cooler Signature, ISX, and QSX15 Engi [...]
Page 10-10 Section 10 - Air Intake System - Group 10

Leak Test
To check the charge-air cooler for cracked tubes or
header, remove the inlet and outlet hoses from the cooler.
The charge-air cooler does not have to be removed from
the chassis.

WARNING
To prevent possible injury if either plug blows off
during the test, secure safety chains on the test plugs
to any convenient capscrew on the radiator assembly.
This test must not be performed without securely
fastened safety chains.
Install the charge-air cooler tester, Part Number 3824556.

Apply 207 kPa [30 psi] of air pressure to the cooler. Close
the air pressure regulator.
Determine if pressure decay is caused by a leak in the
charge-air cooler or from a leaky connection. Use a spray
bottle filled with soapy water and apply to all hose
connections. Watch for bubbles to appear at the location
of the leak.

If the pressure decay is caused by a leaky connection,


repair the connection and repeat the test. If the leak is
within the charge-air cooler, repeat the test to verify the
accuracy of the pressure decay measurement. Similar
pressure decay readings must be obtained in at least
three consecutive tests before the reading can be
considered accurate.
Signature, ISX, and QSX15 Engi [...] Charge-Air Cooler
Section 10 - Air Intake System - Group 10 Page 10-11

Monitor the pressure gauge and determine the rate of


pressure decay with a stopwatch.

Charge-Air Cooler Pressure Drop


kPa psi
49 MAX 5
If the pressure drop is greater than the specification listed,
the charge-air cooler must be replaced.
Refer to the manufacturer's repair manual for
replacement instructions.
NOTE: If a charge-air cooler leaks more than 49 kPa [5
psi] in 15 seconds, it will appear as a major leak in a leak
tank.
NOTE: Charge-air coolers are not designed to be 100-
percent leak-free. If the pressure decay is less than 49 kPa
[5 psi] in 15 seconds, then the charge-air cooler does
not need to be replaced.

Temperature Differential Test


Inspect the charge-air cooler fins for obstructions to
airflow. Remove obstructions such as a winterfront or
debris. Manually lock the shutters, if equipped, in the
OPEN position.

Install a fluke digital thermometer, Part Number 3822666,


and thermocouple wire kit, Part Number 3822988, into the
intake air connection.
Install another thermocouple at the air cleaner inlet to the
outside of the vehicle.
Charge-Air Cooler Signature, ISX, and QSX15 Engi [...]
Page 10-12 Section 10 - Air Intake System - Group 10

Perform a road test with the engine at peak power and a


vehicle speed of 30 mph or greater.
Record the intake air temperature and the ambient air
temperature.
Calculate the differential temperature:
Intake Air Ambient Air Differential
• =
Temperature Temperature Temperature

If the temperature differential is greater than the


specifications, check the charge-air cooler for dirt and
debris on the fins and clean as necessary. If the problem
still exists, check the charge-air cooler for debris in the fins
or between the charge-air cooler and the radiator. Confirm
full fan engagement.

Charge Air Cooler Temperature Rise


°C °F
11 MAX 20
Ambient above 0°C [32°F]

Pressure Differential Test

Preferred Method: Measure the charge-air cooler system


pressure drop with a manometer, Part Number ST 1111-3.

Install one end of the manometer to the tap in the


turbocharger compressor outlet elbow.
Signature, ISX, and QSX15 Engi [...] Air Intake Restriction
Section 10 - Air Intake System - Group 10 Page 10-13

Install the other end of the manometer to the tap in the


intake air connection.

Operate the engine at the maximum advertised


horsepower and correlating rpm. Record the readings on
the manometer.

Charge-Air Cooler System Differential Pressure


mm Hg in Hg
152 MAX 6

Charge-Air Cooler System Differential Pressure


kPa psi
21 MAX 3
If the differential pressure is greater than the specification,
check the charge-air cooler and associated piping for
plugging. Clean or replace if necessary.
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.

Air Intake Restriction (010-031)


Measure
Install a vacuum gauge or water manometer in the intake
air piping.
NOTE: The gauge adapter must be installed at a 90-
degree angle to the airflow in a straight section of pipe,
127 mm [5 in], before the turbocharger compressor inlet.
Air Intake Restriction Signature, ISX, and QSX15 Engi [...]
Page 10-14 Section 10 - Air Intake System - Group 10

Operate the engine at full throttle and maximum


horsepower rpm with maximum load.
Record the reading on the gauge or manometer.
NOTE: Restriction must not exceed 635 mm H20 [25 in
H20].

If the restriction exceeds specifications, do the following:


• Replace or clean the air filter element. Refer to the
equipment manufacturer's instructions.

• Inspect the intake air piping for damage. Check for


collapsed and dented piping or elbows, and loose
connections. Refer to the equipment manufacturer's
repair instructions.

Remove the test equipment.


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.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-15

Turbocharger (010-033)
Initial Check
Automotive with CM870 and CM871
Add one unit of fluorescent tracer, Part Number 3376891,
to each 38 liters [10 gal] of engine lubricating oil.
If a bearing housing coolant leak is suspected, use the
turbocharger coolant leak test kit, Part Number 3164682.
Operate the engine at low idle for 10 minutes.

Shut off the engine.


Allow the turbocharger to cool.
Remove the intake and the exhaust pipes from the
turbocharger.
Remove the intake piping and compressor discharge
piping.

Inspect the turbocharger compressor impeller blades for


damage.
Replace the turbocharger if damage is found.

Inspect the compressor intake and discharge for signs of


oil.
If oil is present in the compressor intake as, well as the
discharge, check upstream of the turbocharger for the
source of the oil.
If oil is present only in the discharge side, check for intake
restriction.
If no intake restriction is found, replace the turbocharger.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-16 Section 10 - Air Intake System - Group 10

If the compressor impeller is damaged, inspect the intake


air piping and the filter element for damage.
Repair any damage before operating the engine.

Inspect the turbine wheel for damage.


Replace the turbocharger if damage is found.

Use a high-intensity black light, Part Number 3163337


(100 watt), or 3163338 (50 watt), to inspect the turbine
outlet for leaks.
A dark blue glow indicates a fuel leak. A yellow glow
indicates an oil leak.

If oil is found in the exhaust outlet of the turbine housing,


remove the oil drain line and check for restrictions.
Clear any restrictions found and/or replace damaged
components as required.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-17

Check the engine breather or the crankcase vent tube for


restrictions.
Clear any restrictions and/or replace damaged
components. Refer to Procedure 003-001.
If equipped, check the engine crankcase ventilation filter
assembly for excessive restriction or blockage. Refer to
Procedure 003-001.

Test
Flourescent Tracer Dye Test

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

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Variable Geometry
• Drain the cooling system. Refer to Procedure
008-018.
• Inspect the bearing housing for external oil or
coolant leaks.
• Remove the oil supply, oil drain, coolant inlet, and
coolant outlet tubes from the turbocharger.
• Disconnect the variable geometry turbocharger
actuator air supply line (CM870 engines).
• Discard the oil drain tube gasket.
• Check for evidence of coolant in the oil supply and
oil drain fittings.

Leak Test
All Applications
Remove the air intake and charge air cooler piping from
the turbocharger.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-18 Section 10 - Air Intake System - Group 10

Examine the compressor intake and discharge for oil.


If oil is present in the compressor intake, as well as the
discharge, check upstream of the turbocharger for the
source of the oil.
If oil is present only in the discharge side, check for intake
restriction. Refer to Procedure 010-031.
If no intake restriction is found, replace the turbocharger.

Install the air intake and charge air cooler piping to the
turbocharger and tighten the clamp.
Torque Value: 8.5 N•m [ 75 in-lb ]
Operate the engine at full throttle and maximum load, and
check for air leaks.

Automotive with CM870


Connect a turbocharger coolant leak test kit, Part Number
3164682, to the coolant inlet and outlet.
Use shop air supply to pressurize the turbocharger to 276
kPa [40 psi].
Close the air pressure regulator.

Watch for the pressure to decrease. Pressure must not


decrease more than 34 kPa [5 psi] in 1 minute.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-19

If the pressure decreases greater than 34 kPa [5 psi] in 1


minute, use a spray bottle of soapy water to wet all hose
connections. Bubbles will appear if the connections are
leaking.
If the pressure does decrease and the hose connections
are not leaking, replace the turbocharger.

Preparatory Steps
Automotive, Industrial with CM570 and Power
Generation without CM570
• Remove the wastegate actuator hose. Refer to
Procedure 010-050.

Automotive with CM870

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

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the coolant. Refer to Procedure 008-018.
• Disconnect the turbocharger speed sensor. See
Procedure 019-390 in the Troubleshooting and
Repair Manual, CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
• Disconnect the turbocharger compressor air inlet
temperature sensor. See Procedure 019-395 in the
Troubleshooting and Repair Manual, CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Disconnect the variable geometry actuator air supply
line. Refer to Procedure 010-113.
• Remove the turbocharger coolant hoses. Refer to
Procedure 010-041.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-20 Section 10 - Air Intake System - Group 10

Automotive With CM871

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

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the coolant. Refer to Procedure 008-018.
• Disconnect the turbocharger speed sensor. See
Procedure 019-390 in the ISX CM871 and ISM
CM876 Electronic Control System, Troubleshooting
and Repair Manual, Bulletin 4021560.
• Disconnect the turbocharger compressor air inlet
temperature sensor. See Procedure 019-395 in the
ISX CM871 and ISM CM876 Electronic Control
System, Troubleshooting and Repair Manual,
Bulletin 4021560.
• Remove the turbocharger coolant hoses. Refer to
Procedure 010-041.
• Remove the charge air piping. Refer to Procedure
010-027.
• Disconnect the aftertreatment adapter pipe. Refer to
Procedure 011-043.

Remove
Automotive, Industrial with CM570 and Power
Generation without CM570

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 oil supply, oil drain tube, and brace (if
equipped) from the turbocharger.

Remove the intake and exhaust pipes from the


turbocharger.
Remove the charge air cooler piping from the discharge
elbow.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-21

Remove the clamp, o-ring, and discharge elbow from the


turbocharger.
Discard the o-ring.

NOTE: In some applications, the turbocharger will not


clear the lubricating oil cooler assembly during removal
and installation. It will, perhaps, be necessary to remove
the exhaust manifold and turbocharger together, and then
separate the two components. If the two components
must be removed together, refer to Procedure 011-007 for
removal and installation of the exhaust manifold.
If the turbocharger mounting nuts do not loosen freely,
split the nuts to avoid breaking a mounting stud.
Remove the four turbocharger mounting nuts.
Remove the turbocharger and discard the gasket.

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.

CAUTION
When installing a lifting eye, be sure the shoulder of
the lifting eye is bottomed against bearing housing.
Failure to do so can result in failure of the lifting eye
and personal injury.

CAUTION
If the lifting eye is installed in the turbocharger
bearing housing, it is to be used exclusively for
turbocharger removal and installation. It is not to be
used in removal of the exhaust manifold, or engine.
Doing so will cause damage to the turbocharger.
Remove the oil supply and the oil drain tube from the
turbocharger.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-22 Section 10 - Air Intake System - Group 10

Remove the intake and the exhaust pipes from the


turbocharger.
Remove the charge air cooler piping from the discharge
elbow.

Remove the clamp, o-ring, and discharge elbow from the


turbocharger.
Discard the o-ring.

The capscrew in the top of the turbocharger bearing


housing can be removed and replaced with a lifting eye to
aid in removal of the turbocharger.
If the turbocharger mounting nuts do not loosen freely,
split the nuts to avoid breaking a mounting stud.
Remove the four turbocharger mounting nuts.
Remove the turbocharger and discard the gasket.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-23

Automotive With CM871

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.
Thread a lifting strap around the turbocharger bearing
housing. Take care not to bend the coolant lines when
lifting the turbocharger.
Care must be taken not to damage the turbocharger
compressor inlet air temperature sensor, the turbocharger
speed sensor, and the turbocharger actuator coolant lines
when removing the turbocharger.
Remove the four turbocharger mounting nuts.
NOTE: If the turbocharger mounting nuts do not loosen
freely, split the nuts to avoid breaking a mounting stud.
Remove the turbocharger and discard the gaskets.

Disassemble
Turbine Housing Replacement for ISX Automotive with
CM570, QSX15 with CM570 and Power Generation with
CM570
Place turbocharger outlet on a clean flat surface. Create
an alignment mark on the turbine housing, bearing
housing and the V-band clamp. This mark will make
certain the components are oriented correctly during the
assembly process.

Loosen the turbine side V-band locknut. Remove and


discard the V-band clamp.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-24 Section 10 - Air Intake System - Group 10

CAUTION
Turbine blades can be easily damaged and care is
required for the turbine housing removal process.
Use a soft hammer to tap the turbine housing down
against a soft bench surface.
As the bearing housing and compressor housing
assembly loosen, gently lift the assembly out of the turbine
housing.
Wastegate mounting is not affected by this disassembly
process.
Always clean the turbine housing before assembly,
paying particular attention to the surface close to the
turbine housing and the bearing housing location.

Clean
Turbocharger Turbine Housing Cleaning
The turbocharger turbine housing surface adjacent to the
turbine compressor wheels must be clean, smooth, and
free from deposits.
Inspect the components to detect signs of burning and
other conditions, in order to obtain as much information
as possible before washing.

CAUTION
Wear appropriate eye and face protection when using
non-corrosive metal cleaner.
Soak the turbocharger turbine housing in a non-corrosive,
low flash point metal cleaner to loosen deposits.

CAUTION
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Scale-like deposits, if any, must be removed by using a
non-metallic bristle brush. After removing the deposits,
wash and dry the components.
Dry the components with compressed air.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-25

CAUTION
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
NOTE: Do not bead blast aluminum and cast iron
components together.
NOTE: To prevent bead spray impinging directly on the
clamp plate and turbine flange threads, mask and plug off
all items.
NOTE: Prevent the bead spray impinging directly on the
wastegate valve spindle, as beads can penetrate the
spindle bore, leading to spindle seizure.
It is permissible to bead blast the turbocharger turbine
housing if chemical and brush cleaning is not effective.

After removing the deposits, wash and dry the


components.

Inspect for Reuse


ISX Automotive with CM570, QSX15 with CM570 and
Power Generation with CM570
Clean the retaining nut mating surfaces of the
turbocharger and the exhaust manifold.
Clean the mating surfaces with Scotch Brite™ 7448
abrasive pad.
The surface under the mounting nuts must be free of dirt,
rust, or any other debris, before applying anti-seize
compound, Part Number 3823097.

Inspect the wastegate actuator. Refer to Procedure


010-050.
Inspect the turbocharger casings.
Replace the housing if through cracks are found in the
outer walls.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-26 Section 10 - Air Intake System - Group 10

Cracking of the turbine housing inlet flange and the inlet


duct generally requires replacement of the turbine
housing. Acceptance and rejection guidelines are shown
in these illustrations. If an exhaust gasket is available,
always make certain that cracks do not exist within the
sealing area.
Check that the turbine housing inlet flange flatness is
within 0.1 mm [0.004 in] before accepting the housing for
reuse.

Flange Fasteners - Clearance Holes


Check the fastener hole diameter. It must not be more
than 1.5 mm [0.006 in] larger than the maximum thread
diameter of the fastener.

CAUTION
If external cracks are found on the turbine housing,
the turbine housing must be replaced.

CAUTION
Turbine blades can be easily damaged and care is
required for the turbine housing installation process.
Cracking of the internal wall at the entry to the turbine
wheel (tongue) is acceptable as a service condition, and
the turbine housing can be re-used.

Inspect the turbocharger compressor v-band outlet and


the discharge elbow v-band connection for dents or
fretting.
Replace the turbocharger or discharge elbow, if damaged,
to prevent compressed air leaks.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-27

Use dial depth gauge, Part Number ST-537.


Push the rotor assembly away from the gauge.
Set the gauge to zero (0).

Push the rotor assembly toward the gauge and record the
reading.

Turbocharger Axial Clearance


mm in
0.025 MIN 0.001
0.127 MAX 0.005
If the turbocharger axial clearance is not within
specifications, the turbocharger must be replaced.

Use a dial indicator to check radial movement at the


compressor impeller nose.
Push the impeller away from the gauge and set the
indicator to zero. Push the impeller toward the gauge and
record the reading.

Turbocharger Radial Bearing Clearance


mm in
0.406 MIN 0.016
0.610 MAX 0.024
If the turbocharger radial clearance is not within
specifications, the turbocharger must be replaced.

If the engine experiences a turbocharger failure or any


other occasion where oil or debris is put into the charge
air system, the charge air system must be inspected and
cleaned. Refer to Procedure 010-027.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-28 Section 10 - Air Intake System - Group 10

Automotive with CM870


Inspect for cracks in the turbocharger and compressor
casings.
Replace the housing if through cracks in the outer walls
are found.
Inspect for cracks on the turbine inlet and exhaust
mounting flanges. Replace if any cracks are found.

Clean the retaining nut mating surfaces of the


turbocharger and the exhaust manifold.
Clean the mating surfaces with Scotch Brite™ 7448
abrasive pad.
The surface under the mounting nuts must be free of dirt,
rust, or any other debris before applying anti-seize
compound, Part Number 3823097.

Inspect the turbocharger compressor v-band outlet and


the discharge elbow v-band connection for dents or
fretting.
Replace the turbocharger or discharge elbow, if damaged,
to prevent compressed air leaks.
Inspect the compressor wheel for signs of rubbing against
the compressor cover. Replace the turbocharger if
rubbing evidence is seen.
Use light finger pressure to push the compressor wheel.
If the compressor wheel contacts the cover, replace the
turbocharger.
If the engine experiences a turbocharger failure or any
other occasion where oil or debris is put into the charge
air system, the charge air system must be inspected and
cleaned. Refer to Procedure 010-027.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-29

Check the axial movement of the turbocharger wheels and


shaft.

Turbocharger Axial Clearance


mm in
0.025 MIN 0.001
0.127 MAX 0.005
If the turbocharger axial clearance is not within
specifications, the turbocharger must be replaced.

Check the radial movement of the turbocharger wheels


and shaft.
Use light finger pressure to push the compressor wheel
toward the side of the compressor housing.
Repeat the procedure for the turbine wheel and housing.
Replace the turbocharger if either wheel contacts the
housing.

Automotive With CM871


Clean the turbocharger and exhaust manifold where the
retaining nut contacts the turbocharger and exhaust
manifold.
Clean the mating surfaces with Scotch Brite™ 7448
abrasive pad.
The surface under the mounting nuts must be free of dirt,
rust, or any other debris, before applying anti-seize
compound, Part Number 3823097.

Inspect the bearing housing and actuator for external oil


or coolant leaks.
Check for evidence of coolant in the oil supply and oil drain
fitting.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-30 Section 10 - Air Intake System - Group 10

Assemble
ISX Automotive with CM570, QSX15 with CM570 and
Power Generation with CM570
To install the turbine housing, position the V-band clamp
over the bearing housing and align the ink marks applied
during the disassembly process.
Apply anti-seize compound to the bearing housing
locating bore of the turbine housing.
Carefully slide the bearing and compressor housing
assembly into the turbine housing. Use the ink alignment
mark to locate the turbine housing assembly in the correct
orientation with the turbine housing.

Place the new V-band clamp in the correct orientation and


torque the locknut.
Torque value for Cummins®-branded turbochargers.
Torque Value: 18 N•m [ 160 in-lb ]
Torque value for Holset®-branded turbochargers.
Torque Value: 11.3 N•m [ 100 in-lb ]
Loosen the locknut 180 degrees, and torque the locknut.
Torque value for Cummins®-branded turbochargers.
Torque Value: 18 N•m [ 160 in-lb ]
Torque value for Holset®-branded turbochargers.
Torque Value: 11.3 N•m [ 100 in-lb ]
Make certain that the rotor assembly rotates freely and
neither compressor wheel nor turbine wheel is rubbing
against the housing.

Install
Automotive, Industrial with CM570 and Power
Generation without CM570
Apply a film of high-temperature anti-seize compound,
Part Number 3823097, to the turbocharger mounting
studs.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-31

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.
NOTE: If the exhaust manifold and turbocharger were
removed together in order for the turbocharger to clear the
lubricating oil cooler assembly, refer to Procedure
011-007 for installation of the exhaust manifold.
Install a new mounting gasket, the turbocharger, and the
four mounting nuts.
Tighten the mounting nuts.
Torque Value: 60 N•m [ 44 ft-lb ]

Install the discharge elbow and clamp onto the charge air
cooler pipe connection.
Do not tighten the clamp until the elbow is installed on the
turbocharger.

