Vol2

Cummins Inc.
Service Manual
Service Manual Signature, ISX and QSX15 Volume 2

Box 3005
Columbus, Indiana, U.S.A., 47202 Signature, ISX and QSX15
Registered Office Volume 2
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright 2010
Cummins Inc.
Bulletin 3666239
Printed in U.S.A. 27-APRIL-2010 p41
302158_Cummins_Vol2.indd 1 5/11/10 9:37 AM

Service Manual
Signature, ISX, and QSX15
Volume 2
Copyright 2010 Bulletin 3666239

Cummins Inc. Printed 27-APRIL-2010
All rights reserved
Foreword
This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild
procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing
of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be
contacted directly for any information not covered in this manual.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
- Introduction.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild
procedures require the use of special service tools. Make sure the correct tools are used as described in the
procedures.
When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used
in place of the recommended item.
A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair)
are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office
listing is located in Service Literature (Section L).
Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement.
Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating
your comments.
The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between
your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS
(1-800-343-7357) toll free in the U.S. and Canada.
The latest technology and the highest quality components are used to manufacture Cummins engines. When
replacement parts are needed, we recommend using only genuine Cummins or ReCon exchange parts.
Table of Contents
Section
Introduction .............................................................................................................................................. i
Cylinder Head - Group 02 ......................................................................................................................... 2
Rocker Levers - Group 03 ........................................................................................................................ 3
Fuel System - Group 05 ........................................................................................................................... 5
Injectors and Fuel Lines - Group 06 ........................................................................................................ 6
Lubricating Oil System - Group 07 .......................................................................................................... 7
Cooling System - Group 08 ...................................................................................................................... 8
Drive Units - Group 09 .............................................................................................................................. 9
Air Intake System - Group 10 ................................................................................................................... 10
Exhaust System - Group 11 ..................................................................................................................... 11
Compressed Air System - Group 12 ........................................................................................................ 12
Electrical Equipment - Group 13 .............................................................................................................. 13
Engine Testing - Group 14 ....................................................................................................................... 14
Mounting Adaptations - Group 16 ............................................................................................................ 16
Vehicle Braking - Group 20 ...................................................................................................................... 20
Service Literature ..................................................................................................................................... L
Specifications ........................................................................................................................................... V
Back .......................................................................................................................................................... back

Signature, ISX, and QSX15 Eng [...]
Section i - Introduction Page i-a
Section i - Introduction
Section Contents
Page
About the Manual ...............................................................................................................................................i-1
General Information...........................................................................................................................................i-1
Acronyms and Abbreviations ...........................................................................................................................i-15
General Information..........................................................................................................................................i-15
General Cleaning Instructions ......................................................................................................................... i-10
Abrasive Pads and Abrasive Paper...................................................................................................................i-10
Definition of Clean............................................................................................................................................i-10
Fuel System.....................................................................................................................................................i-13
Gasket Surfaces...............................................................................................................................................i-11
Plastic Bead Cleaning......................................................................................................................................i-12
Solvent and Acid Cleaning................................................................................................................................i-11
Steam Cleaning................................................................................................................................................i-12
General Repair Instructions ...............................................................................................................................i-8
Welding on a Vehicle with an Electronic Controlled Fuel System........................................................................i-9
General Safety Instructions ...............................................................................................................................i-6
Important Safety Notice......................................................................................................................................i-6
How to Use the Manual ......................................................................................................................................i-2
Illustrations .........................................................................................................................................................i-5
Symbols ..............................................................................................................................................................i-4
Page i-b Section i - Introduction
This Page Left Intentionally Blank

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

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

General Information
The troubleshooting and repair section of this manual is organized to provide an easy system installation and flow
from problem identification to problem correction.
System Installation
The installation guidelines section has been designed to provide instructions for installing the system. A technician
should read the instruction, learn the intent of the step, and install the component in a fashion that will comply to the
vehicle's configuration. Each deviation from the specific instructions provided in this procedure should be noted.
Refer to the OEM service manual for OEM specifications.
A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms,
Section (TS). The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and
directing the end user to the correct procedure for making the repair. Complete the following steps to locate and
correct the problem.
(Step 1) Locate the symptom on the Section Contents pages of