Install a new o-ring, the clamp, and the discharge elbow


to the turbocharger.
Tighten the clamp.
Torque Value: 9 N•m [ 80 in-lb ]

Install a new gasket, oil drain tube, and capscrews.


Tighten the capscrews.
Torque Value: 25 N•m [ 18 ft-lb ]
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-32 Section 10 - Air Intake System - Group 10

Install the turbocharger anti-rotation brace (if equipped) .


The end rests on the oil cooler housing.
This brace requires longer, 1.25 mm [0.049 in],
capscrews.
Tighten the capscrews.
Torque Value: 25 N•m [ 18 ft-lb ]

Pour approximately 50 to 60 cc [1.7 to 2 oz] of clean


engine oil into the turbocharger oil supply opening.

CAUTION
Proper routing of the turbocharger oil supply tube is
critical to prevent failure. Avoid any tube-to-metal
contact. (The inlet supply fitting must be oriented
slightly off vertical to allow proper alignment.)
If installing a new turbocharger, make sure the
turbocharger is aligned, loosen the compressor and
turbine v-bands, and adjust as needed. Tighten the v-
bands.
Torque Value: 9 N•m [ 80 in-lb ]
Torque Value: 12 N•m [ 106 in-lb ]
If installing a new turbocharger, install the male union
elbow.
Torque Value: 30 N•m [ 22 ft-lb ]
Install the turbocharger oil supply tube on the elbow.
Torque Value: 30 N•m [ 22 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-33

Install the intake and exhaust pipes to the turbocharger.


Tighten the clamp.
Torque Value: 9 N•m [ 80 in-lb ]

Automotive with CM870


Variable Geometry
Apply a film of high-temperature anti-seize compound,
Part Number 3823097, to the turbocharger mounting
studs.

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.

CAUTION
When installing lifting eye, be sure the shoulder of the
lifting eye is bottomed against bearing housing.
Failure to do so can result in failure of lifting eye and
personal injury.

CAUTION
If a lifting eye is installed in turbocharger bearing
housing, it is to be used exclusively for turbocharger
removal and installation. It is not to be used in
removal of the exhaust manifold, or engine. Doing so
will cause damage to the turbocharger.

CAUTION
Do not rotate the turbocharger turbine housing.
Loosening turbine v-band and rotating the turbine
housing can cause damage to internal variable
geometry mechanism.
The capscrew in the top of the turbocharger bearing
housing can be removed and replaced with a lifting eye to
aid in the installation of the turbocharger.
Install a new gasket, the turbocharger, and the four
mounting nuts. Tighten the mounting nuts.
Torque Value: 88 N•m [ 65 ft-lb ]
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-34 Section 10 - Air Intake System - Group 10

Install the discharge elbow and clamp onto the charge air
cooler pipe connection.
Do not tighten the clamp until the elbow is installed on the
turbocharger.

Install a new o-ring, the clamp, and the discharge elbow


to the turbocharger.
Tighten the clamp.
Torque Value: 9 N•m [ 80 in-lb ]

Install a new gasket, oil drain tube, and capscrews.


Tighten the capscrews.
Torque Value: 30 N•m [ 22 ft-lb ]

Install the intake and exhaust pipes to the turbocharger,


and tighten the clamps.
Torque Value: 9 N•m [ 80 in-lb ]
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-35

Automotive With CM871


Apply a film of high-temperature anti-seize compound,
Part Number 3823097, to the turbocharger mounting
studs and to the flange area on the retaining nuts. Properly
applying anti-seize compound will reduce the possibility of
the nuts loosening over time.

If installing a new turbocharger, install the coolant and oil


fittings into the bearing housing.
NOTE: Use a ratchet and deepwell socket to install these
fittings.
Torque Value: 30 N•m [ 22 ft-lb ]

CAUTION
Proper routing of the turbocharger oil supply tube is
critical to prevent failure. Avoid any tube-to-metal
contact.
Install the turbocharger oil supply hose onto the oil supply
fitting. The oil supply hose must point directly downward
in order for it to properly connect to the oil supply fitting
on the lubricating oil filter head.
Torque Value: 30 N•m [ 22 ft-lb ]
Install the turbocharger actuator coolant supply and return
fittings into the electronic actuator. Refer to Procedure
010-041.

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

CAUTION
Do not rotate the turbocharger turbine housing.
Loosening turbine v-band and rotating the turbine
housing can cause damage to internal variable
geometry mechanism.
NOTE: Thread a lifting strap around the turbocharger
bearing housing. Take care not to bend the coolant lines
when lifting the turbocharger.
Care must be taken not to damage the turbocharger
compressor inlet air temperature sensor, the turbocharger
speed sensor, and the turbocharger actuator coolant lines
when installing the turbocharger.
Install a new gasket, the turbocharger, and the four
mounting nuts. Tighten the mounting nuts.
Torque Value: 88 N•m [ 65 ft-lb ]
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-36 Section 10 - Air Intake System - Group 10

Install a new o-ring seal, the clamp, and the discharge


elbow to the turbocharger.
Tighten the clamps.
Torque Value: 9 N•m [ 80 in-lb ]

Install a new gasket, oil drain tube, and capscrews.


Tighten the capscrews.
Torque Value: 25 N•m [ 18 ft-lb ]
Connect the oil supply hose to the oil supply fitting located
on the lubricating oil filter head.
Tighten the oil supply hose.
Torque Value: 30 N•m [ 22 ft-lb ]

Finishing Steps
Automotive, Industrial with CM570 and Power
Generation without CM570
• Install the wastegate actuator hose. Refer to
Procedure 010-050.
• Start and operate the engine until the coolant
temperature reaches 82°C [180°F] and check for air,
coolant, and oil leaks.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-37

Automotive with CM870

CAUTION
Turbocharger speed sensor harness and turbocharger
compressor inlet air temperature sensor harnesses
must be tied securely and away from heat sources,
such as the exhaust manifold and exhaust pressure
sensor tube. Failure to do so can cause damage to the
sensor harness.

CAUTION
The turbocharger compressor inlet air temperature
sensor must be positioned so the sensor body is
pointing up and away from the exhaust manifold.
Failure to do so can cause sensor damage.

CAUTION
Do not twist coolant lines while tightening. Failure to
do so will damage coolant lines.
• Install the turbocharger coolant hoses. Refer to
Procedure 010-041.
• Connect the variable geometry actuator air supply
line. Refer to Procedure 010-113.
• Connect the electrical connectors on the
turbocharger speed sensor and the turbocharger
compressor air inlet temperature sensor. Refer to
Procedures 019-395 and 019-390 in the
Troubleshooting and Repair Manual, CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Fill the cooling system with coolant. Refer to
Procedure 008-018.
• Start and operate the engine until the coolant
temperature reaches 82°C [180°F] and check for air,
coolant, and oil leaks.
Turbocharger Coolant Hoses Signature, ISX, and QSX15 Engi [...]
Page 10-38 Section 10 - Air Intake System - Group 10

Automotive With CM871


• Install the charge air piping. Refer to Procedure
010-027.
• Install the aftertreatment adapter pipe. Refer to
Procedure 011-043.
• Install the turbocharger coolant hoses. Refer to
Procedure 010-041.
• Connect the turbocharger compressor air inlet
temperature sensor. Refer to Procedure 019-395 in
the ISX CM871 and ISM CM876 Electronic Control
System, Troubleshooting and Repair Manual,
Bulletin 4021560.
• Connect the electrical connector on the turbocharger
speed sensor, turbocharger electric actuator and the
turbocharger compressor air inlet temperature
sensor. Refer to Procedure 019-390 in the ISX
CM871 and ISM CM876 Electronic Control System,
Troubleshooting and Repair Manual, Bulletin
4021560.
• Connect the aftertreatment adapter pipe. Refer to
Procedure 011-043.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine and check for leaks.
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.

Turbocharger Coolant Hoses (010-041)


Preparatory Steps
Automotive 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.

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

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Disconnect the batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
• Drain the coolant. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Remove the turbocharger oil supply and oil drain
lines from the turbocharger. Refer to Procedure
010-033 (Turbocharger) in Section 10.
Signature, ISX, and QSX15 Engi [...] Turbocharger Coolant Hoses
Section 10 - Air Intake System - Group 10 Page 10-39

Automotive With CM871

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 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Disconnect the batteries. Refer to Procedure
013-009 (Battery and Cable Connections) in Section
13.
• Drain the coolant. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Remove the turbocharger oil drain line from the
turbocharger. Refer to Procedure 010-033
Turbocharger) in Section 10.

Remove
Automotive with CM870
Use a second wrench to hold the coolant hose coupling
while loosening the line.
Remove the turbocharger coolant supply line from the
bottom of the turbocharger and the lubricating oil filter
head.

Use a second wrench to hold the coolant hose coupling


while loosening the line.
Remove the turbocharger coolant return line from the top
of the turbocharger and the thermostat housing.
Turbocharger Coolant Hoses Signature, ISX, and QSX15 Engi [...]
Page 10-40 Section 10 - Air Intake System - Group 10

Automotive With CM871


Use a second wrench to hold the coolant hose coupling
while loosening the line.
Remove the turbocharger coolant supply hose from the
lubricating oil filter head (1).
Remove the smaller banjo bolt from the turbocharger
electric actuator coolant inlet port (2) and the large banjo
bolt from the turbocharger bearing housing coolant inlet
port (3).

Use a second wrench to hold the coolant hose coupling


while loosening the line.
Remove the turbocharger bearing housing coolant return
hose from the top of the turbocharger and the thermostat
housing (1).
Remove the turbocharger actuator coolant return hose
from the top of the turbocharger and the thermostat
housing (2).

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.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the turbocharger coolant hoses with solvent.
Dry with compressed air.
Signature, ISX, and QSX15 Engi [...] Turbocharger Coolant Hoses
Section 10 - Air Intake System - Group 10 Page 10-41

Check the o-rings for cuts or deformation. Replace as


necessary.
Check the turbocharger coolant hoses for cracks or other
damage.
Replace if damage is found.

Check the face of the coolant fittings on the engine and


on the turbocharger to be sure the o-ring is in place and
is not damaged.
A damaged or missing o-ring will result in a coolant leak.

Install
Automotive with CM870

CAUTION
Do not bend or kink hoses while tightening. Doing so
can damage the hoses.
Install the turbocharger coolant supply hose to the bottom
of the turbocharger and the lubricating oil filter head.
Tighten the fittings.
Use a second wrench to hold the coolant hose coupling
while tightening the line.
Torque Value: 46 N•m [ 34 ft-lb ]

CAUTION
Do not bend or kink hoses while tightening. Doing so
can damage the lines.
Check the face of the coolant fittings on the engine and
on the turbocharger to be sure the o-ring is in place and
is not damaged.
A damaged or missing o-ring will result in a coolant leak.
Install the turbocharger coolant return hose to the top of
the turbocharger and the thermostat housing. Tighten the
fittings.
Use a second wrench to hold the coolant hose coupling
while tightening the line.
Torque Value: 46 N•m [ 34 ft-lb ]
Turbocharger Coolant Hoses Signature, ISX, and QSX15 Engi [...]
Page 10-42 Section 10 - Air Intake System - Group 10

Install the tube brace onto the turbocharger coolant return


hose and the air tube.
Torque Value: 18 N•m [ 159 in-lb ]

Automotive With CM871

CAUTION
Do not bend or kink hoses while tightening. Doing so
can damage the hoses.

CAUTION
Do not use petroleum products on the turbocharger
coolant hose o-rings. The o-rings will swell and cause
the connection to leak.
Install the four new banjo sealing washers on the
turbocharger coolant supply hose.
Lubricate the sealing washers with clean engine coolant,
soapy water, or vegetable oil.
Install the turbocharger coolant supply hose to the
turbocharger bearing housing (3).
Torque Value: 41 N•m [ 30 ft-lb ]
Install the turbocharger coolant supply hose to the
turbocharger actuator (2).
Torque Value: 15 N•m [ 133 in-lb ]
Install the turbocharger coolant supply hose to the
lubricating oil filter head (1).
Torque Value: 54 N•m [ 40 ft-lb ]
NOTE: Use a second wrench to hold the coolant hose
coupling while tightening the hose.
Tighten the fittings.
Signature, ISX, and QSX15 Engi [...] Turbocharger Coolant Hoses
Section 10 - Air Intake System - Group 10 Page 10-43

CAUTION
Do not bend or kink hoses while tightening. Doing so
can damage the lines.

CAUTION
Do not use petroleum products on the turbocharger
coolant line o-rings. The o-rings will swell and cause
the connection to leak.
Install four new banjo sealing washers on the turbocharger
bearing housing coolant return hose and turbocharger
actuator coolant return tube.
Install the turbocharger coolant return hose to the
turbocharger. Tighten the fitting.
Torque Value: 46 N•m [ 34 ft-lb ]
Install the turbocharger coolant return hose in the
thermostat housing. Tighten the banjo fitting.
Torque Value: 24 N•m [ 18 ft-lb ]
Install the turbocharger actuator coolant hose to the
thermostat housing. Tighten the fitting.
Torque Value: 16 N•m [ 142 in-lb ]
It is possible for the turbocharger actuator coolant return
hose to contact the turbocharger coolant return hose
when the fittings are torqued. Be sure to space the hoses
apart while the fittings are torqued. If the hoses are not
spaced apart, hose failure can result.
NOTE: Use a second wrench to hold the coolant line
coupling while tightening the line.
Install the turbocharger actuator coolant hose to the
turbocharger actuator. Tighten the banjo fitting.
Torque Value: 24 N•m [ 18 ft-lb ]

Finishing Steps
Automotive 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 turbocharger oil supply and oil drain hoses
from the turbocharger. Refer to Procedure 010-033
(Turbocharger) in Section 10.
• Fill the engine with coolant. Refer to Procedure
008-018 (Coolant System) in Section 8.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Start the engine and check for leaks.
Turbocharger Wastegate Actuator Signature, ISX, and QSX15 Engi [...]
Page 10-44 Section 10 - Air Intake System - Group 10

Automotive With CM871

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 turbocharger oil drain line from the
turbocharger. Refer to Procedure 010-033.
• Fill the engine with coolant. Refer to Procedure
008-018.
• Connect the batteries. Refer to Procedure 013-009.
• Start the engine and check for leaks.

Turbocharger Wastegate Actuator


(010-050)
Initial Check
Most Signature, ISX and QSX15 engine models are
equipped with wastegate turbochargers to limit the peak
boost level and increase engine response at low rpm.
The wastegate actuator hose takes boost pressure from
the intake manifold through the control valve to the
wastegate capsule.

Inspect the wastegate actuator hose for cracks or holes.


Replace the hose if damaged.

CAUTION
A bent wastegate mounting bracket, actuator rod, or
lever can cause improper operation.
Inspect the wastegate mounting bracket, actuator rod,
and lever for damage.
If the wastegate mounting bracket, actuator rod, or lever
is bent, it must be replaced.
Signature, ISX, and QSX15 Engi [...] Turbocharger Wastegate Actuator
Section 10 - Air Intake System - Group 10 Page 10-45

WARNING
Exhaust and turbocharger components could be hot.
Use caution and wear protective clothing when
handling these components.
To verify the wastegate actuator travel, install Service Tool
Part Number 3165168 on the wastegate cover with the
magnetic base and the dial indicator resting on the end of
the actuator end link.

Disconnect the air supply line from the wastegate actuator


and install the air line from the air control valve, Part
Number ST-990-40, to the wastegate actuator.

Install the male quick-connect fitting, Part Number


3377244 (1), into the air control valve, Part Number
ST-990-40 (2), to the wastegate actuator for use with the
Compuchek® quick-disconnect fitting, Part Number
3376859 (3) attached to the pressure transducer, Part
Number 3164491 (4).

Connect the pressure adapter, Part Number 3164491 (1),


to the multimeter, Part Number 3164488 (2).
Turbocharger Wastegate Actuator Signature, ISX, and QSX15 Engi [...]
Page 10-46 Section 10 - Air Intake System - Group 10

Air leaks should not be detected through a functional


wastegate capsule.
Connect the air supply to the control valve. Apply
regulated air pressure of 100 kPa [14.7 psi] to the
wastegate actuator to measure the travel.
Cycle the air pressure to the actuator assembly several
times to work the system. Do not exceed 100 kPa [14.7
psi].

Measure the actuator rod for correct travel. If the actuator


travel is not within the specifications, the wastegate
must be adjusted. If adjustment is required, remove the
turbocharger.
To make sure an accurate measurement is obtained, it is
essential to use the specified tools and procedures.

Turbocharger Wastegate Rod Travel at 100 kPa [14.7


psi]
mm in
0.356 MIN 0.014
3.810 MAX 0.150

Preparatory Steps
Remove the turbocharger. Refer to Procedure 010-033.
Signature, ISX, and QSX15 Engi [...] Turbocharger Wastegate Actuator
Section 10 - Air Intake System - Group 10 Page 10-47

Inspect
To obtain an accurate measurement, do not remove the
wastegate valve cover or take the measurement from the
top of the capscrew that secures the wastegate valve
cover.
Using a micrometer depth gauge, take a measurement
from the face of the wastegate valve cover to the end of
the wastegate actuator end link. Do not apply air pressure
to the wastegate actuator.
If the wastegate wear measurement is less than 25.654
mm [1.010 in] then the turbocharger wastegate actuator
can be recalibrated and the turbocharger returned to
service. If the wastegate wear measurement is greater
than 25.654 mm [1.010 in], replace the turbocharger
turbine housing.

Remove
Remove the retaining clip from the control lever.

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

CAUTION
Be careful not to bend the control lever.
Air Regulator with Pressure Gauge
Slowly apply regulated air pressure to the boost capsule,
a maximum of 310 kPa [45 psi] can be used. Disconnect
the boost capsule actuator rod end from the turbocharger
wastegate lever rod when the rod is loose on the lever.
Turbocharger Wastegate Actuator Signature, ISX, and QSX15 Engi [...]
Page 10-48 Section 10 - Air Intake System - Group 10

NOTE: If the boost capsule diaphragm material is


ruptured and will not hold air pressure, it can be
necessary to manually pull the control rod outward in order
to overcome boost capsule spring-tension for removal of
the control rod from the turbocharger wastegate lever pin
while applying air pressure.
Disconnect the control rod from the turbocharger
wastegate lever pin.

Loosen the boost capsule mounting capscrews,


disconnect the wastegate actuator hose, and remove
assembly from the mounting bracket.

Inspect for Reuse


A new hose clamp is required to reinstall the signal line.
Disconnect the actuator hose from the wastegate actuator
by cutting the crimped hose clamp.

Air leaks should not be detected through a functional


wastegate capsule.
Connect clean regulated air pressure and a pressure
gauge to the actuator.
Apply 100 kPa [14.7 psi] to make sure the wastegate is
functioning properly.
Signature, ISX, and QSX15 Engi [...] Turbocharger Wastegate Actuator
Section 10 - Air Intake System - Group 10 Page 10-49

Measure the actuator rod for correct travel. If the actuator


travel is not within the specifications, the wastegate
must be calibrated.

Turbocharger Wastegate Rod Travel at 100 kPa [14.7


psi]
mm in
0.356 MIN 0.014
3.810 MAX 0.150
If no actuator travel is observed, inspect the wastegate
valve for seizure or damage. Refer to Procedure 010-055.

Adjust
CAUTION
To reduce the possibility of breaking the wastegate
pivot pin, use a wrench on the end link to support it
while loosening and/or tightening the actuator end-
link locknut.
Leave the setting pressure air supply connected to the
wastegate capsule.
Loosen the actuator end-link locknut.

Remove the actuator end-link retaining clip.


Remove the actuator end link from the wastegate lever.

Adjust the length of the end link by rotating to obtain


nominal travel.

Turbocharger Wastegate Actuator Rod Travel


mm in
0.78 NOM 0.031
Turbocharger Wastegate Actuator Signature, ISX, and QSX15 Engi [...]
Page 10-50 Section 10 - Air Intake System - Group 10

After adjusting is completed, tighten the end-link locknut


against the end link.
Torque Value: 8.5 N•m [ 75 in-lb ]

Cycle the air pressure to the wastegate actuator several


times to work the system.
Verify the actuator travel is within specifications.

Install the retaining clip.


Disconnect the regulated air pressure line from the
wastegate actuator.

Install
If a new actuator is being installed, install the adjusting
end link onto the shaft of the precalibrated wastegate
actuator assembly.
Thread the new end link several turns onto the shaft of the
new pre-set actuator assembly.
Signature, ISX, and QSX15 Engi [...] Turbocharger Wastegate Actuator
Section 10 - Air Intake System - Group 10 Page 10-51

Install the new pre-set actuator assembly onto the bracket,


so the actuator clamp is in position to give access to the
capscrew.
If the capscrew can not be reached, remove the actuator
and carefully rotate the actuator assembly until the
capscrew is accessible.
Fit the actuator assembly and nuts.
Torque Value: 8.5 N•m [ 75 in-lb ]

With the valve held closed (pushed toward the compressor


housing), rotate the end link until the hole aligns with the
crank-arm pin, so the end link can be fitted over the pin
without using force.
The setting is correct if, by rotating the end link
clockwise an extra half-turn, the end link can no longer
be fitted onto the crank-arm pin.

Fit the new e-clip (snap ring) provided in the kit.

Tighten jam-nut against end link.


Torque Value: 8.5 N•m [ 75 in-lb ]
Turbocharger Wastegate Valve Body Signature, ISX, and QSX15 Engi [...]
Page 10-52 Section 10 - Air Intake System - Group 10

Remove the actuator clamp.

Finishing Steps
Reinstall the turbocharger. Refer to Procedure 010-033.

Turbocharger Wastegate Valve Body


(010-055)
Inspect for Reuse
The wastegate actuator end-link must be removed to
inspect the turbocharger wastegate. Refer to Procedure
010-050.
Inspect the lever pin.
If the lever pin is worn excessively, replace the
turbocharger. Refer to Procedure 010-033.

Rotate the lever by hand to verify that the shaft turns freely
and is not seized.
Check for excessive movement between the shaft and
bushing.
Replace the turbine housing if the shaft and bushing are
damaged or seized.
Refer to the Turbocharger Master Repair Manual, Bulletin
3580555.
Signature, ISX, and QSX15 Engi [...] Intake Manifold Pressure
Section 10 - Air Intake System - Group 10 Page 10-53

The turbocharger must be removed from the engine and


placed in a vertical position sitting on the compressor inlet
to perform the wastegate valve wear measurement. Refer
to Procedure 010-033.
To make sure of an accurate measurement, do not
remove the wastegate valve cover or take the
measurement from the top of the capscrews securing the
wastegate valve cover.
Use a micrometer depth gauge to take a measurement
from the face of the wastegate valve cover to the end of
the wastegate actuator end link. Do not apply any air
pressure to the wastegate actuator.

Wastegate Wear Measurement


mm in
25.654 MAX 1.010
Calibrate the turbocharger wastegate actuator if the
wastegate wear measurement is less than specifications.
Refer to Procedure 010-050 for wastegate actuator
recalibration procedure.
Replace the turbocharger if the wastegate wear
measurement is greater than specifications. Refer to
Procedure 010-033 for the replacement procedure.

Intake Manifold Pressure (010-057)


Measure
Install a 0 to 2030 mm Hg [0 to 80 in Hg] manometer (or
gauge) in the straight threaded plug hole in the air inlet
connection.

Operate the engine at rated rpm and full load. Compare


the value to the specifications given in the engine
performance data sheets.
NOTE: Stall speed is not full power.
Air Intake Connection Signature, ISX, and QSX15 Engi [...]
Page 10-54 Section 10 - Air Intake System - Group 10

Air Intake Connection (010-080)


Preparatory Steps
Automotive, Industrial with CM570 and Power
Generation without CM570
Disconnect the air pipe from the charge air cooler to the
air inlet connection.
Disconnect the boost sensor wire.
Remove the four-step wastegate controller wires, hose,
mounting capscrews, and controller.

Automotive with CM870


• Remove the charge air cooler piping. Refer to
Procedure 010-027.
• Remove the EGR mixer. Refer to Procedure
011-021.
• Disconnect the engine wiring harness from the
intake manifold pressure sensor and intake manifold
air temperature sensor.

Automotive With CM871


Remove or disconnect the following:
• Change air piping. Refer to Procedure 010-027.
• Intake manifold pressure temperature sensor. Refer
to Procedure 019-370 in the CM871 and CM876
Troubleshooting and Repair Manual Electronic
Control System ISX and ISM Engines, Bulletin
4021560.
• Air compressor supply line. Refer to Procedure
012-014.
• Front EGR Connection tube and EGR venturi. Refer
to Procedure 011-025.
• EGR differential pressure sensor. Refer to
Procedure 019-370 in the Electronic Control System
CM871 and CM876 Signature, ISX and QSX15
Engines, Bulletin 4021560.
• EGR differential pressure sensing tubes. Refer to
Procedure 011-027.
Signature, ISX, and QSX15 Engi [...] Air Intake Connection
Section 10 - Air Intake System - Group 10 Page 10-55

Remove
Automotive with CM870
Remove the four capscrews holding the air intake
connection to the cylinder head.
Remove and discard the gasket.

Automotive With CM871


Remove the four capscrews that hold the air intake
connection to the cylinder head.
Remove and discard the gasket.

Automotive, Industrial with CM570 and Power


Generation without CM570
Remove the four mounting capscrews, air inlet
connection, and gasket.
Remove and discard the gasket.

Clean and Inspect for Reuse


All Applications

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.
Inspect the air intake connection for the amount of carbon
on the inside of the air intake connection.
Air Intake Connection Signature, ISX, and QSX15 Engi [...]
Page 10-56 Section 10 - Air Intake System - Group 10

Clean the air intake connection. Saturate the inside of the


air intake with safety solvent. Mineral based solvents can
be used if expected results with the safety solvent are
not acceptable.
Clean the debris with a non-abrasive brush. Dry the air
intake connection with compressed air.
Inspect for cracks or damage threads. Replace if
necessary.
Inspect the cylinder head air intake area.
Some soot build up inside the cylinder head is normal and
will not affect engine performance. Clean the air intake to
cylinder head surface with Scotch Brite™ 7448 abrasive
pad or a gasket scrapper. Do not use power tools
combined with an abrasive pad to clean the gasket
surfaces.

Install
Automotive, Industrial with CM570 and Power
Generation without CM570
Install the four mounting capscrews, air inlet connection,
and new gasket.

Install the four-step wastegate controller, mounting


capscrews, hose, and controller wires.
Connect the boost sensor wire.
Connect the air pipe from the charge air cooler to the air
inlet connection.
Signature, ISX, and QSX15 Engi [...] Air Intake Connection
Section 10 - Air Intake System - Group 10 Page 10-57

Automotive with CM870


Install a new gasket between the cylinder head and the air
intake connection.
Install and tighten the four capscrews.
Torque Value: 45 N•m [ 33 ft-lb ]

Automotive With CM871


Install a new gasket between the cylinder head and the air
intake connection.
Install and tighten the four capscrews.
Torque Value: 45 N•m [ 33 ft-lb ]

Finishing Steps
Automotive, Industrial with CM570 and Power
Generation without CM570
Connect the air pipe from the charge air cooler to the air
inlet connection.
Connect the boost sensor wire.
Install the four-step wastegate controller wires, hose,
mounting capscrews, and controller.

Automotive with CM870


• Install the four-step wastegate controller, mounting
capscrews, hose, and controller wires.
• Connect the boost sensor wire.
• Connect the air pipe from the charger air cooler to
the air inlet connection.
• Connect the engine wiring harness to the intake
manifold pressure sensor and intake manifold air
temperature sensor.
• Install the EGR mixer. Refer to Procedure 011-021.
• Install the charge air cooler piping. Refer to
Procedure 010-027.
• Start and operate the engine. Check for air leaks.
Turbocharger Wastegate Controller Signature, ISX, and QSX15 Engi [...]
Page 10-58 Section 10 - Air Intake System - Group 10

Automotive With CM871


Install or connect the following:
• Front EGR connection tube and EGR venturi. Refer
to Procedure 011-025.
• Air compressor supply line. Refer to Procedure
012-014.
• Intake manifold pressure/temperature sensor. Refer
to Procedure 019-370 in the CM871 and CM875
Troubleshooting and Repair Electronic Control
System ISX and ISM Engines, Bulletin 4021560.
• Charge air cooler piping. Refer to Procedure
010-027.
• Start and operate the engine. Check for air 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.

Turbocharger Wastegate Controller


(010-109)
Remove
Use a 3/8-inch wrench to remove the nut holding the
electrical connection of the four-step wastegate controller
coil.
Remove the connection.

Remove the four capscrews.


Remove the coil and the fuel shield.
Remove the spring washer, valve disc, and actuator
spacer from the valve housing.
Signature, ISX, and QSX15 Engi [...] Turbocharger Wastegate Controller
Section 10 - Air Intake System - Group 10 Page 10-59

Inspect for Reuse


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 coil if not within specifications.
NOTE: If the coil assembly shows 0 ohm, there is an
electrical short in the coil.
Tighten the nut that holds the electrical connection post
on the coil.
Torque Value: 3 N•m [ 25 in-lb ]

Resistance
12-VDC 6 to 10 ohms
24-VDC 24 to 40 ohms

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

NOTE: The coil must be orientated with the electrical


connection post on the bottom.
NOTE: Make sure the coil is the correct voltage (12 VDC).
The coil voltage and part number are cast into the terminal
connection end of the coil.
• Align the spacer and valve disc on the control valve
body.
• Install a new o-ring.
• Put the spring washer on the valve disc with the
cavity side positioned upward.
• Install the shield and coil on the front cover.
• Install a new o-ring and tighten the capscrews.
Torque Value: 3 N•m [ 25 in-lb ]
Turbocharger, Variable Geometry Actuator Signature, ISX, and QSX15 Engi [...]
Page 10-60 Section 10 - Air Intake System - Group 10

• Install the electrical connection on the coil.


• Install the nut on the threaded post of the coil.
• Use two wrenches to hold the post of the nut firmly
while tightening the connection nut.
Torque Value: 3 N•m [ 25 in-lb ]

Turbocharger, Variable Geometry


Actuator (010-113)
General Information
Variable Geometry
The purpose of the variable geometry turbocharger is:
When the EGR flow is commanded, the variable geometry
turbocharger will close the nozzle in the turbine housing
to create more back pressure in the exhaust manifold to
force exhaust gas back into the engine.

The turbocharger also functions to improve engine


performance by building boost more quickly during
acceleration.
Signature, ISX, and QSX15 Engi [...] Turbocharger, Variable Geometry Actuator
Section 10 - Air Intake System - Group 10 Page 10-61

The variable geometry turbocharger functions as a


standard turbocharger with the addition of the following:
• A speed sensor (1) in the bearing housing to monitor
turbocharger operation.
• Water-cooled bearing housings (in addition to oil
lubrication)
• The sliding nozzle (2) is actuated by a pneumatic
actuator attached to the vehicle (brake) air supply
system
• The pneumatic actuator (3) operated by an air control
valve (4)
• On some engines, a filter and shutoff valve (5) are
used in the air line between the control valve (4) and
the air supply tank (6)
• When the variable geometry turbocharger
mechanism opens, a noise can be heard as air is
released from the actuator (3) through the control
valve (4).

Preparatory Steps
Variable Geometry

CAUTION
The keyswitch must be in the OFF position to make
sure no air pressure is present at the actuator.
• Remove the air line from the actuator.

Remove
Variable Geometry

CAUTION
The keyswitch must be in the OFF position to make
sure no air pressure is present at the actuator.
Remove the capscrew holding the actuator rod to the
turbocharger cross-shaft.
Remove the snap ring from the cross-shaft.
Turbocharger, Variable Geometry Actuator Signature, ISX, and QSX15 Engi [...]
Page 10-62 Section 10 - Air Intake System - Group 10

WARNING
Keep fingers and hands away from the actuator link to
reduce the possibility of personal injury as a result of
sudden movement when air is supplied.
Loosen the two capscrews holding the actuator to the
turbocharger bearing housing.
Use coupling, Part Number 3824843, to apply 414 kPa [60
psi] regulated air pressure to the actuator air inlet, to
reduce the spring load at the linkage.
Remove the two loosened capscrews and actuator.

Inspect for Reuse


Variable Geometry
Inspect the actuator mounting bracket, rod, and body.
If the actuator is bent or cracked, it must be replaced.
Inspect the bushing in the actuator rod end that attaches
to the turbocharger cross-shaft for wear, scoring, or other
damage.
Replace the actuator if damage is found.

Inspect the outside diameter of the turbocharger cross-


shaft pin.
Replace the turbocharger if wear is found.
Signature, ISX, and QSX15 Engi [...] Turbocharger, Variable Geometry Actuator
Section 10 - Air Intake System - Group 10 Page 10-63

Test
Variable Geometry
Attach a dial indicator as shown, so the shaft is in line with
the actuator rod.
Set the dial indicator to zero, with no air pressure applied
to the actuator.
Connect clean, regulated air pressure and a pressure
gauge to the actuator.
Apply a minimum of 414 kPa [60 psi] to make sure the
actuator is functioning properly.
The rod must move without any sticking.

Actuator Movement Range


mm in
12 MIN 0.472
Air must not be heard leaking through a functional
actuator.
Spray soapy water on the actuator housing to check for
air leaks.
Replace the actuator housing if leaks are found.
Replace the actuator if no movement of the actuator rod
is detected, the actuator is sticking, or an air leak is found.
This test can be performed with the actuator removed or
installed on the turbocharger.

Install
Variable Geometry

WARNING
Keep fingers and hands away from the actuator link to
reduce the possibility of personal injury as a result of
sudden movement when air is supplied.
Use coupling, Part Number 3824843, to apply 414 kPa [60
psi] regulated air pressure to the actuator.
Install the actuator on the turbocharger bearing housing.
Install and tighten the two capscrews.
Torque Value: 17 N•m [ 150 in-lb ]

Install the actuator rod to the turbocharger cross-shaft.


Install the snap ring.
Install and tighten the capscrew.
Torque Value: 23 N•m [ 17 ft-lb ]
Turbocharger Air Shutoff Valve Filter Signature, ISX, and QSX15 Engi [...]
Page 10-64 Section 10 - Air Intake System - Group 10

Finishing Steps
Variable Geometry
• Install actuator air line.
• Start and operate the engine.
• Verify proper operation and check for air leaks.
If a 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.

Turbocharger Air Shutoff Valve Filter


(010-114)
Preparatory Steps
Variable Geometry

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

WARNING
Air pressure must be released from the system before
removing the turbocharger control shutoff valve. The
turbocharger control shutoff valve is under pressure
and can cause personal injury.
• Release the air pressure from the compressed air
system.

Remove
Variable Geometry
Use filter wrench and remove the air filter from the
turbocharger control shutoff valve.
Signature, ISX, and QSX15 Engi [...] Turbocharger Air Shutoff Valve Filter
Section 10 - Air Intake System - Group 10 Page 10-65

Clean and Inspect for Reuse


Variable Geometry

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the turbocharger control shutoff valve filter head
threads with a lint free cloth.
Inspect the threads for damage. If damage is found,
replace the turbocharger control shutoff valve filter head.
Refer to Procedure 010-115.
Inspect the filter head for signs of water entrapment or
contamination. If water entrapment or contamination is
found, inspect the turbocharger control shutoff valve lines,
turbocharger control shutoff valve, and turbocharger
control valve. Replace if signs of corrosion are found.
Use compressed air to clean fittings, lines, and
turbocharger control shutoff valve.

Install
Variable Geometry
Apply a thin coat of lubricant on the filter gasket.
Install and hand tighten a new turbocharger control shutoff
valve filter on the turbocharger control shutoff valve body.
Use a filter wrench to tighten the filter full turn after gasket
contact.

Finishing Steps
Variable Geometry
• Start the engine and verify proper operation.
• Inspect for air leaks and proper variable geometry
turbocharger operation.
Turbocharger Control Shutoff Valve Filter Head Signature, ISX, and QSX15 Engi [...]
Page 10-66 Section 10 - Air Intake System - Group 10

Turbocharger Control Shutoff Valve


Filter Head (010-115)
Preparatory Steps
Variable Geometry

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

WARNING
Air pressure must be released from the system before
removing the turbocharger control shutoff valve. The
turbocharger control shutoff valve is under pressure
and can cause personal injury.
• Remove the turbocharger control shutoff valve filter.
Refer to Procedure 010-114.
• Remove the air line from the turbocharger control
valve. Refer to Procedure 019-388 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Disconnect the air line from the air tank.
• Disconnect the electrical harness from the
turbocharger air control shutoff valve.
• Remove the air shutoff valve. Refer to Procedure
019-386 in the Troubleshooting and Repair Manual
CM870 Electronic Control System Signature and ISX
Engines, Bulletin 4021334.

Remove
Variable Geometry
Remove the two mounting capscrews.
Remove the turbocharger control shutoff valve filter head.
Signature, ISX, and QSX15 Engi [...] Turbocharger Control Shutoff Valve Filter Head
Section 10 - Air Intake System - Group 10 Page 10-67

Clean and Inspect for Reuse


Variable Geometry

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the turbocharger control shutoff valve filter head
threads with a lint free cloth.
Inspect the threads for damage. If damage is found,
replace the turbocharger control shutoff valve filter head.
Inspect the fittings and lines for signs of water entrapment
or contamination. If water entrapment or contamination is
found, inspect the turbocharger control shutoff valve.
Use compressed air to clean the fittings, lines, and
turbocharger control shutoff valve and the turbocharger
control valve.
Inspect the vehicle air drier for proper operation.
Replace the lines and turbocharger control shutoff valve,
if necessary.
Repair the cause of water entrapment or contamination.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
Clean the turbocharger control shutoff valve filter head
mounting surfaces with solvent.
Dry with compressed air.
Check for cracks or damage. Replace the turbocharger
control shutoff valve filter head, if cracks or damage are
found.

Install
Variable Geometry
Install the two mounting capscrews and the turbocharger
control shutoff valve filter head.
Torque Value: 45 N•m [ 33 ft-lb ]
Turbocharger, Variable Geometry Actuator Air Supply Lin [...] Signature, ISX, and QSX15 Engi [...]
Page 10-68 Section 10 - Air Intake System - Group 10

Finishing Steps
Variable Geometry
• Install the air shutoff valve. Refer to Procedure
019-386 in the Troubleshooting and Repair Manual
CM870 Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Connect the air line from the air tank.
• Install the air line from the turbocharger control
valve. Refer to Procedure 019-388 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Install the turbocharger control shutoff valve filter.
Refer to Procedure 010-114.
• Connect the electrical harness to the turbocharger
control shutoff valve.
• Operate the engine and check for leaks.

Turbocharger, Variable Geometry


Actuator Air Supply Line (010-120)
Remove
CAUTION
The turbocharger control valve is very sensitive to
contamination. Failure to prevent contamination from
entering the turbocharger control valve air lines will
cause damage to the turbocharger control valve.
Make sure the keyswitch is in the OFF position.
Disconnect the air line at the turbocharger actuator.
Mask the end of the air line and turbocharger actuator to
prevent contamination.

Remove the p-clip at the thermostat housing.


Disconnect the air line from the turbocharger control
valve.
Mask the end of the air line and turbocharger control valve
to prevent contamination.
Remove the turbocharger control valve air line.
Signature, ISX, and QSX15 Engi [...] Turbocharger, Variable Geometry Actuator Air Supply Lin [...]
Section 10 - Air Intake System - Group 10 Page 10-69

Inspect for Reuse


Inspect the air line connections for wear, cracks, or other
damage.
Inspect the o-rings for signs of damage or distortion.
Replace as necessary.

Install
CAUTION
The turbocharger control valve is very sensitive to
contamination. Failure to prevent contamination from
entering the turbocharger control valve air lines will
cause damage to the turbocharger control valve.

CAUTION
Do not use thread sealant. The use of thread sealant
will cause damage to the turbocharger control valve.
Mask both ends of the turbocharger actuator supply line
before installing.
Install the turbocharger actuator air supply line.