Section TS.
Reference to the page number where the
Troubleshooting Symptom Tree is found is made to the
right of the symptom tree title.
(Step 2) The left column of boxes in the Troubleshooting Symptom
Charts indicates a probable cause of the problem,
starting at the top with the simplest and easiest to repair,
and continuing downward to the most difficult.
The right column of boxes provides a brief description of
the corrective action with a reference number to the
correct procedure used to make the repair.
(Step 3) Locate the probable cause in the left column then turn to
the procedure referenced in the right column.
(Step 4) The Troubleshooting Symptom Charts are based on the
following assumptions:
The engine has been installed according to the
manufacturer's specifications.
The easiest repairs are done first.
"Generic" solutions to cover problems with the most
common applications and Original Equipment
Manufacturer (OEM).
The disassemble/assemble sections of this manual is divided into the same group system used for previous manuals
and the Cummins' filmcard system.
Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical
sequence. Refer to the Table of Contents at the front of the book to determine the section that details the desired
information.
Each section contains the following in sequence:
Table of Contents
Required Service Tool Listings
General Information containing the basic service, maintenance, design and revision information necessary to assist
in the rebuild of an engine or a component
Procedure instructions for the disassembly, inspection, maintenance, and assembly that can be required to rebuild
an engine; additional procedures that are not necessary during every rebuild, but can be necessary, are included.
These procedures depend on the length of time an engine has been in service and the conditions of the parts.
All the procedures are identified with a name and a number. Each digit in the procedure number has a specific
meaning.
The first three digits of the number refer to the specific section that the procedure can be found within the manual. In
this example, 001 represents Section 01 Cylinder Block. This number will range from 000 to 022.
Signature, ISX, and QSX15 Eng [...] How to Use the Manual
The second three digits of the number are unique and refer to a specific subject. In this example, 028 represents
Cylinder Liner. This number will range from 001 to 999.
Refer to Section V for specifications recommended by Cummins Engine Company, Inc. for your engine. Specifications
and torque values for each engine system are given in that section.
NOTE: Discharge of oil or oily water into or upon the water is a direct violation of today's laws. Violators are subject
to a penalty of various monetary charges. Dispose of these substances in accordance with standard set by the EPA.
Symbols Signature, ISX, and QSX15 Eng [...]
Symbols
General Information
The following symbols have been used in this manual to help communicate the intent of the instructions. When one
of the symbols appears, it conveys the meaning defined below:
Signature, ISX, and QSX15 Eng [...] Illustrations
Illustrations
General Information
Some of the illustrations throughout this manual are
generic and will not look exactly like the engine or parts
used in your application. The illustrations can contain
symbols to indicate an action required and an acceptable
or not acceptable condition.
The illustrations are intended to show repair or

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

Important Safety Notice
WARNING
Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation
or other personal injury or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included
in the procedures when they apply.
Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition
sources and hazardous substances. Be aware of hazardous conditions that can exist.
Always wear protective glasses and protective shoes when working.
Rotating parts can cause cuts, mutilation or strangulation.
Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.
Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in
the operator's compartment or on the controls.
Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or
damage to the fan blade(s) causing premature fan failure.
If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler
cap to relieve the pressure from the cooling system.
Always use blocks or proper stands to support the product before performing any service work. Do not work on
anything that is supported ONLY by lifting jacks or a hoist.
Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure.
Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid
refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be
properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the
atmosphere. Federal law requires capturing and recycling refrigerant.
To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23
kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of
the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The
lifting hooks must not be side-loaded.
Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes.
Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash
skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum
of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas
flow, and hot fluids in lines, tubes, and compartments.
Always use tools that are in good condition. Make sure you understand how to use the tools before performing
any service work. Use ONLY genuine Cummins or Cummins ReCon replacement parts.
Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
lesser quality if replacements are necessary.
When necessary, the removal and replacement of any guards covering rotating components, drives, and/or belts
should only be carried out be a trained technician. Before removing any guards the engine must be turned off and
any starting mechanisms must be isolated. All fasteners must be replaced on re-fitting the guards.
Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
Signature, ISX, and QSX15 Eng [...] General Safety Instructions
Some state and federal agencies in the United States of America have determined that used engine oil can be
carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact
with used engine oil.
Do not connect the jumper starting or battery charging cables to any ignition or governor control wiring. This can
cause electrical damage to the ignition or governor.
Always torque fasteners and fuel connections to the required specifications. Overtightening or undertightening
can allow leakage. This is critical to the natural gas and liquefied petroleum gas fuel and air systems.
Always test for fuel leaks as instructed, as odorant can fade.
Close the manual fuel valves prior to performing maintenance and repairs, and when storing the vehicle inside.
Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.
The catalyst reagent contains urea. Do not get the substance in your eyes. In case of contact, immediately flood
eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of
contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent
is ingested, contact a physician immediately.
The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. Always wear protective gloves and eye protection when handling the catalyst assembly.
Do not get the catalyst material in your eyes. In Case of contact, immediately flood eyes with large amounts of
water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin
with soap and water.
The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local
regulations.
California Proposition 65 Warning - Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
General Repair Instructions Signature, ISX, and QSX15 Eng [...]
General Repair Instructions