Connect the air supply line to the turbocharger air control


valve.
Torque Value: 16 N•m [ 12 ft-lb ]
Connect the p-clip to the thermostat housings.
Torque Value: 20 N•m [ 15 ft-lb ]
Connect the air supply line to the turbocharger actuator.
Torque Value: 16 N•m [ 12 ft-lb ]
Start and run the engine.
Verify proper operation.
Check for air leaks.
Turbocharger, Variable Geometry Control Valve Air Suppl [...] Signature, ISX, and QSX15 Engi [...]
Page 10-70 Section 10 - Air Intake System - Group 10

Turbocharger, Variable Geometry


Control Valve Air Supply Line
(010-121)
Remove
CAUTION
The turbocharger control valve is very sensitive to
contamination. Failure to prevent contamination from
entering the turbocharger control valve air lines will
cause damage to the turbocharger control valve.
Make sure the keyswitch is in the OFF position.
Bleed the air from the control valve air supply line.
Disconnect the air line at the turbocharger control valve.
Mask the end of the air line and turbocharger control valve
to prevent contamination.
Remove the p-clips holding the air line to the engine.
Disconnect the air line from the turbocharger control
shutoff valve.

Remove the turbocharger control valve air supply line.


Mask the end of the air line and turbocharger control
shutoff valve to prevent contamination.

Inspect for Reuse


Inspect the air line connections for wear, cracks, or other
damage.
Inspect the o-rings for signs of damage or distortion.
Replace as necessary.
Signature, ISX, and QSX15 Engi [...] Variable Geometry Turbocharger Actuator, Electric
Section 10 - Air Intake System - Group 10 Page 10-71

Install
CAUTION
The turbocharger control valve is very sensitive to
contamination. Failure to prevent contamination from
entering the turbocharger control valve air lines will
cause damage to the turbocharger control valve.

CAUTION
Do not use thread sealant. The use of thread sealant
will cause damage to the turbocharger control valve.
Mask both ends of the turbocharger control valve air
supply line before installing.
Install the turbocharger control valve air supply line.

Connect the air supply line to the turbocharger control


valve.
Torque Value: 20 N•m [ 15 ft-lb ]
Connect the p-clips holding air line to engine.
Torque Value: 20 N•m [ 15 ft-lb ]
Connect the air supply line to the turbocharger control
shutoff valve.
Torque Value: 16 N•m [ 12 ft-lb ]
Start and run the engine.
Verify proper operation.
Check for air leaks.

Variable Geometry Turbocharger


Actuator, Electric (010-134)
General Information
The purpose of the variable geometry turbocharger:
When the EGR flow is commanded, the variable
geometry turbocharger will close the nozzle in the
turbine housing to create more back pressure in the
exhaust manifold, to force the EGR flow back into the
engine.
Closing the variable geometry turbocharger will also
increase exhaust gas temperature under certain
normal engine operating conditions and during
aftertreatment regeneration events.
The turbocharger also functions to improve engine
performance by building boost more quickly during
acceleration.
Refer to Procedure 011-999, Exhaust System - Overview,
for further information regarding variable geometry
turbocharger and aftertreatment system interactions.
This procedure provides service information for the
electronically controlled variable geometry turbocharger
actuators.
NOTE: To avoid improper installation of the turbocharger
actuator, follow each step in its entirety and in the proper
sequence.
Variable Geometry Turbocharger Actuator, Electric Signature, ISX, and QSX15 Engi [...]
Page 10-72 Section 10 - Air Intake System - Group 10

Preparatory Steps

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
• Clean the area around the turbocharger actuator and
dry with compressed air.
• Drain the engine coolant. Refer to Procedure
008-018.
• Disconnect the turbocharger actuator coolant supply
and return lines from the turbocharger actuator.
Refer to Procedure 010-041.
• Remove the turbocharger actuator wiring harness
zip ties.

Remove
Disconnect the wiring harness from the turbocharger
actuator by sliding the locking tang to the open position,
and then pushing down on the release lever and pulling
the connection apart.

Remove the four turbocharger actuator mounting


capscrews with a 5-mm allen wrench and discard the
capscrews.
Remove the actuator.
Remove and discard the turbocharger actuator sealing
gasket.

Inspect for Reuse


Use a clean cloth to wipe around the surface where the
turbocharger actuator seals to the turbocharger.
NOTE: Take care not to drop any dirt or debris into the
turbocharger.
Inspect the sealing surfaces and the sealing gasket for
signs of leaks, cracks, or other damage.
Signature, ISX, and QSX15 Engi [...] Variable Geometry Turbocharger Actuator, Electric
Section 10 - Air Intake System - Group 10 Page 10-73

If the sealing surface of the turbocharger is damaged and


causing a leak, replace the turbocharger. Refer to
Procedure 010-033.
If the sealing surface of the actuator is causing a leak,
replace only the actuator.

Inspect the pinion gear on the actuator for seizure,


excessive wear, or damaged teeth.
Replace the actuator if the pinion gear is seized or if the
teeth are worn or damaged.

Inspect the sector gear on the turbocharger for excessive


wear, damaged teeth, or a broken shaft.
Grasp the sector gear by hand and move it through its
operational range.
Within the turbocharger, there are solid end stops which
limit sector gear travel in both directions.
The sector gear must move smoothly by hand through the
range of motion. It takes considerable effort to begin
moving the sector gear. However, once the sector gear
begins to move, minimal force is required to continue
moving the sector gear through its operating range.

Rotate the sector gear toward the turbocharger


compressor cover (1) until it stops. The through hole in the
center of the sector gear must line up with the blind hole
in the bearing housing.
Verify that the sector gear is aligned by inserting the
alignment pin included in the actuator kit or a 3/16” or
5mm drill bit through the sector gear and into the bearing
housing.
Variable Geometry Turbocharger Actuator, Electric Signature, ISX, and QSX15 Engi [...]
Page 10-74 Section 10 - Air Intake System - Group 10

NOTE: Some ISX CM871 turbochargers were


manufactured without the small 3-mm alignment hole. In
order to check for full stroke when the sector gear is
rotated toward the turbine housing (2), half of the 5-mm
alignment hole (B) will be exposed at the compressor
housing side of the sector gear, as shown here.

Rotate the sector gear toward the turbocharger turbine


housing (2) until it stops. Half of the smaller 3-mm [.12 in]
alignment hole (A) will be exposed at the turbine housing
side of the sector gear.
If the sector gear does not go through the full range of
motion or if the sector gear requires excessive force to
move it by hand, replace the turbocharger. Refer to
Procedure 010-033.

Time
CAUTION
During the turbocharger actuator install test, the
pinion gear on the actuator will move. Keep hands and
tools away from the pinion gear during the test.
Signature, ISX, and QSX15 Engi [...] Variable Geometry Turbocharger Actuator, Electric
Section 10 - Air Intake System - Group 10 Page 10-75

• Continue through the entire turbocharger actuator


Time Step before attempting to troubleshoot any
other fault codes.
• Verify that the turbocharger actuator is removed
from the turbocharger bearing housing.
• Verify that the turbocharger actuator electrical
connector is disconnected from the engine wiring
harness.
• Turn the keyswitch ON.
• Connect the turbocharger actuator electrical
connector to the engine wiring harness.
• If at any point the INSITE™ electronic service tool
status message indicates the test was stopped or
failed, turn the keyswitch OFF for 30 seconds and
key back ON. Then start over, beginning with the
actuator Time Step.
If Fault Code 2634 becomes active, disconnect the
turbocharger actuator connector from the engine wiring
harness with the keyswitch ON. Reconnect the
turbocharger actuator electrical connector. Fault Code
2634 will go inactive.
Fault Code 2198 could be active at this point in the
installation procedure when installing a new turbocharger
actuator on an engine built prior to January 1, 2007.
It is normal and expected to have Fault Code 2449 active
when a new turbocharger actuator is connected to the
engine, because it is not calibrated to the turbocharger.
Continue through the engine turbocharger actuator
installation procedure before attempting to troubleshoot
any other fault codes.

Connect INSITE™ electronic service tool.


In INSITE™ electronic service tool, go to the ECM
Diagnostic Tests screen.
From the list of tests, select VGT Electronic Actuator
Installation and Calibration and click on the “next” button.
Locate the column labeled “Value” and left click on the
down arrow. Select INSTALL ACTUATOR and select
START.
This will set the actuator pinion gear to a known position
to prepare it for installation to the turbocharger. This step
should take less than 30 seconds to complete with
INSITE™ electronic service tool.
INSITE™ electronic service tool will indicate when this step
is complete.
Disconnect the turbocharger actuator from the engine
wiring harness. Be sure to keep the keyswitch in the ON
position.
Fault Codes 2449 and 2636 will be active at this point in
the procedure. Continue through the turbocharger
actuator procedure before troubleshooting fault codes.
If the INSITE™ electronic service tool status message
indicates the test was stopped or failed, turn the keyswitch
OFF for 30 seconds and key back ON. Then start over,
beginning with the actuator Time Step.
Variable Geometry Turbocharger Actuator, Electric Signature, ISX, and QSX15 Engi [...]
Page 10-76 Section 10 - Air Intake System - Group 10

Grasp the sector gear by hand and rotate the sector gear
toward the turbocharger compressor cover until the
through hole in the sector gear lines up with the blind hole
in the bearing housing. Verify the sector gear is aligned
by inserting the alignment pin included in the actuator kit
or a 3/16” or 5mm drill bit through the sector gear and into
the bearing housing.
Coat the teeth on the sector gear with the high-
temperature grease from the packet supplied in the
installation kit.
NOTE: It is critical for smooth reliable operation of the
actuator to use the full amount of the Holset® supplied
high-temperature grease.

Remove the alignment pin or drill bit.

Install
CAUTION
Do not attempt to force the actuator onto the bearing
housing by using the capscrews. Misalignment can
cause damage to the actuator or turbocharger.
Align the actuator and gasket assembly with the
turbocharger bearing housing face with the two lower
capscrews. Be sure to use the new capscrews available
in the turbocharger actuator mounting kit.
Align the actuator to the bearing housing and slide the
actuator into place. The actuator pinion gear and the
turbocharger sector gear must engage smoothly. If not,
verify that the sector gear through-hole and the bearing
housing blind-hole are aligned.
You could possibly have to twist the actuator housing in
order to align it with the mounting holes.
Signature, ISX, and QSX15 Engi [...] Variable Geometry Turbocharger Actuator, Electric
Section 10 - Air Intake System - Group 10 Page 10-77

With the actuator aligned on the bearing housing, install


the remaining two capscrews.
Tighten the four capscrews in a crisscross pattern.
Torque Value: Step1 3 N•m [ 27 in-lb ]
Step2 11 N•m [ 97 in-lb ]

Calibrate
The turbocharger actuator must be calibrated to the
turbocharger. This step must be performed to make sure
proper turbocharger operation is achieved.
With the keyswitch in the ON position, connect the
turbocharger actuator into the engine wiring harness.
Calibration instructions:
Within the INSITE™ electronic service tool screen labeled
“VGT Electric Actuator Install and Calibrate”, locate the
column labeled “Value” and left click on the down arrow.
Select “Calibrate Actuator”.
Follow the instruction on the screen in order to calibrate
the new turbocharger actuator to the turbocharger.
INSITE™ electronic service tool will indicate when this step
is complete.
If INSITE™ electronic service tool status message
indicates the test was stopped or failed, turn the keyswitch
OFF for 30 seconds and key back ON. Then start over
beginning with the Timing Step.
It is normal to have an active Fault Code 2387 at this point.
Turn the keyswitch in the OFF position for 30 seconds.
Then key ON and refresh the fault code screen. All
turbocharger actuator fault codes can be inactive. Use
INSITE™ electronic service tool to clear all fault codes.

Finishing Steps
• Install the turbocharger actuator coolant supply and
return lines. Refer to Procedure 010-041.
• Fill the cooling system. Refer to Procedure 008-018.
Variable Geometry Turbocharger Actuator, Electric Signature, ISX, and QSX15 Engi [...]
Page 10-78 Section 10 - Air Intake System - Group 10

• Secure the turbocharger actuator wiring away from


hot and abrasive parts .
• Zip tie the turbocharger actuator harness to the two
ears on the actuator housing (1).
• Secure the turbocharger actuator harness,
turbocharger compressor inlet temperature sensor
harness, and the turbocharger speed sensor
harness to the turbocharger coolant outlet hose (2).
In order to prevent the wire harness from being
damaged, use two zip ties as shown.
• Secure the turbocharger actuator, speed sensor,
and compressor inlet temperature sensor wiring
harness as indicated (3).
• Operate the engine to make sure the turbocharger
actuator operates properly and all turbocharger
actuator fault codes are inactive.
Signature, ISX, and QSX15 Engi [...]
Section 11 - Exhaust System - Group 11 Page 11-a

Section 11 - Exhaust System - Group 11


Section Contents
Page
Aftertreatment Adapter Pipe .........................................................................................................................11-79
Clean and Inspect for Reuse......................................................................................................................... 11-80
Finishing Steps............................................................................................................................................. 11-81
Install............................................................................................................................................................11-81
Preparatory Steps......................................................................................................................................... 11-79
Remove.........................................................................................................................................................11-79
Aftertreatment Diesel Oxidation Catalyst .....................................................................................................11-96
Assemble....................................................................................................................................................11-101
Clean and Inspect for Reuse......................................................................................................................... 11-98
Finishing Steps............................................................................................................................................11-102
General Information.......................................................................................................................................11-96
Install..........................................................................................................................................................11-102
Preparatory Steps......................................................................................................................................... 11-96
Remove.........................................................................................................................................................11-97
Aftertreatment Diesel Particulate Filter ........................................................................................................11-71
Clean and Inspect for Reuse......................................................................................................................... 11-73
Finishing Steps............................................................................................................................................. 11-75
General Information.......................................................................................................................................11-71
Install............................................................................................................................................................11-74
Preparatory Steps......................................................................................................................................... 11-71
Remove.........................................................................................................................................................11-72
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting Bracket ...........................11-83
Clean and Inspect for Reuse......................................................................................................................... 11-84
Finishing Steps............................................................................................................................................. 11-86
General Information.......................................................................................................................................11-83
Install............................................................................................................................................................11-85
Preparatory Steps......................................................................................................................................... 11-84
Remove.........................................................................................................................................................11-84
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes ..............................................11-86
Clean and Inspect for Reuse......................................................................................................................... 11-87
General Information.......................................................................................................................................11-86
Install............................................................................................................................................................11-89
Remove.........................................................................................................................................................11-87
Aftertreatment Fuel Injector ..........................................................................................................................11-76
Clean and Inspect for Reuse......................................................................................................................... 11-77
Finishing Steps............................................................................................................................................. 11-79
Install............................................................................................................................................................11-78
Preparatory Steps......................................................................................................................................... 11-76
Remove.........................................................................................................................................................11-76
Aftertreatment Fuel Injector Flow ...............................................................................................................11-123
Finishing Steps............................................................................................................................................11-129
Initial Check................................................................................................................................................11-123
Leak Test....................................................................................................................................................11-127
Setup..........................................................................................................................................................11-123
Test.............................................................................................................................................................11-126
Aftertreatment Fuel Shutoff Manifold .........................................................................................................11-117
Clean and Inspect for Reuse........................................................................................................................11-119
Automotive With CM871...........................................................................................................................11-119
Automotive with CM876............................................................................................................................11-120
Finishing Steps............................................................................................................................................11-122
Install..........................................................................................................................................................11-121
Automotive With CM871...........................................................................................................................11-121
Automotive with CM876............................................................................................................................11-121
Preparatory Steps........................................................................................................................................11-117
Remove.......................................................................................................................................................11-117
Automotive With CM871...........................................................................................................................11-117
Automotive with CM876............................................................................................................................11-118
Signature, ISX, and QSX15 Engi [...]
Page 11-b Section 11 - Exhaust System - Group 11

Aftertreatment Injector Lines ......................................................................................................................11-106


Clean and Inspect for Reuse........................................................................................................................11-110
Automotive With CM871...........................................................................................................................11-110
Automotive with CM876............................................................................................................................11-112
Finishing Steps............................................................................................................................................11-116
Automotive With CM871...........................................................................................................................11-116
Automotive with CM876............................................................................................................................11-116
Install..........................................................................................................................................................11-113
Automotive With CM871...........................................................................................................................11-113
Automotive with CM876............................................................................................................................11-115
Preparatory Steps........................................................................................................................................11-106
Automotive With CM871...........................................................................................................................11-106
Automotive with CM876............................................................................................................................11-107
Remove.......................................................................................................................................................11-107
Automotive With CM871...........................................................................................................................11-107
Automotive with CM876............................................................................................................................11-109
Aftertreatment Inlet and Outlet .....................................................................................................................11-90
Assemble......................................................................................................................................................11-93
Clean and Inspect for Reuse......................................................................................................................... 11-92
Disassemble..................................................................................................................................................11-92
Finishing Steps............................................................................................................................................. 11-95
General Information.......................................................................................................................................11-90
Install............................................................................................................................................................11-93
Preparatory Steps......................................................................................................................................... 11-91
Remove.........................................................................................................................................................11-92
Aftertreatment System ................................................................................................................................11-103
Assemble....................................................................................................................................................11-105
Clean and Inspect for Reuse........................................................................................................................11-104
Disassemble................................................................................................................................................11-104
Finishing Steps............................................................................................................................................11-106
General Information.....................................................................................................................................11-103
Install..........................................................................................................................................................11-105
Preparatory Steps........................................................................................................................................11-103
Remove.......................................................................................................................................................11-103
EGR Connection Tubes .................................................................................................................................11-43
Clean and Inspect for Reuse......................................................................................................................... 11-46
Automotive with CM870..............................................................................................................................11-46
Automotive With CM871.............................................................................................................................11-46
Finishing Steps............................................................................................................................................. 11-50
Automotive with CM870..............................................................................................................................11-50
Automotive With CM871.............................................................................................................................11-51
Install............................................................................................................................................................11-47
Automotive with CM870..............................................................................................................................11-47
Automotive With CM871.............................................................................................................................11-49
Preparatory Steps......................................................................................................................................... 11-43
Automotive with CM870..............................................................................................................................11-43
Automotive With CM871.............................................................................................................................11-44
Remove.........................................................................................................................................................11-44
Automotive with CM870..............................................................................................................................11-44
Automotive With CM871.............................................................................................................................11-45
EGR Cooler ....................................................................................................................................................11-15
Clean and Inspect for Reuse......................................................................................................................... 11-18
Automotive with CM870..............................................................................................................................11-18
Automotive With CM871.............................................................................................................................11-21
Finishing Steps............................................................................................................................................. 11-29
Automotive with CM870..............................................................................................................................11-29
Automotive With CM871.............................................................................................................................11-30
Install............................................................................................................................................................11-26
Automotive with CM870..............................................................................................................................11-26
Automotive With CM871.............................................................................................................................11-28
Preparatory Steps......................................................................................................................................... 11-15
Automotive with CM870..............................................................................................................................11-15
Automotive With CM871.............................................................................................................................11-16
Signature, ISX, and QSX15 Engi [...]
Section 11 - Exhaust System - Group 11 Page 11-c

Pressure Test................................................................................................................................................11-24
Automotive with CM870..............................................................................................................................11-24
Automotive With CM871.............................................................................................................................11-25
Remove.........................................................................................................................................................11-16
Automotive with CM870..............................................................................................................................11-16
Automotive With CM871.............................................................................................................................11-17
EGR Cooler Connection ................................................................................................................................11-40
Clean and Inspect for Reuse.........................................................................................................................11-40
Finishing Steps.............................................................................................................................................11-42
Install............................................................................................................................................................11-42
Preparatory Steps.........................................................................................................................................11-40
Remove.........................................................................................................................................................11-40
EGR Cooler Coolant Lines ............................................................................................................................11-60
Clean and Inspect for Reuse.........................................................................................................................11-63
Automotive with CM870..............................................................................................................................11-63
Automotive With CM871.............................................................................................................................11-64
Finishing Steps.............................................................................................................................................11-67
Automotive with CM870..............................................................................................................................11-67
Automotive With CM871.............................................................................................................................11-67
Install............................................................................................................................................................11-64
Automotive with CM870..............................................................................................................................11-64
Automotive With CM871.............................................................................................................................11-65
Preparatory Steps.........................................................................................................................................11-60
Automotive with CM870..............................................................................................................................11-60
Automotive With CM871.............................................................................................................................11-61
Remove.........................................................................................................................................................11-61
Automotive with CM870..............................................................................................................................11-61
Automotive With CM871.............................................................................................................................11-61
EGR Differential Pressure Sensor Adapter ...................................................................................................11-57
Clean and Inspect for Reuse.........................................................................................................................11-58
Finishing Steps.............................................................................................................................................11-58
Install............................................................................................................................................................11-58
Preparatory Steps.........................................................................................................................................11-57
Remove.........................................................................................................................................................11-57
EGR Differential Pressure Sensor Tubes .....................................................................................................11-51
Clean and Inspect for Reuse.........................................................................................................................11-52
Automotive with CM870..............................................................................................................................11-52
Automotive With CM871.............................................................................................................................11-54
Finishing Steps.............................................................................................................................................11-55
Automotive with CM870..............................................................................................................................11-55
Automotive With CM871.............................................................................................................................11-55
Install............................................................................................................................................................11-54
Automotive with CM870..............................................................................................................................11-54
Automotive With CM871.............................................................................................................................11-55
Preparatory Steps.........................................................................................................................................11-51
Automotive With CM871.............................................................................................................................11-51
Remove.........................................................................................................................................................11-51
Automotive with CM870..............................................................................................................................11-51
Automotive With CM871.............................................................................................................................11-52
EGR Mixer ......................................................................................................................................................11-30
Clean and Inspect for Reuse.........................................................................................................................11-31
Finishing Steps.............................................................................................................................................11-32
Install............................................................................................................................................................11-31
Preparatory Steps.........................................................................................................................................11-30
Remove.........................................................................................................................................................11-30
EGR Valve ......................................................................................................................................................11-32
Assemble......................................................................................................................................................11-37
Automotive With CM871.............................................................................................................................11-37
Clean and Inspect for Reuse.........................................................................................................................11-35
Automotive with CM870..............................................................................................................................11-35
Automotive With CM871.............................................................................................................................11-35
Disassemble..................................................................................................................................................11-34
Automotive With CM871.............................................................................................................................11-34
Signature, ISX, and QSX15 Engi [...]
Page 11-d Section 11 - Exhaust System - Group 11

Finishing Steps.............................................................................................................................................11-39
Automotive with CM870..............................................................................................................................11-39
Automotive With CM871.............................................................................................................................11-39
Install............................................................................................................................................................11-38
Automotive with CM870..............................................................................................................................11-38
Automotive With CM871.............................................................................................................................11-38
Preparatory Steps.........................................................................................................................................11-32
Automotive with CM870..............................................................................................................................11-32
Automotive With CM871.............................................................................................................................11-33
Remove.........................................................................................................................................................11-33
Automotive with CM870..............................................................................................................................11-33
Automotive With CM871.............................................................................................................................11-34
EGR Valve Coolant Lines ..............................................................................................................................11-59
Clean and Inspect for Reuse.........................................................................................................................11-59
Finishing Steps.............................................................................................................................................11-60
Install............................................................................................................................................................11-60
Preparatory Steps.........................................................................................................................................11-59
Remove.........................................................................................................................................................11-59
EGR Valve Mounting Bracket ........................................................................................................................11-81
Clean and Inspect for Reuse.........................................................................................................................11-82
Finishing Steps.............................................................................................................................................11-82
Install............................................................................................................................................................11-82
Preparatory Steps.........................................................................................................................................11-81
Automotive With CM871.............................................................................................................................11-81
Remove.........................................................................................................................................................11-81
Exhaust Gas Pressure Sensor Adapter ........................................................................................................11-69
Finishing Steps.............................................................................................................................................11-70
Automotive with CM870..............................................................................................................................11-70
Inspect for Reuse..........................................................................................................................................11-70
All Applications...........................................................................................................................................11-70
Install............................................................................................................................................................11-70
All Applications...........................................................................................................................................11-70
Preparatory Steps.........................................................................................................................................11-69
Automotive with CM870..............................................................................................................................11-69
Remove.........................................................................................................................................................11-70
All Applications...........................................................................................................................................11-70
Exhaust Gas Pressure Sensor Tube .............................................................................................................11-55
Clean and Inspect for Reuse.........................................................................................................................11-56
Finishing Steps.............................................................................................................................................11-57
Install............................................................................................................................................................11-56
Preparatory Steps.........................................................................................................................................11-55
Remove.........................................................................................................................................................11-56
Exhaust Manifold, Dry .....................................................................................................................................11-1
Assemble........................................................................................................................................................11-9
Automotive with CM870................................................................................................................................11-9
Automotive, Industrial with CM570 and Power Generation without CM570....................................................11-9
Automotive With CM871...............................................................................................................................11-9
Clean and Inspect for Reuse...........................................................................................................................11-5
Automotive, Industrial with CM570 and Power Generation without CM570....................................................11-5
Automotive with CM870 and CM871.............................................................................................................11-6
Disassemble...................................................................................................................................................11-4
Automotive with CM870................................................................................................................................11-4
Automotive, Industrial with CM570 and Power Generation without CM570....................................................11-5
Automotive With CM871...............................................................................................................................11-5
Finishing Steps.............................................................................................................................................11-13
Automotive with CM870..............................................................................................................................11-13
Automotive, Industrial with CM570 and Power Generation without CM570..................................................11-13
Automotive With CM871.............................................................................................................................11-13
Initial Check....................................................................................................................................................11-1
Automotive with CM870................................................................................................................................11-1
Automotive With CM871...............................................................................................................................11-1
Install............................................................................................................................................................11-10
Automotive with CM870 and CM871...........................................................................................................11-10
Signature, ISX, and QSX15 Engi [...]
Section 11 - Exhaust System - Group 11 Page 11-e

Automotive, Industrial with CM570 and Power Generation without CM570..................................................11-11


Preparatory Steps...........................................................................................................................................11-3
Automotive with CM870................................................................................................................................11-3
Automotive, Industrial with CM570 and Power Generation without CM570....................................................11-3
Automotive With CM871...............................................................................................................................11-4
Remove..........................................................................................................................................................11-4
Repair.............................................................................................................................................................11-1
Automotive with CM870................................................................................................................................11-1
Exhaust Restriction .......................................................................................................................................11-14
Initial Check.................................................................................................................................................. 11-14
Heat Shield .................................................................................................................................................... 11-67
Clean and Inspect for Reuse......................................................................................................................... 11-68
Finishing Steps............................................................................................................................................. 11-69
Automotive with CM870..............................................................................................................................11-69
Install............................................................................................................................................................11-69
Automotive with CM870..............................................................................................................................11-69
Automotive With CM871............................................................................................................................. 11-69
Preparatory Steps......................................................................................................................................... 11-67
Automotive with CM870..............................................................................................................................11-67
Remove.........................................................................................................................................................11-68
Automotive with CM870..............................................................................................................................11-68
Automotive With CM871............................................................................................................................. 11-68
Signature, ISX, and QSX15 Engi [...]
Page 11-f Section 11 - Exhaust System - Group 11

This Page Left Intentionally Blank


Signature, ISX, and QSX15 Engi [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-1

Exhaust Manifold, Dry (011-007)


Initial Check
Automotive with CM870
Operate the engine and inspect the exhaust manifold for
leaks at the slip joints.
If the exhaust manifold is leaking at the slip joints, it
must be repaired.
NOTE: Some CM870 engines are equipped with exhaust
seal rings at the slip joints.

Automotive With CM871


NOTE: CM871 engines are equipped with exhaust seal
rings at the slip joints.
Operate the engine and inspect the exhaust manifold for
leaks at the slip joints.
If the exhaust manifold is leaking at the slip joints, it
must be repaired.

Repair
Automotive with CM870

WARNING
To reduce the possibility of personal injury from hot
surfaces, allow the engine to cool before beginning
work. Wear appropriate hand and eye protection.

Exhaust Manifold Slip Joint Seal Kit Contents


Part Description Quantity per Kit
Covers 2
Seal 1
Clamp 1
NOTE: Each kit contains parts for one slip joint repair.
Two kits will be needed to service an engine that has both
slip joints leaking.

Remove the turbocharger inlet piping. Refer to the OEM


troubleshooting and repair manual.
Twist the graphite seal in order to open it, allowing it to be
placed onto the exhaust manifold.
Exhaust Manifold, Dry Signature, ISX, and QSX15 Engi [...]
Page 11-2 Section 11 - Exhaust System - Group 11

The chamfered edge of the graphite seal faces the


exhaust manifold center section.
Slide the graphite seal ring over the exhaust manifold end
section and press it against the center section.
Align the split in the graphite ring so the open ends point
towards the parting line in the exhaust manifold, as shown
in the illustration.

NOTE: The EGR water return tube was removed in the


illustration in order to show the seal kit installation. The
seal kit can be installed without removing the EGR water
return tube.
Place the top cover over the slip joint and graphite seal
with the notch in the cover towards the center of the
exhaust manifold center section.
Because of tight clearances at the slip joint, it will possibly
be necessary to press the cover down and roll it to the top
of the slip joint.

NOTE: The EGR water return tube was removed in the


illustration in order to show the seal kit installation. The
seal kit can be installed without removing the EGR water
return tube.
Place the bottom cover over the slip joint and graphite seal
with the notch in the cover towards the center of the
exhaust manifold center section.
Signature, ISX, and QSX15 Engi [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-3

CAUTION
To reduce the possibility of damage to the EGR cooler
bellows, do not use the cooler bellows as a pivot point
for a pry bar when compressing the covers.
NOTE: The EGR water return tube was removed in the
illustration in order to show the seal kit installation. The
seal kit can be installed without removing the EGR water
return tube.
Compress the two covers together. The use of a pry bar
and/or mallet to accommodate the T bolt clamp will
possibly be necessary.
The T bolt of the clamp can be removed to aid in
installation.
Separate the clamp and place it over the two covers.
Tighten the clamp.
Torque Value: 11 N•m [ 100 in-lb ]
Or until the ends of the cover make contact.

Preparatory Steps
Automotive with CM870

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

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the charge air cooler piping. Refer to the
manufacturer's instructions.
• Remove the variable geometry turbocharger. Refer
to Procedure 010-033.
• Remove the heat shield. Refer to Procedure
011-032.
• Remove the EGR valve. Refer to Procedure 011-022.

Automotive, Industrial with CM570 and Power


Generation without CM570
• Remove the turbocharger. Refer to Procedure
010-033.
Exhaust Manifold, Dry Signature, ISX, and QSX15 Engi [...]
Page 11-4 Section 11 - Exhaust System - Group 11

Automotive With CM871

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

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Drain the cooling system. Refer to Procedure 008-018.
Remove the following:
• Charger air cooler piping. Refer to the OEM
troubleshooting and repair manual.
• Variable geometry turbocharger. Refer to Procedure
010-033
• Exhaust gas pressure sensor tube. Refer to
Procedure 011-027.

Remove

WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Remove two mounting capscrews and install two guide
studs.
Remove the remaining mounting capscrews, the spacers,
the exhaust manifold assembly and the gaskets.
Discard the gaskets.

Disassemble
Automotive with CM870
Disassemble the exhaust manifold end sections.
Discard the exhaust seal ring on the slip-joint, if equipped.
Signature, ISX, and QSX15 Engi [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-5

Automotive, Industrial with CM570 and Power


Generation without CM570
Remove the exhaust manifold end sections.

Automotive With CM871


Disassemble the exhaust manifold end sections.

Clean and Inspect for Reuse


Automotive, Industrial with CM570 and Power
Generation without CM570

WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to reduce the possibility of
personal injury when using a steam cleaner or high-
pressure water.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a 240-grit emery cloth to remove carbon deposits from
the sealing surfaces.
Steam-clean and dry with compressed air.
Exhaust Manifold, Dry Signature, ISX, and QSX15 Engi [...]
Page 11-6 Section 11 - Exhaust System - Group 11

Inspect for cracks or damage.


Inspect the manifold seal bore for wear.
Inspect the exhaust manifold turbocharger mounting
flange for warping.
NOTE: A charge air cooler failure can cause progressive
damage to the exhaust manifold. If the exhaust manifold
is damaged, check the charge air cooler. Refer to
Procedure 010-027.

Automotive with CM870 and CM871

WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to reduce the possibility of
personal injury when using a steam cleaner or high
pressure water.

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

Use a soft cloth or a shop towel wetted with a safety


solvent to remove carbon deposits from the sealing
surfaces.

Inspect the exhaust manifold turbocharger mounting


flange for warpage. The exhaust manifold mounting
surface must be flat to within 0.25 mm [0.010 in]. The
turbocharger mounting flange must have a surface
flatness of 0.13 mm [0.005 in].
Signature, ISX, and QSX15 Engi [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-7

Inspect for cracks or damage.


NOTE: A charge air cooler failure can cause progressive
damage to the exhaust manifold. If the exhaust manifold
is damaged, check the charge air cooler. Refer to
Procedure 010-027.

Check that the exhaust seal is fully seated against the


shoulder of the exhaust manifold male end section.
If the exhaust seal ring is not fully seated against the
shoulder, the exhaust seal ring must be replaced.

Inspect the exhaust manifold seal bore for wear.


Inspect the exhaust seal ring for signs of damage or
excessive wear.
The exhaust seal ring must not show signs of dents or
other signs of damage.
Measure the wear width on the exhaust seal ring.
The wear width must not be more than 1mm [0.04 in] wide
anywhere on the seal.

Wear width larger than 1 mm [0.04 in] indicates a failure


and the exhaust seal must be replaced.
Exhaust Manifold, Dry Signature, ISX, and QSX15 Engi [...]
Page 11-8 Section 11 - Exhaust System - Group 11

The wear width must be uniform around the seal ring. If


one side of the exhaust seal ring is worn more than the
other, the exhaust seal ring must be replaced.

Inspect the exhaust manifold slip-joints for signs of soot


leakage.
If there is no evidence of an exhaust leak from the slip-
joints and there is not visible cracks or damage, do not
remove the exhaust manifold seal rings.
If there is a failure or damage, remove the exhaust
manifold seal rings.

Remove the exhaust seal rings, located within the slip-


joint.
Use tin snips or side cuts, to cut half way through seal in
two locations about 25.4 mm [1 in] apart.

Grasp the portion of the seal between the cuts with a pair
of pliers.
Twist and pull the seal off of the exhaust manifold end
sections.
NOTE: Take care not to damage the seal carrier surface.
Discard the exhaust seal rings.
Signature, ISX, and QSX15 Engi [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-9

Inspect the exhaust seal ring mating surfaces of the male


and female sections of the exhaust manifolds.
If scratches or nicks can be felt with a fingernail on the
exhaust seal ring mating surfaces, the exhaust manifold
section must be replaced.

Assemble
Automotive with CM870
The exhaust manifold sections must be assembled on a
flat surface for proper alignment.
Install exhaust seal rings, if equipped.
Install the exhaust manifold end sections to the center
section.

Automotive, Industrial with CM570 and Power


Generation without CM570
The exhaust manifold sections must be assembled on a
flat surface for proper alignment.
Install the exhaust manifold end sections to the center
section.

Automotive With CM871


Place the exhaust seal ring onto the lip of the Exhaust Seal
Installer, Part Number 4918709.
Use a light coat of grease or clean engine oil to lubricate
the exhaust seal ring during assembly onto the male and
female sections of the exhaust manifolds.
Exhaust Manifold, Dry Signature, ISX, and QSX15 Engi [...]
Page 11-10 Section 11 - Exhaust System - Group 11

Position the seal installer and seal ring in line with the
sealing surface on the exhaust manifold and strike with a
lead or dead blow hammer until the seal is fully seated.

Install the exhaust manifold end sections to the center


section.
The end section bolt holes must be 152.4 mm [6 in] center
to center before installing onto the cylinder head.

Install
Automotive with CM870 and CM871
Install two guide studs into the center section mounting
location.
Do not use adhesive, grease, or heavy grease to hold the
gaskets in place on the cylinder head.
Install a new center section gasket.

Special capscrews with spacers are required for this


particular manifold.
Do not use short capscrews.
Signature, ISX, and QSX15 Engi [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-11

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.
Install the exhaust manifold over the guide studs.
Apply a film of high-temperature anti-seize compound to
the capscrew threads to make sure of proper loading on
capscrews.
Slide each manifold gasket between the exhaust manifold
and the cylinder head.
Install the capscrews and spacers through the exhaust
manifold and gasket into the cylinder head.
Remove the two guide studs and install the two remaining
capscrews.

Tighten the capscrews in the sequence shown.


Torque Value: 60 N•m [ 44 ft-lb ]

Automotive, Industrial with CM570 and Power


Generation without CM570
Install two guide studs into center section mounting
location.

Install the center mounting gasket over the guide studs.


Exhaust Manifold, Dry Signature, ISX, and QSX15 Engi [...]
Page 11-12 Section 11 - Exhaust System - Group 11

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.
Install the exhaust manifold assembly on the guide pins.

Special capscrews with spacers are required for this


particular manifold.
Do not use short capscrews.

Slide each exhaust manifold gasket between the manifold


and cylinder head.
Insert the exhaust manifold mounting capscrews and
spacer through the manifold and gasket and start
capscrews into the cylinder head.

To aid in future capscrew removal, apply a film of high-


temperature anti-seize compound to the capscrew
threads.
Remove the guide studs and install the remaining two
capscrews.
Signature, ISX, and QSX15 Engi [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-13

Tighten the capscrews in the sequence shown.


Torque values given have been established using anti-
seize compound as a lubricant.
Torque Value: Step1 30 N•m [ 22 ft-lb ]
Step2 55 N•m [ 41 ft-lb ]

Finishing Steps
Automotive with CM870
• Install the EGR valve. Refer to Procedure 011-022.
• Install the heat shield. Refer to Procedure 011-032.
• Install the variable geometry turbocharger. Refer to
Procedure 010-033.
• Install the charge air cooler piping. Refer to the
manufacturer's instructions.
• Fill the cooing system. Refer to Procedure 008-018.
• Start and operate the engine. Listen and feel for air
leaks and exhaust gas leaks.

Automotive, Industrial with CM570 and Power


Generation without CM570
• Install the turbocharger. Refer to Procedure 010-033.
• Start and operate the engine. Listen and feel for air
leaks and exhaust gas leaks.

Automotive With CM871


Install the following:
• Exhaust gas pressure sensor tube. Refer to
Procedure 011-027.
• Variable geometry tubes. Refer to Procedure
010-033.
• Charge air cooler piping. Refer to the OEM
troubleshooting and repair manual.
Fill the cooling system. Refer to Procedure 008-018.
Operate engine and check for leaks.
Start and operate the engine. Listen and feel for air leaks
and exhaust gas leaks.
Exhaust Restriction Signature, ISX, and QSX15 Engi [...]
Page 11-14 Section 11 - Exhaust System - Group 11

Exhaust Restriction (011-009)


Initial Check
For CM871 and CM876 engine remove the aftertreatment
diesel oxidation catalyst inlet temperature sensor from the
aftertreatment inlet and disconnect it from the wiring
harness. Install the pressure gauge adapter, Part Number
4918576. Connect a manometer or pressure gauge, Part
Number ST-1273, to the pressure gauge adapter.
Protect the hose from heat by using a 305 mm [12 in]
minimum length of metal tubing leading from the exhaust
pipe connection.
NOTE: Disconnecting the aftertreatment diesel oxidation
catalyst inlet temperature sensor will trigger Fault Code
1666. Do not troubleshoot this fault code during this
exhaust restriction procedure.

Operate the engine at rated rpm and load. Record the


reading on the manometer.

Exhaust Restriction
mm Hg in Hg
Without Aftertreatment 75.0 MAX 3.0
With Aftertreatment 305.0 MAX 12.0

If the exhaust pressure exceeds the specifications,


inspect the exhaust piping for damage. Refer to the OEM
troubleshooting and repair manual.
If the vehicle is equipped with an aftertreatment system,
inspect the aftertreatment system for a plugged
aftertreatment diesel particulate filter and/or a plugged
aftertreatment diesel oxidation catalyst.
Extended engine operation with high exhaust restriction
can lead to damaged turbocharger oil seals. Refer to
Procedure 010-033 to inspect the turbocharger for
progressive damage.
Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-15

Remove the test equipment and install the aftertreatment


diesel oxidation catalyst inlet temperature sensor.
Operate the engine and verify that all fault codes are
inactive.