General Information
This engine incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using
normal repair practices performed to quality standards.
CAUTION
Cummins Inc. does not recommend or authorize any modifications or repairs to engines or components
except for those detailed in Cummins Service Information. In particular, unauthorized repair to safety-related
components can cause personal injury or death. Below is a partial listing of components classified as safety-
related:
1 Air Compressor
2 Air Controls
3 Air Shutoff Assemblies
4 Balance Weights
5 Cooling Fan
6 Fan Hub Assembly
7 Fan Mounting Bracket(s)
8 Fan Mounting Capscrews
9 Fan Hub Spindle
10 Flywheel
11 Flywheel Crankshaft Adapter
12 Flywheel Mounting Capscrews
13 Fuel Shutoff Assemblies
14 Fuel Supply Tubes
15 Lifting Brackets
16 Throttle Controls
17 Turbocharger Compressor Casing
18 Turbocharger Oil Drain Line(s)
19 Turbocharger Oil Supply Line(s)
20 Turbocharger Turbine Casing
21 Vibration Damper Mounting Capscrews
Follow all safety instructions noted in the procedures

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

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

Definition of Clean
Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to
appear as new.
Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forming
a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface. Gaskets are
designed to fill small voids in the specified surface finish.
Sanding gasket surfaces where edge-molded gaskets are used is most often unnecessary. Edge-molded gaskets are
those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal portion forms a
metal to metal joint for stability. Any of the small amounts of sealing material that can stick to the parts are better
removed with a blunt-edged scraper on the spots rather than spending time polishing the whole surface with an air
sander or disc.
For those gaskets that do not have the edge molding, nearly all have a material that contains release agents to prevent
sticking. Certainly this is not to say that some gaskets are not difficult to remove because the gasket has been in
place a long time, has been overheated or the purpose of the release agent has been defeated by the application of
some sealant. The object however is just to remove the gasket without damaging the surfaces of the mating parts
without contaminating the engine (don't let the little bits fall where they can not be removed).
Bead blasting piston crowns until the dark stain is removed is unnecessary. All that is required is to remove the carbon
build-up above the top ring and in the ring grooves. There is more information on bead blasting and piston cleaning
later in this document.
Cummins Inc. does not recommend sanding or grinding the carbon ring at the top of cylinder liners until clean metal
is visible. The liner will be ruined and any signs of a problem at the top ring reversal point (like a dust-out) will be
destroyed. It is necessary to remove the carbon ring to provide for easier removal of the piston assembly. A medium
bristle, high quality, steel wire wheel that is rated above the rpm of the power tool being used will be just as quick and
there will be less damage. Yes, one must look carefully for broken wires after the piston is removed but the wires are
more visible and can be attracted by a magnet.
Oil on parts that have been removed from the engine will attract dirt in the air. The dirt will adhere to the oil. If possible,
leave the old oil on the part until it is ready to be cleaned, inspected and installed, and then clean it off along with any
attracted dirt. If the part is cleaned then left exposed it can have to be cleaned again before installation. Make sure
parts are lubricated with clean oil before installation. They do not need to be oiled all over but do need oil between
moving parts (or a good lube system priming process conducted before cranking the engine).
Bead blasting parts to remove exterior paint is also usually unnecessary. The part will most likely be painted again
so all that needs happen is remove any loose paint.
Abrasive Pads and Abrasive Paper
The keyword here is "abrasive". There is no part of an engine designed to withstand abrasion. That is they are all
supposed to lock together or slide across each other. Abrasives and dirt particles will degrade both functions.
WARNING
Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive material
in oil passages can cause bearing and bushing failures that can progress to major component damage beyond
reuse. This is particularly true of main and rod bearings.
Cummins Inc. does not recommend the use of emery cloth or sand paper on any part of an assembled engine or
component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks or
counterbores.
Great care must be taken when using abrasive products to clean engine parts, particularly on partially assembled
engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum oxide particles,
silicon carbide, or sand or some other similar hard material. These particles are harder than most of the parts in the
engine. Since they are harder, if they are pressed against softer material they will either damage the material or
become embedded in it. These materials fall off the holding media as the product is used. If the products are used
with power equipment the particles are thrown about the engine. If the particles fall between two moving parts, damage
to the moving parts is likely.
If particles that are smaller than the clearance between the parts while they are at rest (engine stopped), but larger
than the running clearance then damage will occur when the parts move relative to each other (engine started). While
the engine is running and there is oil pressure, particles that are smaller than the bearing clearance are likely to pass
between the parts without damage and be trapped in the oil filter. However, particles larger than the bearing clearance