EGR Cooler (011-019)


Preparatory Steps
Automotive with CM870

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

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Drain the engine coolant. Refer to Procedure
008-018.
• Remove the air intake pipe to turbocharger. Refer to
the OEM service manual.
• Remove the turbocharger. Refer to Procedure
010-033.
• Remove the exhaust gas pressure sensor tube.
Refer to Procedure 011-027.
• Remove the EGR cooler coolant lines. Refer to
Procedure 011-031.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-16 Section 11 - Exhaust System - Group 11

Automotive With CM871

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

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Drain the engine coolant. Refer to Procedure
008-018.
• Remove the air intake pipe to turbocharger. Refer to
the OEM service manual.
• Remove the aftertreatment adapter pipe and
aftertreatment injector lines. Refer to Procedures
011-051 and 011-043.
• Remove the turbocharger. Refer to Procedure
010-033.
• Remove the EGR cooler coolant lines. Refer to
Procedure 011-031.

Remove
Automotive with CM870
Loosen the v-band clamp between the EGR cooler and the
EGR cooler connection.

Loosen the hose clamps at the rear EGR connection tube.


Remove and discard the EGR hose.
Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-17

CAUTION
The straps on the EGR cooler are not serviceable.
Adjusting or removing the straps can damage the EGR
cooler.
Remove the four capscrews that attach the EGR cooler to
the block.
Remove the four nuts that attach the EGR cooler to the
lubricating oil cooler assembly.
Remove the EGR cooler assembly from the engine.
Remove the coolant supply and vent jumper tubes, if they
remain in the block after the cooler is removed.

Automotive With CM871


Loosen the v-band clamp between the EGR cooler and the
exhaust manifold. In order to prevent damage to the EGR
cooler bellows, place the v-band clamp over the exhaust
manifold flange.

Loosen the rear EGR connection tube retaining


capscrews at the EGR cooler gas outlet.
Remove and discard the gasket.

Remove the four capscrews that attach the EGR cooler to


the block.
Remove the four nuts that attach the EGR cooler to the
lubricating oil cooler assembly.
Remove the EGR cooler bracket clamping plates from the
EGR cooler.
Remove the EGR cooler assembly from the engine.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-18 Section 11 - Exhaust System - Group 11

Clean and Inspect for Reuse


Automotive with CM870
Inspect the v-band clamp threads for damage. Replace
the clamp if damage is found.
Inspect the hose clamps for damage. Replace if damage
is found.

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.
Cap the outlet end of the EGR cooler with parts supplied
in the EGR cooler leak check kit, Part Number 3164225.
Completely fill the EGR cooler with mineral spirits.
Cap the gas inlet end of the EGR cooler with parts
supplied in the EGR cooler leak check kit, Part Number
3164225.

Lay the EGR cooler on its side.


Allow the EGR cooler to soak for approximately 20
minutes.
Drain approximately 25 percent of the liquid from the
cooler and recap.
Shake the cooler by hand, from end to end, for
approximately 30 seconds.
Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-19

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.
Drain the mineral spirits from the EGR cooler and properly
dispose of the liquid.
Use compressed air to dry the inside of the EGR cooler
and remove any loose debris or particles.
Cap the outlet end of the EGR cooler with parts supplied
in service kit, Part Number 3164225.
Completely fill the EGR cooler with water.
Cap the gas inlet end of the EGR cooler with parts
supplied in service kit, Part Number 3164225.
Drain the water from the EGR cooler and properly dispose
of the liquid.
Use compressed air to dry the inside of the EGR cooler.
Clean the EGR valve, with safety solvent, where the EGR
cooler connection attaches to the EGR valve. Refer to
Procedure 011-022.
Clean the EGR cooler connection with safety solvent and
dry with compressed air.
Inspect the EGR valve where the EGR cooler connection
attaches to the EGR valve. Replace the EGR valve if
cracks or other damage is found. Refer to Procedure
011-022.
Replace the EGR cooler if cracks or other damage is found
on the EGR cooler.

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.
With the EGR connection tube attached, clean the cooler
end of the EGR connection tube with safety solvent.
Dry with compressed air.
Inspect the EGR connection tube for cracks or other
damage, while still attached to the block. Replace the
EGR connection tube, if necessary. Refer to Procedure
011-025.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-20 Section 11 - Exhaust System - Group 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.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the EGR cooler connection with safety solvent and
dry with compressed air.
Inspect the EGR cooler connection for cracks or other
damage. Replace the EGR cooler connection if cracks or
other damage is found. Refer to Procedure 011-024.

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 mounting surfaces with safety solvent to remove
debris or other deposits.

Clean the opening in the block where the EGR cooler


coolant supply and vent jumper tubes are installed, to
remove any coolant deposits or debris. Otherwise, the o-
ring joint can leak.
Clean the coolant supply and vent jumper tubes to remove
any coolant deposits or debris.
Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-21

Automotive With CM871

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
Inspect the v-band clamp threads for damage. Replace
the clamp if damage is found.

Inpsect the EGR cooler and the EGR cooler clamping


plates for cracks or other damage. Replace the EGR
cooler or EGR cooler clamping plates, if damage is found

WARNING
Do not use chlorinated water to clean or rinse the EGR
cooler. Chlorides are very corrosive to the stainless
alloys internal and external to the EGR cooler.
Cap the outlet end of the EGR cooler with the plastic caps
supplied in the service kit, Part Number 4918655.
Completely fill the EGR cooler with safety solvent.
Cap the gas inlet end of the EGR cooler with the plastic
cap supplied in the service kit.

Lay the EGR cooler on its side.


Allow the EGR cooler to soak for approximately 20
minutes.
Drain approximately 25 percent of the liquid from the
cooler and recap.
Shake the cooler by hand, from end to end, for
approximately 30 seconds.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-22 Section 11 - Exhaust System - Group 11

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
Drain the safety solvent from the EGR cooler and properly
dispose of the liquid.
Use compressed air to dry the inside of the EGR cooler
and remove any loose debris or particles.
Cap the outlet end of the EGR cooler with the plastic cap
supplied in the service kit, Part Number 4918655.
Completely fill the EGR cooler with water.
Cap the gas inlet end of the EGR cooler with the plastic
cap supplied in the service kit.
Shake the cooler by hand, from end to end, for
approximately 30 seconds.
Drain the water from the EGR cooler and properly dispose
of the liquid.
Use compressed air to dry the inside of the EGR cooler.
Clean the exhaust manifold with safety solvent, where the
EGR cooler connection attaches to the exhaust manifold.
Refer to Procedure 011-007.
Inspect the exhaust manifold where the EGR cooler
connection attaches to the exhaust manifold. Replace the
exhaust manifold if cracks or other damage is found. Refer
to Procedure 011-007.
Replace the EGR cooler, if cracks or other damage is
found.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris or dirt can cause
personal injury.
Clean the EGR cooler exhaust gas outlet with safety
solvent.
Dry with compressed air.
Inspect the EGR cooler exhaust gas outlet for signs of
fretting, cracks, or other damage.
Replace the EGR cooler if damage is found. Refer to
Procedure 011-025.
Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-23

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
Clean the EGR cooler bellows with safety solvent and dry
with compressed air.
Inspect the EGR cooler bellows for cracks or other
damage.
Replace the EGR cooler bellows if cracks or other damage
is found.

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 mounting surfaces with safety solvent to remove
debris or other deposits.

Clean the opening in the block where the EGR cooler


coolant return elbow connection is installed, to remove
any coolant deposits or debris. Otherwise, the press-in-
place seal joint can leak.
Clean the EGR cooler coolant supply and return jumper
tubes to remove any coolant deposits or debris.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-24 Section 11 - Exhaust System - Group 11

Pressure Test
Automotive with CM870
Cap off the coolant inlet and vents of the cooler with the
parts supplied in the EGR cooler leak check kit, Part
Number 3164225. Jumper tube, Part Number 3683068,
and jumper tube, Part Number 3682540, from the cooler,
are also used.

Cap off the coolant outlet with the plugged jumper tube
and pressure regulator assembly. Secure the jumper tube
with a hose clamp.

Make sure the air pressure regulator is closed and


connect compressed air to the pressure regulator.
Completely submerge the EGR cooler in room
temperature water. Make sure to submerge the cooler
vertically with the outlet end down so that air can not be
left in the open (gas) side of the cooler.
Apply 206 kPa [30 psi] of air pressure to the cooler.
Inspect for bubbles escaping from uncapped gas ports of
the EGR cooler or from the exterior shell of the cooler.
Verify that bubbles are not a result of loose fittings or
trapped air.
Bubbles coming from a failed EGR cooler can be very
small and/or not in a steady stream.
If bubbles are not observed, the EGR cooler is reusable.
If the EGR cooler is not reusable, inspect the turbocharger
turbine housing for any signs of coolant deposits.
If coolant deposits are found, run the variable geometry
operational test with INSITE™ electronic service tool to
make sure the turbocharger is operating properly.
Coolant deposits can be identified as dried white deposits
coating the inside of the turbine housing.
Remove the parts supplied in the EGR cooler leak check
kit, Part Number 3164225.
Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-25

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Drain all of the water from the gas side of the EGR cooler
before reuse.
Dry the cooler with compressed air.

Automotive With CM871


Install the plug with the o-ring supplied in Service Kit, Part
Number 4918655, into the coolant inlet side of the EGR
cooler, using a M8x1.25 capscrew.

Install the three straight threaded plugs (1) from Service


Kit, Part Number 4918655, into the coolant line and vent
ports.

Install the collet and cap over the pipe coupling and
coolant outlet and secure with the hose clamp provided in
Service Kit, Part Number 4918655.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-26 Section 11 - Exhaust System - Group 11

Make sure the air pressure regulator is closed and


connect compressed air to the pressure regulator.
Completely submerge the EGR cooler in room
temperature water. Make sure to submerge the cooler
vertically with the outlet end down so that air can not be
left in the open (gas) side of the cooler.
Apply 206 kPa [30 psi] of air pressure to the cooler.
Inspect for bubbles escaping from uncapped gas ports of
the EGR cooler or from the exterior shell of the cooler.
Verify that bubbles are not a result of loose fittings or
trapped air.
Bubbles coming from a failed EGR cooler can be very
small and/or not in a steady stream.
If bubbles are not observed, the EGR cooler is reusable.
If the EGR cooler is not reusable, inspect the turbocharger
turbine housing and rear EGR connection tube for any
signs of coolant deposits.
Coolant deposits can be identified as dried white deposits
coating the inside of the turbine housing.
If coolant deposits are found in the turbocharger turbine
housing, inspect the turbocharger and aftertreatment
system for progressive damage.
Coolant can cause the turbocharger to stick. Refer to
procedure 010-033 for inspection guidelines.
Coolant in the aftertreatment system can cause damage
to the aftertreatment diesel particulate filter . Refer to
Procedure 011-050, Aftertreatment System (exhaust
catalyst system) for inspection guidelines.
If coolant deposits are found in the rear EGR connection
tube, inspect the EGR valve for progressive damage.
Coolant can cause the EGR valve to stick and allow the
water to collect.
Remove the EGR valve and inspect for reuse. Refer to
Procedure 011-022.
Remove the parts supplied in the Service Kit.

Install
Automotive with CM870
Install a new hose onto the rear EGR connection tube and
install the hose clamps.
Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-27

Install new o-rings on the coolant supply and vent tubes


on the EGR cooler and the jumper tubes.
Use clean engine coolant, soapy water, or vegetable oil to
lubricate the o-rings for easier installation.
Install the coolant supply and the vent jumper tubes onto
the EGR cooler.
Align the coolant supply and vent tubes to the
corresponding openings on the block.
Install the EGR cooler on the studs in the lubricating oil
cooler assembly.

Install a new gasket on the pilot end of the EGR cooler,


where it connects to the EGR cooler connection.
Apply a film of high-temperature anti-seize compound to
the inside of the v-band clam, to make sure of proper
loading on the clamp.
Install a v-band clamp.
Torque Value: 17 N•m [ 150 in-lb ]

Install and hand tighten the four mounting nuts and


capscrews. Torque the capscrews and nuts in the
sequence shown.
Torque Value:
Capscrews 47 N•m [ 35 ft-lb ]
Nuts 23 N•m [ 17 ft-lb ]

Connect the EGR cooler to the new hose on the rear EGR
connection tube.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-28 Section 11 - Exhaust System - Group 11

Tighten the hose clamps.


Torque Value:
Breeze Clamp 7 N•m [ 60 in-lb ]
(1)
Torque Value:
Norma Clamp 5 N•m [ 44 in-lb ]
(2)

Tighten the v-band clamp between the EGR cooler


connection and the EGR cooler.
Torque Value: 17 N•m [ 150 in-lb ]

Automotive With CM871


Apply a film of high-temperature anti-seize compound to
the inside of the v-band clamp, to make sure of proper
loading on the clamp.
Install a v-band clamp onto the exhaust manifold front
section.
Install a new gasket on the pilot end of the EGR cooler
where it connects to the exhaust manifold front section.
Install the EGR cooler on the studs in the lubricating oil
cooler assembly.

Install the EGR cooler bracket clamping plates.


Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-29

Install the four EGR cooler mounting capscrews at the top


of the EGR cooler mounting bracket.
Install and hand tighten the four mounting nuts. Torque
the capscrews and nuts in the sequence shown.
Torque Value:
Capscrews 47 N•m [ 35 ft-lb ]
Torque Value:
Nuts 23 N•m [ 17 ft-lb ]

CAUTION
Do not use air tools to remove or install the nut on the
v-band clamp. Use of these tools can seriously
damage the threads or the bolt and cause the clamp
to not be able to be reused.
Position the v-band clamp onto the EGR cooler inlet
connection.
Torque Value: 17 N•m [ 150 in-lb ]

Tighten the two retaining capscrews on the rear EGR


connection tube.
Torque Value: 20 N•m [ 177 in-lb ]

Finishing Steps
Automotive with CM870
• Install the EGR cooler coolant lines. Refer to
Procedure 011-031.
• Install the exhaust gas pressure sensor tube. Refer
to Procedure 011-027.
• Install the turbocharger. Refer to Procedure 010-033.
• Install the air intake pipe to the turbocharger. Refer
to OEM service manual.
• Fill the engine cooling system. Refer to Procedure
008-018.
• Start the engine, check for leaks, and verify proper
operation.
EGR Mixer Signature, ISX, and QSX15 Engi [...]
Page 11-30 Section 11 - Exhaust System - Group 11

Automotive With CM871


• Install the EGR cooler coolant lines. Refer to
Procedure 011-031.
• Install the turbocharger. Refer to Procedure 010-033.
• Install the aftertreatment adapter pipe and
aftertreatment injector lines. Refer to Procedure
011-043 and 011-051.
• Install the air intake pipe to the turbocharger. Refer
to the OEM manual.
• Fill the engine cooling system. Refer to Procedure
008-018.
• Start the engine, check for leaks, and verify proper
operation.
If a 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.

EGR Mixer (011-021)


Preparatory Steps
• Remove the charge air cooler connection hose and
hose clamp from the EGR mixer inlet. Refer to
Procedure 010-027.
• Remove the air compressor supply line. Refer to
Procedure 012-014.
• Remove the v-band clamp between the EGR mixer
and the charge air cooler inlet adapter.

Remove
Do not remove the EGR inlet pipe into the EGR mixer.
This is a precision interface and performance will be
affected if disturbed. There is no service procedure for this
and none is required.
Remove the capscrews at the four-bolt flange between the
EGR mixer and the air intake horn.
Signature, ISX, and QSX15 Engi [...] EGR Mixer
Section 11 - Exhaust System - Group 11 Page 11-31

Clean and Inspect for Reuse

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
Use compressed air to blow out any debris or soot buildup
inside the EGR mixer.
Clean all mounting surfaces with solvent.
Dry with compressed air.
Inspect the EGR mixer for cracks. Replace the EGR mixer
if cracks are found.

Inspect the v-band clamps for signs of overextension. The


band must not be bent or cracked.
Inspect the v-band clamp thread for damage.
Replace the v-band clamp if damage is found.

Install
Install a new hose at the EGR mixer inlet.
Install a new o-ring between the EGR mixer and the air
intake connection. Install and tighten capscrews.
Torque Value: 34 N•m [ 25 ft-lb ]
EGR Valve Signature, ISX, and QSX15 Engi [...]
Page 11-32 Section 11 - Exhaust System - Group 11

Finishing Steps
• Install the v-band clamp on the inlet adapter and the
EGR mixer.
• Install the air compressor supply line. Refer to
Procedure 012-014.
• Install the charge air cooler connection. Refer to
Procedure 010-027.
• Start and operate the engine and check for leaks at
the air connections.
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.

EGR Valve (011-022)


Preparatory Steps
Automotive with CM870

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

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the engine coolant. Refer to Procedure
008-018.
• Remove the water pump drive belt. Refer to
Procedure 008-003.
• On some applications, removal of the alternator is
required. Refer to Procedure 013-001.
• Remove the air intake pipe to the turbocharger.
Refer to the OEM troubleshooting and repair
manual.
• Remove the heat shield. Refer to Procedure
011-032.
• Disconnect the EGR valve motor and position sensor
connectors from the harness.
• Remove the EGR valve coolant lines. Refer to
Procedure 011-030.
Signature, ISX, and QSX15 Engi [...] EGR Valve
Section 11 - Exhaust System - Group 11 Page 11-33

Automotive With CM871


• Disconnect EGR temperature sensor. Refer to
Procedure 019-378 in the Troubleshooting and
Repair Manual CM871 and CM876 Electronic
Control System, ISX and ISM Engines, Bulletin
4021560.
• Remove the front EGR connection tube from the
EGR valve. Refer to Procedure 011-025.
• Disconnect the OEM fuel return hose from the
integrated fuel system module. Refer to the OEM
Troubleshooting and Repair Manual. Or, loosen the
fuel hose enough to position it away from the EGR
valve mounting capscrew and tighten the fuel line.
• Remove the EGR valve heat shield. Refer to
Procedure 011-032.
• Disconnect the OEM air compressor discharge line.
Refer to the OEM troubleshooting and repair
manual.

Remove
Automotive with CM870
Loosen the v-band clamp connecting the EGR valve to the
exhaust manifold.
Loosen the v-band clamp connecting the EGR valve to the
EGR cooler connection.

Remove the EGR valve and v-band clamps.


Remove and discard the gaskets.
EGR Valve Signature, ISX, and QSX15 Engi [...]
Page 11-34 Section 11 - Exhaust System - Group 11

Automotive With CM871


Disconnect the EGR valve electrical connector.

Be sure to support the EGR valve by hand before


removing the mounting capscrews. If the EGR valve is
not supported, it can fall off of the engine, causing
damage to the EGR valve and actuator.

Loosen and remove the four EGR valve mounting


capscrews.
Remove the EGR valve from the EGR valve support
bracket.
The EGR valve will need to be moved at an angle forward
and downward in order to disengage it from the EGR valve
support bracket.

Disassemble
Automotive With CM871
Remove the pipe seal from the EGR valve inlet port.
Pry the lip of the pipe seal up from the EGR valve, use a
small flat headed screwdriver. Take care not to nick the
EGR valve housing when removing the seal.
Discard the pipe seal.
Signature, ISX, and QSX15 Engi [...] EGR Valve
Section 11 - Exhaust System - Group 11 Page 11-35

Clean and Inspect for Reuse


Automotive with CM870

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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 injury.
Clean the mounting surfaces with a shop towel wetted with
a safety solvent to remove any deposits or debris.
Dry with compressed air.
Inspect the mounting surfaces for cracks, fretting, or other
damage. Inspect the EGR motor and position sensor for
damage.
Replace the valve if damage is found.

Inspect the v-band clamps for signs of overextension. The


band must not be bent or cracked.
Inspect the v-band clamp threads for damage.
Replace the v-band clamp if damage is found.

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 EGR valve mounting and sealing surfaces with
a shop towel wetted with safety solvent to remove any
deposits or debris.
EGR Valve Signature, ISX, and QSX15 Engi [...]
Page 11-36 Section 11 - Exhaust System - Group 11

Clean the accumulated soot from the EGR valve inlet port
using a wire brush, then soaking with carburetor cleaner
and cleaning again with a wire brush. Be sure the loose
soot is removed from the EGR valve housing. This can be
done by vacuuming the soot out of the EGR valve inlet
port.
Dry with compressed air.
Inspect the mounting surfaces for cracks, fretting, or other
damage.

Inspect the EGR valve poppets for a stuck open condition.


If the EGR valve is stuck open, replace the EGR valve. Do
not try to pry the poppets open or closed.

Inspect the EGR valve actuator for cracks or other


damage. Replace if damage is found.
Inspect the EGR valve actuator connector for corrosion,
worn pins, or other damage.
Replace the EGR valve assembly if corrosion, worn pins,
or other damage is found.

Inspect the engine wiring harness EGR valve actuator


connector for corrosion, worn receptacles, or other
damage.
Replace the engine wiring harness EGR valve connector
if corrosion, worn receptacles, or other damage is found.
Signature, ISX, and QSX15 Engi [...] EGR Valve
Section 11 - Exhaust System - Group 11 Page 11-37

Soot leakage at the EGR valve weep hole is normal and


is to be expected. Do not replace the EGR valve if soot
streaks are found at the EGR valve weep hole.

Inspect the EGR valve mounting bracket for soot leaks at


the EGR valve joint. If a leak is found, replace the EGR
valve seal.

Assemble
Automotive With CM871
Use a light coat of clean engine oil to lubricate the outer
diameter of the EGR valve seal during assembly on to the
EGR valve. Push the EGR valve seal into the EGR valve
inlet port by hand. The EGR seal must remain square in
the EGR valve inlet port during installation.

Hammer the EGR valve seal fully, using a flat piece of


steel across the EGR valve seal. The EGR valve seal
must be fully seated onto the EGR valve inlet port
shoulder.
EGR Valve Signature, ISX, and QSX15 Engi [...]
Page 11-38 Section 11 - Exhaust System - Group 11

Install
Automotive with CM870
Before installing the v-band clamp, coat the clamping
surface with high temperature anti-seize compound.

Install the smaller v-band clamp on the EGR cooler


connection. Do not tighten.
Install the larger v-band clamp on the end of the EGR valve
that connects with the exhaust manifold. Do not tighten.
Install a new gasket on the piloted end of the EGR cooler
connection.
Install a new gasket on the piloted end of the EGR valve
where it connects to the exhaust manifold.
Install the EGR valve. Position the EGR connection v-band
clamp, as shown, and tighten.
Torque Value: 17 N•m [ 150 in-lb ]

Automotive With CM871


Lubricate the EGR valve seal with clean engine oil.
Install the EGR valve onto the EGR valve mounting
bracket.

Install the four mounting capscrews into the EGR valve


mounting bracket.
Tighten the capscrews.
Torque Value: 54 N•m [ 40 ft-lb ]
NOTE: The longest capscrew passes through the EGR
valve and EGR valve mounting bracket and threads into
the engine block.
Signature, ISX, and QSX15 Engi [...] EGR Valve
Section 11 - Exhaust System - Group 11 Page 11-39

Connect the EGR valve connector.

Finishing Steps
Automotive with CM870
• Install the EGR valve coolant lines. Refer to
Procedure 011-030.
• Connect the EGR valve motor and position sensor
connectors to the harness (clean off the wiring
harness and connector before connecting to the
valve).
• Install the heat shield. Refer to Procedure 011-032.
• Install the air intake pipe to the turbocharger. Refer
to the OEM troubleshooting and repair manual.
• Install the alternator, if removed. Refer to Procedure
013-001.
• Install the water pump drive belt. Refer to Procedure
008-003.
Fill the engine cooling system. Refer to Procedure
008-018.
Start and operate the engine. Check for exhaust and
coolant leaks.

Automotive With CM871


• Install the EGR heat shield. Refer to Procedure
011-032.
• Connect the OEM air compressor discharge line.
Refer to the OEM troubleshooting and repair
manual.
• Install the front EGR connection tube. Refer to
Procedure 011-025.
• Connect the OEM fuel return hose from the
integrated fuel system module. Refer to the OEM
troubleshooting and repair manual.
• Connect the EGR temperature sensor. Refer to
Procedure 019-378 in the Troubleshooting and
Repair Manual CM871 and CM876 Electronic
Control System ISX and ISM Engines, Bulletin
4021560.
Start and operate the engine. Check for exhaust or coolant
leaks.
Verify active fault codes.
If a 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.
EGR Cooler Connection Signature, ISX, and QSX15 Engi [...]
Page 11-40 Section 11 - Exhaust System - Group 11

EGR Cooler Connection (011-024)


Preparatory Steps

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

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Drain the cooling system. Refer to Procedure 008-018.
Remove or loosen the following:
• Air intake pipe to the turbocharger. Refer to the OEM
service manual.
• Heat shield. Refer to Procedure 011-032.
• EGR cooler coolant line. Refer to Procedure
011-031.
• V-band clamp that holds the EGR valve to the
exhaust manifold. Rotate the V-band clamp out of
the way to access the V-band clamp that holds the
EGR cooler connection to the EGR valve. Refer to
Procedure 011-022.

Remove
Loosen the V-band clamps on each end of the exhaust gas
recirculation (EGR) cooler connection.
Remove the EGR cooler connection and V-bands.
Remove the gaskets and discard.

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 EGR cooler connection with safety solvent.
Dry with compressed air.
Inspect the EGR cooler connection for cracks or other
damage.
Signature, ISX, and QSX15 Engi [...] EGR Cooler Connection
Section 11 - Exhaust System - Group 11 Page 11-41

Clean the EGR cooler mounting flange with safety solvent.


Dry with compressed air.
Inspect the EGR cooler mounting flange for cracks or
damage. Replace the EGR cooler, if cracks or other
damage is found.

Clean the EGR valve with safety solvent.


Dry with compressed air.
Inspect the EGR valve where the EGR cooler connection
interfaces for cracks or damage. Replace the EGR valve
if necessary.

Inspect the hose clamps for damage. Replace if damage


is found.

Inspect the V-band clamps for signs of overextension. The


band must not be bent or cracked.
Inspect the V-band clamp threads for damage.
Replace the V-band clamp if damage is found.
EGR Cooler Connection Signature, ISX, and QSX15 Engi [...]
Page 11-42 Section 11 - Exhaust System - Group 11

Install
Before installing the V-band clamp, coat the clamping
surface with high temperature anti-seize compound.

The EGR cooler connection has a male and female end.


The male end of the connection goes to the cooler, the
female end goes to the EGR valve.
Install new gaskets on the pilot end of the EGR cooler
connection and the EGR valve.
Install V-band clamps loosely on the EGR cooler
connection.

Install the EGR cooler connection.


Position V-band clamps that hold the EGR cooler
connection between the EGR cooler and the EGR valve,
as shown. Tighten the V-band clamps.
Rotate the exhaust manifold V-band clamp into position,
as shown and tighten the V-band clamps.
Torque Value: 17 N•m [ 150 in-lb ]

Finishing Steps
Install or connect the following:
• EGR cooler coolant line. Refer to Procedure
011-031.
• Heat Shield. Refer to Procedure 011-032.
• Air intake pipe to the turbocharger. Refer to the OEM
service manual.
Fill the engine cooling system. Refer to Procedure
008-018.
Start engine and verify proper operation.
Signature, ISX, and QSX15 Engi [...] EGR Connection Tubes
Section 11 - Exhaust System - Group 11 Page 11-43

EGR Connection Tubes (011-025)


Preparatory Steps
Automotive with CM870

WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to reduce the possibility of
personal injury when using a steam cleaner or high-
pressure water.

WARNING
The differential pressure sensor tube can be hot. To
reduce the possibility of personal injury, allow the
engine to cool before removing.
• Use steam or high-pressure water to clean the rear
of the engine, specifically around the rear EGR
connection tube area.
• Remove the fuel filter. Refer to Procedure 006-015
(Fuel Filter, Spin-On Type) in Section 6.
• Remove the engine wiring harness from the exhaust
temperature sensor. Refer to Procedure 019-043
(Engine Wiring Harness) in Section 19 in the
Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature and ISX
Engines, Bulletin 4021334.
• Remove the dipstick tube. Refer to Procedure
007-011 (Lubricating Oil Dipstick Tube) in Section 7.
• Remove the differential pressure sensor tubes from
the connection tube and the sensor adapter. Refer
to Procedure 011-026 (EGR Differential Pressure
Sensor Tubes) in Section 11.
• Remove the oil pressure sensor. Refer to the
Procedure 019-066 (Engine Oil Pressure Sensor) in
Section 19 in the Troubleshooting and Repair
Manual, CM870 Electronic Control System,
Signature and ISX Engines, Bulletin 4021334.
EGR Connection Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-44 Section 11 - Exhaust System - Group 11

Automotive With CM871

WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to reduce the possibility of
personal injury when using a steam cleaner or high-
pressure water.

WARNING
The differential pressure sensor tube can be hot. To
reduce the possibility of personal injury, allow the
engine to cool before removing.
Use steam or high-pressure water to clean the engine,
specifically around the EGR connection tube joints.
• Remove the engine wiring harness from the exhaust
temperature sensor. Refer to Procedure 019-013
(Exhaust Gas Temperature Sensor) in Section 19 in
the Troubleshooting and Repair Manual, CM871 and
CM876 Electronic Control System, ISX and ISM
Engines, Bulletin 4021560.
• Remove the EGR differential pressure sensing tubes
from the EGR venturi. Refer to Procedure 011-026
(EGR Differential Pressure Sensor Tubes) in Section
11.

Remove
Automotive with CM870

WARNING
The EGR connection tubes can be hot. To reduce the
possibility of personal injury, allow the engine to cool
before removing.
Loosen all hose clamps on the EGR connection tubes and
remove the two p-clip mounting capscrews or nuts
(depending on the vintage of the engine) on the front EGR
connection tube.
If the M10 stud comes out upon removal of the nut, install
the M10 stud into the block until the stud bottoms out.
Remove the one capscrew and one nut or the two nuts
that attach the rear section of the connection tube to the
cylinder block.
If the M10 stud comes out upon removal of the nut, install
the M10 stud into the block until the stud bottoms out.
Remove the front EGR connection tube.
Signature, ISX, and QSX15 Engi [...] EGR Connection Tubes
Section 11 - Exhaust System - Group 11 Page 11-45

Remove the one capscrew and one nut that attach the rear
section of the connection tube to the cylinder block.
Remove the rear EGR connection tube from the EGR
cooler.

Automotive With CM871

WARNING
The EGR connection tubes can be hot. To reduce the
possibility of personal injury, allow the engine to cool
before removing.
Loosen the hose clamps on the front EGR connection tube
and remove the hose.
Remove the two retaining capscrews on the lower portion
of the tube at the EGR valve housing outlet.
Remove the front EGR connection tube and hose.
Discard the hose.

Remove the three EGR venturi mounting capscrews.


Remove the EGR venturi.

Remove the two rear EGR connection capscrews from the


EGR cooler.
Loosen the hose clamp on the rear EGR connection tube.
Pull the EGR cooler outlet connection tube from the EGR
cooler.
EGR Connection Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-46 Section 11 - Exhaust System - Group 11

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.
Clean the connection tubes with solvent.
Dry with compressed air.
Inspect the ends and mating joints of the connection tubes
for cracks or other damage. Replace the tube if cracks or
other damage is found.

Inspect the p-clips for missing or torn rubber sleeves.


Replace the p-clips if the rubber sleeve is missing or torn.

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 connection tubes with solvent.
Make sure that gasket sealing surfaces at the EGR valve
outlet and EGR cooler outlet are free of packed soot and
other debris. Avoid wiping dirt or debris down into the
tubes or valve.
Dry with compressed air.
Signature, ISX, and QSX15 Engi [...] EGR Connection Tubes
Section 11 - Exhaust System - Group 11 Page 11-47

Inspect the EGR measurement venturi for soot plugging


at the EGR differential pressure sensing tube ports. The
port labeled R has a hook inside which makes visual
inspection difficult.
Insert a flexible pipe cleaner or wire through this port to
verify the port is not plugged inside the tube, past the
bend.

Inspect the ends and mating joints of the connection tubes


for signs of fretting, or material transfer, cracks, or other
damage.
Replace the tube if fretting, material transfer, cracks, or
other damage is found.
Inspect the rear EGR connection hose for cracks, fraying,
or tearing.
Replace the entire rear EGR crossover tube if the hose is
damaged or if hose material is found on the EGR valve
mounting bracket.

Install
Automotive with CM870
Mask the end of the rear EGR connection tube that
interfaces with the EGR cooler before working the tube
into position, to reduce the possibility of introducing dirt or
debris.
Install the p-clips onto the rear EGR connection tube.
Make sure the tube insulation is properly and fully located
under the p-clips and that the p-clip rubber sleeve does
not block the mounting hole.
Install the rear EGR connection tube and the p-clip
mounting capscrew and nuts.
Finger tighten the capscrew and nuts.
EGR Connection Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-48 Section 11 - Exhaust System - Group 11

Tighten the p-clip mounting capscrew, nuts, and hose


clamps.
Torque Value:
M10 P-clip nut 46 N•m [ 34 ft-lb ]
M8 P-clip nut 23 N•m [ 17 ft-lb ]
P-clip 45 N•m [ 33 ft-lb ]
capscrew and
nut
Breeze Clamp 7 N•m [ 62 in-lb ]
(1)
Norma Clamp 5 N•m [ 44 in-lb ]
(2)
Remove the masking tape.
Install a new hose with the hose clamps loosely attached
between the rear EGR connection tube and the EGR
cooler.
Tighten the p-clip mounting capscrew, nut, and hose
clamps.
Torque Value:
P-clip 45 N•m [ 33 ft-lb ]
capscrew and
nut
Torque Value:
Breeze Clamp 7 N•m [ 62 in-lb ]
(1)
Torque Value:
Norma Clamp 5 N•m [ 44 in-lb ]
(2)

Install a new hose with the hose clamps loosely attached


on the rear EGR connection tube where it interfaces with
the front EGR connection tube.
Install the p-clips onto the front EGR connection tube.
Install the front EGR connection tube and the p-clip
mounting capscrews or nuts. Finger tighten the
capscrews or nuts.
Tighten the p-clip mounting capscrews or nuts and the
hose clamps.
Torque Value:
M10 p-clip nut 46 N•m [ 34 ft-lb ]
Hose clamps 5 N•m [ 44 in-lb ]
P-clip 45 N•m [ 33 ft-lb ]
capscrew and
nut
Install a new hose with the hose clamps loosely attached
between the front EGR connection tube and the EGR
mixer.
Tighten the p-clip mounting capscrews, nuts, and clamps.
Torque Value:
P-clip 45 N•m [ 33 ft-lb ]
capscrews and
nut
Hose clamps 5 N•m [ 44 in-lb ]
Signature, ISX, and QSX15 Engi [...] EGR Connection Tubes
Section 11 - Exhaust System - Group 11 Page 11-49

Automotive With CM871


Apply lubricant to the hose end of the rear EGR
connection tube.
Loosely install the hose clamp and install the rear EGR
connection tube and gasket onto the EGR cooler and EGR
valve mounting bracket.
Tighten the two capscrews.
Torque Value: 27 N•m [ 20 ft-lb ]
Tighten the hose clamp.
Torque Value: 5 N•m [ 44 in-lb ]

Make sure the indentation near the end of the hose slides
past the hose bead on the EGR valve mounting bracket.
Position the hose clamp on this indentation groove.

Loosen the two rear tail support mounting capscrews.


Install a new press-in place seal on the EGR venturi.
Install the EGR venturi on the air intake connection by
loosely installing all three capscrews. Finger tighten all
five capscrews.
In order to reduce assembly stress, tighten the capscrews
in the following sequence:
Tighten the two front EGR venturi mounting capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
Tighten the rear EGR venturi mounting capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
Tighten the two rear tail support mounting capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
EGR Connection Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-50 Section 11 - Exhaust System - Group 11

Apply lubricant to the hose end of the front EGR


connection tube and the EGR venturi inlet.
Slide the new EGR connection hose on the EGR venturi
inlet and loosely install both retaining clamps.
Attach a new EGR gasket to the front EGR connection
tube flange, holding it in place with the two retaining
capscrews.
Insert the hose end of the EGR connection tube into the
EGR connection hose, and align the mounting flange with
the EGR valve outlet.
Install the two retaining capscrews into the EGR valve.
Tighten the capscrews in the following sequence: 1-2-1.
Be sure to tighten Number 1 capscrew twice.
Torque Value: 27 N•m [ 20 ft-lb ]
Center the EGR connection hose evenly between the tube
and the EGR venturi and tighten both retaining clamps.
Torque Value: 5 N•m [ 44 in-lb ]

Finishing Steps
Automotive with CM870

WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to reduce the possibility of
personal injury when using a steam cleaner or high-
pressure water.

WARNING
The differential pressure sensor tube can be hot. To
reduce the possibility of personal injury, allow the
engine to cool before removing.
• Install the oil pressure sensor. Refer to Procedure
019-066 (Engine Oil Pressure Sensor) in Section 19
in the Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature and ISX
Engines, Bulletin 4021334.
• Install the differential pressure sensor tubes to the
front connection tube and the sensor adapter. Refer
to Procedure 011-026 (EGR Differential Pressure
Sensor Tubes) in Section 11.
• Install the dipstick tube. Refer to Procedure 007-011
(Lubricating Oil Dipstick Tube) in Section 7.
• Install the engine wiring harness to the exhaust
temperature sensor. Refer to Procedure 019-043
(Engine Wiring Harness) in Section 19 in the
Troubleshooting and Repair Manual, CM870
Electronic System, Signature and ISX Engines,
Bulletin 4021334.
• Install the fuel filter. Refer to Procedure 006-015
(Fuel Filter Spin-On Type) in Section 6.
• Operate the engine and check for leaks.
Signature, ISX, and QSX15 Engi [...] EGR Differential Pressure Sensor Tubes
Section 11 - Exhaust System - Group 11 Page 11-51

Automotive With CM871

WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to reduce the possibility of
personal injury when using a steam cleaner or high-
pressure water.

WARNING
The differential pressure sensor tube can be hot. To
reduce the possibility of personal injury, allow the
engine to cool before removing.
• Install the EGR differential pressure sensing tubes to
the EGR venturi. Refer to Procedure 011-026 (EGR
Differential Pressure Sensor Tubes) in Section 11.
• Install the engine wiring harness to the exhaust
temperature sensor. Refer to Procedure 019-013
(Exhaust Gas Temperature Sensor) in Section 19 in
the Troubleshooting and Repair Manual CM871 and
CM876 Electronic Control System ISX and ISM
Engines, Bulletin 4021560.
• Operate the engine and check for leaks.

EGR Differential Pressure Sensor


Tubes (011-026)
Preparatory Steps
Automotive With CM871
If necessary, remove the EGR differential pressure
sensor. Refer to Procedure 019-370 in the
Troubleshooting and Repair Manual Electronic Control
System CM871 and CM876 ISX and ISM Engines, Bulletin
4021560.

Remove
Automotive with CM870
For engines with an ESN beginning with 14040552, the
pressure sensor does not have to be removed to allow the
removal of the EGR differential pressure sensor tube.
Pressure sensor removal is necessary only if the sensor
adapter is being replaced. Refer to Procedure 011-028.
Tag the ends of the tubes before removing the sensor
tubes. Incorrectly installing the tubes to the sensor
adapter will result in a fault code.
Loosen the tube nuts at the front EGR connection tube
and the sensor adapter.
Remove the tubes.
EGR Differential Pressure Sensor Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-52 Section 11 - Exhaust System - Group 11

Automotive With CM871


Tag the ends of the tubes before removing the sensor
tubes. Incorrectly installing the tubes to the sensor
adapter will result in a fault code.
Loosen the tube nuts at the EGR venturi tube and the
sensor adapter.
Remove the tubes.

Clean and Inspect for Reuse


Automotive with CM870
Carbon deposits inside the tubes can cause a amber
CHECK ENGINE light, in addition to any combination of
the following:
• Low power
• Black smoke
• Engine surge
• Engine runs rough
• Exhaust gas recirculation valve delta pressure fault
code.
• Progressive damage to the Cummins® particulate
filter.

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.
Check the inside of the tubes.
If a tube is partially clogged, saturate the inside of the tube
with a mineral based solvent, or equivalent.
Carefully clean debris from the mouth of the tube, making
sure not to damage the tube.
If the tube is fully clogged or otherwise unable to be
cleaned, the tube must be replaced.
Clean the tube with safety solvent.
Dry the tube with compressed air.
Signature, ISX, and QSX15 Engi [...] EGR Differential Pressure Sensor Tubes
Section 11 - Exhaust System - Group 11 Page 11-53

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.
Inspect the mating orifices of the EGR crossover tubes.
If clogged, saturate the carbon deposit with a mineral
based solvent, or equivalent.
Carefully clean debris from the mouth of the orifice,
making sure not to damage the orifice.
Dry with compressed air.
EGR Differential Pressure Sensor Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-54 Section 11 - Exhaust System - Group 11

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.
Carbon deposits inside the tubes can cause an amber
CHECK ENGINE light, in addition to any combination of
the following:
• Low power
• Black smoke
• Engine surge
• Engine runs rough
• Exhaust gas recirculation valve differential pressure
fault code.
• Progressive damage to the Cummins® particulate
filter.
Check the inside of the tubes.
If a tube is partially clogged, saturate the inside of the tube
with mineral based solvent, or equivalent.
Carefully clean the debris from the mouth of the tube.
Making sure not to damage the tube.
If the tube is fully clogged or otherwise unable to be
cleaned, the tube must be replaced.
Clean the tube with safety solvent.
Dry with compressed air.
Check the tubes for cracks or thread damage.
Inspect the mating orifices for the EGR crossover tubes.
If clogged, remove the EGR venturi tube. Refer to
Procedure 011-025.
Saturate the carbon deposit with a safety solvent or
equivalent.
Carefully clean the debris from the mouth of the orifice,
making sure not to damage the orifice.
Dry with compressed air.

Install
Automotive with CM870
For engines with an ESN beginning with 14040552, the
tubes must be installed so that they do not cross over
each other.
Apply anti-seize compound to the tube threads and install
the tubes.
Torque Value: 17 N•m [ 150 in-lb ]
This insulation is designed to only cover the bottom
portion of the tube which threads to the EGR tube. This
location proves to be most effective and prevents heat
soaking of the EGR differential pressure sensor.
Signature, ISX, and QSX15 Engi [...] Exhaust Gas Pressure Sensor Tube
Section 11 - Exhaust System - Group 11 Page 11-55

Automotive With CM871


The tubes must be installed so that they do not cross each
other.
Apply anti-seize compound to the tube threads and install
the tubes.
Torque Value: 30 N•m [ 22 ft-lb ]
NOTE: It is critical to properly torque the differential
pressure sensor tube to 30 N•m [22 ft-lb]. Exhaust leakage
and subsequent tube plugging can occur when not
properly torqued. If a torque wrench and crow's foot can
not be used to tighten the tubes, use a flare nut wrench
and apply more force than normal. Studies indicate
technicians apply only16 N•m [12 ft lb] of torque to the
tube nuts, when using a flare nut wrench.

Finishing Steps
Automotive with CM870
If removed, install the EGR differential pressure sensor.
Refer to Procedure 019-370 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
Start the engine and verify proper operation.
Check for fault codes.

Automotive With CM871


If removed, install the EGR differential pressure sensor.
Refer to Procedure 019-370, in the Troubleshooting and
Repair Manual Electronic Control System CM871 and
CM876 ISX and ISM Engines, Bulletin 4021560.
Start the engine and verify proper operation.
Check for fault codes.

Exhaust Gas Pressure Sensor Tube


(011-027)
Preparatory Steps
NOTE: Removal of the sensor plumbing does not require
the sensor removal. Remove the sensor only if the sensor
adapter is being replaced.
• Disconnect the electrical connector to the exhaust
gas pressure sensor. Refer to Procedure 019-376 in
the Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
Exhaust Gas Pressure Sensor Tube Signature, ISX, and QSX15 Engi [...]
Page 11-56 Section 11 - Exhaust System - Group 11

Remove
Loosen the tube nuts at the exhaust manifold and at the
sensor adapter.
Remove the tube.

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.
Inspect the inside of the tube. If clogged, use compressed
air to remove debris or soot buildup.
Clean the outside of the tube with solvent.
Dry with compressed air.
Check the tube for cracks and thread damage. Replace
the tube, if cracks or damage are found.

Install
Apply a film of high temperature anti-seize compound to
the threads of the tube nuts.
Install the tube.
Connect and tighten the tube nuts.
Torque Value: 16 N•m [ 146 in-lb ]
Signature, ISX, and QSX15 Engi [...] EGR Differential Pressure Sensor Adapter
Section 11 - Exhaust System - Group 11 Page 11-57

Finishing Steps
• Connect the electrical connectors to the exhaust gas
pressure sensor. Refer to Procedure 019-376 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Start the engine and verify proper operation.
• Check for fault codes.
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.

EGR Differential Pressure Sensor


Adapter (011-028)
Preparatory Steps
Remove or disconnect the following:
• EGR differential pressure sensor connector from the
engine wiring harness.
• EGR differential pressure sensor tubes. Refer to
Procedure 011-026.

Remove
Remove the mounting capscrews.
Remove the EGR pressure sensor adapter.
EGR Differential Pressure Sensor Adapter Signature, ISX, and QSX15 Engi [...]
Page 11-58 Section 11 - Exhaust System - Group 11

Clean and Inspect for Reuse

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
Inspect the EGR pressure sensor adapter tube holes for
clogging.
If clogged, use compressed air to remove debris or soot
buildup. Clean the outside of the adapter with solvent.
Dry with compressed air.
Inspect the EGR pressure sensor adapter for cracks or
fretting. Replace the EGR pressure sensor adapter if
cracks are found.

Install
Install the EGR pressure sensor adapter and capscrews.
Torque Value: 18 N•m [ 13 ft-lb ]

Finishing Steps
Install or connect the following:
• EGR differential pressure sensor tubes. Refer to
Procedure 011-026.
• EGR differential pressure sensor connector to the
engine wiring harness.
Operate the engine and check for leaks.
Signature, ISX, and QSX15 Engi [...] EGR Valve Coolant Lines
Section 11 - Exhaust System - Group 11 Page 11-59

EGR Valve Coolant Lines (011-030)


Preparatory Steps

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

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the air intake piping. Refer to the OEM
service manual.
• Remove the heat shield. Refer to Procedure
011-032.

Remove
Disconnect the EGR valve coolant supply (bottom) and
return (top) lines.

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 EGR valve coolant lines with solvent.
Dry with compressed air.
Inspect the EGR valve coolant lines and rubber grommets
for cracks or damage.
Replace the lines, if cracks or damage is found.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Engi [...]
Page 11-60 Section 11 - Exhaust System - Group 11

Install
Connect the EGR valve coolant lines making sure the
sealing washers are in place on the banjo connector.
Tighten the EGR valve coolant line nut and capscrew.
Torque Value: 10 N•m [ 88 in-lb ]

Finishing Steps
• Install the heat shield. Refer to Procedure 011-032.
• Install the air intake piping. Refer to the OEM service
manual.
• Fill the engine cooling system. Refer to Procedure
008-018.
• Start and operate the engine. Check for leaks.

EGR Cooler Coolant Lines (011-031)


Preparatory Steps
Automotive with CM870

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

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the air intake piping. Refer to the OEM
service manual.
• Remove the exhaust gas pressure sensor tube.
Refer to Procedure 011-027.
Signature, ISX, and QSX15 Engi [...] EGR Cooler Coolant Lines
Section 11 - Exhaust System - Group 11 Page 11-61

Automotive With CM871

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

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the air intake piping. Refer to the OEM
troubleshooting and repair manual.

Remove
Automotive with CM870
Disconnect the EGR cooler coolant vent line from the EGR
cooler coolant return line and the EGR cooler.

Remove the two mounting capscrews from the EGR cooler


coolant return line.
Disconnect the EGR cooler coolant return line from the
EGR cooler and the elbow connection on the thermostat
housing.

Automotive With CM871

CAUTION
Be sure all the components are clean and free of
debris that can cause damage to o-ring seals.
Disconnect the EGR cooler coolant vent line from the
thermostat housing and the EGR cooler.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Engi [...]
Page 11-62 Section 11 - Exhaust System - Group 11

Remove the two EGR cooler coolant return tube mounting


capscrews.

Remove the EGR cooler coolant return jumper tube from


the EGR cooler.

Remove the EGR cooler coolant supply tube mounting


capscrew.

Slide the EGR cooler coolant supply jumper tube all the
way rearward inside the EGR cooler coolant supply tube.
Remove the EGR cooler coolant supply tube retaining
clamp capscrew from the water pump housing.
Signature, ISX, and QSX15 Engi [...] EGR Cooler Coolant Lines
Section 11 - Exhaust System - Group 11 Page 11-63

Slide the EGR cooler coolant supply tube rearward until


the EGR cooler coolant supply tube is disengaged from
the water pump outlet.
Remove the EGR cooler coolant supply tube from the
engine.
Remove and discard all three o-rings.

Remove the nuts from the EGR cooler coolant supply tube
mounting bracket.

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.
Clean the EGR cooler coolant vent and the EGR cooler
coolant return line with solvent.
Dry with compressed air.
Inspect the EGR cooler coolant vent and the EGR cooler
coolant return line for cracks or damage. Replace the lines
if cracked or damaged.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Engi [...]
Page 11-64 Section 11 - Exhaust System - Group 11

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 EGR cooler coolant vent line and the EGR
cooler coolant supply and return tubes with solvent.
Dry with compressed air.

Inspect the EGR cooler for cracks or damage. Replace the


lines if cracked or damaged.

Install
Automotive with CM870

CAUTION
Do not use petroleum products on the EGR cooler
coolant line o-rings. The o-rings will swell and cause
the connection to leak.
Install new the o-rings on the EGR cooler coolant return
line.
Lubricate the o-rings with clean engine coolant, soapy
water, or vegetable oil for easier installation.
Install the EGR cooler coolant return line from the EGR
cooler to the thermostat housing.
Tighten the mounting capscrews.
Torque Value: 25 N•m [ 18 ft-lb ]
Signature, ISX, and QSX15 Engi [...] EGR Cooler Coolant Lines
Section 11 - Exhaust System - Group 11 Page 11-65

Install the EGR cooler coolant vent line. Attach the rigid
section of the vent line to the EGR cooler and the flexible
section to the EGR cooler coolant return line.

Automotive With CM871

CAUTION
Do not use petroleum products on the EGR cooler
coolant line o-rings. The o-rings will swell and cause
the connection to leak.
Install the new o-rings on the EGR cooler coolant supply
tubes and jumper connection.
Lubricate the o-rings with clean engine coolant, soapy
water, or vegetable oil to aid in installation.

Install the EGR cooler coolant supply tube mounting


bracket and nuts.
Tighten the nuts.
Torque Value: 34 N•m [ 25 ft-lb ]

Insert the EGR cooler coolant supply jumper tube into the
EGR cooler coolant supply tube.
Slide the EGR cooler coolant supply jumper tube into the
EGR cooler inlet.
Install the retaining clamp and capscrew to the EGR
cooler.
NOTE: Do not torque at this time.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Engi [...]
Page 11-66 Section 11 - Exhaust System - Group 11

Insert the EGR cooler coolant supply tube into the water
pump outlet.
Install the EGR cooler coolant supply tube retaining clamp
and capscrew.
NOTE: Do not torque at this time.

Tighten in the following sequence.


Install the EGR cooler coolant supply tube mounting
capscrew and tighten.
Torque Value: 47 N•m [ 35 ft-lb ]
Tighten the EGR cooler coolant supply jumper tube
retaining clamp capscrew.
Torque Value: 47 N•m [ 35 ft-lb ]
Tighten the EGR cooler coolant supply tube retaining
clamp capscrew.
Torque Value: 47 N•m [ 35 ft-lb ]

Install the EGR cooler coolant vent line to the thermostat


housing and the EGR cooler.

Install the o-rings on the coolant return tube jumper tube.


Apply lubricant to the o-rings
Install the jumper tube into the EGR cooler.
Signature, ISX, and QSX15 Engi [...] Heat Shield
Section 11 - Exhaust System - Group 11 Page 11-67

Install the press in place seal and the coolant return tube.
Install and tighten the capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]

Finishing Steps
Automotive with CM870
• Install the exhaust gas pressure sensor tube. Refer
to Procedure 011-027.
• Install the air intake piping. Refer to the OEM
troubleshooting and repair manual.
• Fill the cooling system. Refer to Procedure 008-018.
• Start and operate the engine. Check for leaks.

Automotive With CM871


Install the intake piping. Refer to the OEM troubleshooting
and repair manual.
Fill the cooling system. Refer to Procedure 008-018.
Operate the engine and check for leaks.

Heat Shield (011-032)


Preparatory Steps
Automotive with CM870
• Remove the air intake piping from the turbocharger.
Refer to the OEM troubleshooting and repair
manual.
Heat Shield Signature, ISX, and QSX15 Engi [...]
Page 11-68 Section 11 - Exhaust System - Group 11

Remove
Automotive with CM870
Remove the three mounting capscrews from the EGR
valve.
Remove the heat shield.

Automotive With CM871


Remove the four EGR valve heat shield mounting
capscrews from the EGR valve.
Remove the heat shield.

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 heat shield with solvent.
Dry with compressed air.
Inspect the heat shield for cracks or any other damage.
Replace the heat shield, if cracks or any other damage is
found.
Signature, ISX, and QSX15 Engi [...] Exhaust Gas Pressure Sensor Adapter
Section 11 - Exhaust System - Group 11 Page 11-69

Install
Automotive with CM870
Apply high temperature anti-seize compound onto the
mounting capscrews.
Install the three mounting capscrews and the heat shield.
Torque Value: 23 N•m [ 17 ft-lb ]

Automotive With CM871


Apply high temperature anti-seize compound onto the
mounting capscrews.
Install the four capscrews and the heat shield.
Torque Value: 23 N•m [ 17 ft-lb ]

Finishing Steps
Automotive with CM870
Install the air intake piping to the turbocharger. Refer to
the OEM troubleshooting and repair manual.

Exhaust Gas Pressure Sensor Adapter


(011-033)
Preparatory Steps
Automotive with CM870
• Remove the exhaust gas pressure sensor. Refer to
Procedure 019-376 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
• Remove the exhaust pressure sensor tube. Refer to
Procedure 011-027.
Exhaust Gas Pressure Sensor Adapter Signature, ISX, and QSX15 Engi [...]
Page 11-70 Section 11 - Exhaust System - Group 11

Remove
All Applications
Remove the p-clamp mounting capscrew and remove the
adapter.

Inspect for Reuse


All Applications
Inspect the sensor adapter for cracks or fretting.
Replace if damage is found.
Inspect the p-clamp for cracks.
Replace if damage is found.

Install
All Applications
Install the sensor adapter and the p-clamp mounting
capscrew.
Tighten the capscrew.
Torque Value: 23 N•m [ 17 ft-lb ]

Finishing Steps
Automotive with CM870
• Install the exhaust pressure sensor tube. Refer to
Procedure 011-027.
• Install the exhaust gas pressure sensor. Refer to
Procedure 019-376 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Diesel Particulate Filter
Section 11 - Exhaust System - Group 11 Page 11-71

Aftertreatment Diesel Particulate Filter


(011-041)
General Information

WARNING
During regeneration, exhaust gas temperature could
reach 800°C [1500°F], and exhaust system surface
temperature could exceed 700°C [1300°F], which is
hot enough to ignite or melt common materials, and
to burn people. The exhaust and exhaust components
can remain hot after the vehicle has stopped moving.
To avoid the risk of fire, property damage, burns or
other serious personal injury, allow the exhaust
system to cool before beginning this procedure or
repair and make sure that no combustible materials
are located where they are likely to come in contact
with hot exhaust or exhaust components.

CAUTION
The aftertreatment diesel oxidation catalyst elements
contained in the aftertreatment system are made of
brittle material. Do not drop or strike the side of the
aftertreatment system as damage to the
aftertreatment diesel oxidation catalyst element can
result.
Due to the number of various exhaust aftertreatment
applications, this procedure contains generic information.
Not all illustrations within this procedure will represent the
applications.
The aftertreatment system is composed of four sections.
These sections are:
1. Inlet
2. Aftertreatment Diesel Oxidation Catalyst
3. Aftertreatment Diesel Particulate Filter
4. Outlet.
NOTE: In some applications, the aftertreatment diesel
oxidation catalyst can be integrated into the inlet of the
exhaust aftertreatment.

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 vehicle batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section 13.
Disconnect the aftertreatment particulate filter differential
pressure sensor tubes, if necessary. Refer to Procedure
011-047 (Aftertreatment Diesel Particulate Filter
Differential Pressure Sensor Tubes) in Section 11.
Aftertreatment Diesel Particulate Filter Signature, ISX, and QSX15 Engi [...]
Page 11-72 Section 11 - Exhaust System - Group 11

Remove
Mark the direction of exhaust flow on the outside of the
aftertreatment to aid in installation.

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.

CAUTION
The aftertreatment diesel oxidation catalyst elements
contained in the aftertreatment system are made of
brittle material. Do not drop or strike the side of the
aftertreatment system as damage to the
aftertreatment diesel oxidation catalyst element can
result.
NOTE: If necessary, remove additional mounting
hardware to remove the aftertreatment diesel particulate
filter from the vehicle.
Remove the v-band clamps from the inlet and outlet
flanges of the aftertreatment diesel particulate filter.
Separate the flanges by approximately 25 mm [1 in] to
allow removal over the gasket retainer rings.
Remove and discard the gaskets.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Diesel Particulate Filter
Section 11 - Exhaust System - Group 11 Page 11-73

Clean and Inspect for Reuse


CAUTION
Do not use a grinder or abrasive air tool to remove
residual gasket material, as this can damage the
flange and cause the connection to leak.

CAUTION
Do not use an open flame to burn off soot
accumulation from the face of the aftertreatment
diesel particulate filter.

CAUTION
Do not scrape off soot accumulation from the face of
the aftertreatment diesel particulate filter.
NOTE: The aftertreatment diesel particulate filter relies on
gas flow through the walls to collect soot. To accomplish
gas flow through the walls of the filter, every other cell on
the face of the filter is plugged with a ceramic material.
Therefore it is not possible to see light straight through
the holes in the aftertreatment diesel particulate filter.
Remove any residual gasket material from the flanges on
the aftertreatment diesel particulate filter with a scraping
tool.
Avoid dropping fragments of gasket material into the
aftertreatment diesel particulate filter.
NOTE: It is not possible to inspect the outlet of the
aftertreatment diesel oxidation catalyst and inlet of the
aftertreatment diesel particulate filter on aftertreatment
systems with a joined aftertreatment diesel oxidation
catalyst - aftertreatment diesel particulate filter.

Refer to the Catalyst and Aftertreatment Particulate Filter


Reuse Guidelines, Bulletin 4021600, to inspect the inlet
and outlet faces of the aftertreatment diesel particulate
filter for signs of damage.
Replace the aftertreatment diesel particulate filter if
damage is found.
If the aftertreatment diesel particulate filter has been
removed for cleaning and is considered good dirty
according to the Catalyst and Aftertreatment Particulate
Filter Reuse Guidelines, Bulletin 4021600, the filter can be
cleaned using an approved Cummins' aftertreatment
diesel particulate filter cleaning machine.
After cleaning the aftertreatment diesel particulate filter
must be inspected using the approved Cummins'
cleaning machine. If the filter passes inspection, it can be
reused, otherwise the filter cleaning must be repeated.
If the filter does not pass inspection after two successive
cleanings, it must be sent to ReCon® and a replacement
filter must be used.
Aftertreatment Diesel Particulate Filter Signature, ISX, and QSX15 Engi [...]
Page 11-74 Section 11 - Exhaust System - Group 11

Replace the aftertreatment diesel particulate filter if


cracks are present on the face.
If the aftertreatment diesel particulate filter has shifted,
moved, or is loose inside of the canister, replace the
aftertreatment diesel particulate filter.
Return the aftertreatment diesel particulate filter section
to an Authorized Cummins® Repair Location for cleaning
or replacement.

Inspect the v-band clamps and mounting straps for signs


of over-extension. The band must not be bent or
damaged.
Inspect the v-band clamps and mounting strap threads for
damage.
Replace the v-band clamp or strap if damage is found.

Install

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 new gaskets on the inlet and outlet of the
aftertreatment diesel particulate filter canister.
NOTE: In some applications, a locating tab was integrated
into the gasket retaining ring. The locating tab will prevent
the jointed aftertreatment diesel oxidation catalyst -
aftertreatment diesel particulate filter from being installed
backwards, and will restrict the rotational orientation that
the filter can be installed.
NOTE: On vertical aftertreatment orientations, a
aftertreatment diesel particulate filter differential pressure
sensor tube support can be present. Be sure that the
support is aligned with the tube prior to installing the filter.
Loosely tighten the v-band clamps to allow rotation for