will remove material from one part and can become embedded in one of the parts. Once embedded in one part it will
Signature, ISX, and QSX15 Eng [...] General Cleaning Instructions
abrade the other part until contact is no longer being made between the two parts. If the damage sufficiently degrades
the oil film, the two parts will come into contact resulting in early wear-out or failure from lack of effective lubrication.
Abrasive particles can fly about during cleaning it is very important to block these particles from entering the engine
as much as possible. This is particularly true of lubricating oil ports and oil drilling holes, especially those located
downstream of the lubricating oil filters. Plug the holes instead of trying to blow the abrasive particles and debris with
compressed air because the debris is often simply blown further into the oil drilling.
All old gasket material must be removed from the parts gasket surfaces. However, it is not necessary to clean and
polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the gasket
surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member bonded to the steel).
What little sealing material that can adhere is best removed with a blunt-edged scraper or putty knife. Cleaning gasket
surfaces where an edge-molded gasket is used with abrasive pads or paper is usually a waste of time.
WARNING
Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner beyond
reuse. The surface finish will be damaged and abrasive particles can be forced into the liner material which
can cause early cylinder wear-out or piston ring failures.
Tape off or plug all openings to any component interior before using abrasive pads or wire brushes. If really necessary
because of time to use a power tool with abrasive pads, tape the oil drillings closed or use plug and clean as much
of the surface as possible with the tool but clean around the oil hole/opening by hand so as to prevent contamination
of the drilling. Then remove the tape or plug and clean the remaining area carefully and without the tool. DO NOT use
compressed air to blow the debris out of oil drilling on an assembled engine! More likely than not, the debris can be
blown further into the drilling. Using compressed air is fine if both ends of the drilling are open but that is rarely the
case when dealing with an assembled engine.
Gasket Surfaces
The object of cleaning gasket surfaces is to remove any gasket material, not refinish the gasket surface of the part.
Cummins Inc. does not recommend any specific brand of liquid gasket remover. If a liquid gasket remover is used,
check the directions to make sure the material being cleaned will not be harmed.
Air powered gasket scrapers can save time but care must be taken to not damage the surface. The angled part of
the scraper must be against the gasket surface to prevent the blade from digging into the surface. Using air powered
gasket scrapers on parts made of soft materials takes skill and care to prevent damage.
Do not scrape or brush across the gasket surface if at all possible.
Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons. See
Below). Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95
Celsius (180 to 200 Fahrenheit). Kerosene emulsion based cleaners have different temperature specifications, see
below. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results.
Cummins Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's instructions.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the
parts before putting them in the cleaning tank.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons. These cleaners
should not be heated to temperature in excess of 77C (170F). The solution begins to break down at temperatures
in excess of 82C (180F) and will be less effective.
Do not use solutions composed mainly of chlorinated hydrocarbons with cresols, phenols and/or cresylic components.
They often do not do a good job of removing deposits from the ring groove and are costly to dispose of properly.
Solutions with a pH above approximately 9.5 will cause aluminum to turn black; therefore do not use high alkaline
solutions.
Chemicals with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. As you move further away
from the neutral 7.0, the chemicals become highly alkaline or highly acidic.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use hot high
pressure water or steam clean the parts before putting them in the cleaning tank. Removing the heaviest dirt before
placing in the tank will allow the cleaner to work more effectively and the cleaning agent will last longer.
Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all the
capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rust proofing compound. The rust
proofing compound must be removed from the parts before assembly or installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good method
for cleaning the oil drillings and coolant passages
WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Do not steam clean the following components:
Electrical Components
Wiring Harnesses
Injectors
Fuel Pump
Belts and Hoses
Bearings (ball or taper roller)
Electronic Control Module (ECM)
ECM Connectors
Dosing Control Unit
NOx Sensor.
Plastic Bead Cleaning
Cummins Inc. does not recommend the use of glass bead blast or walnut shell media on any engine part. Cummins
Inc. recommends using only plastic bead media, Part Number 3822735 or equivalent on any engine part. Never use
sand as a blast media to clean engine parts. Glass and walnut shell media when not used to the media manufacturer's
recommendations can cause excess dust and can embed in engine parts that can result in premature failure of
components through abrasive wear.
Plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is
controlled by the use of plastic beads, the operating pressure and cleaning time.
CAUTION
Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston, piston
skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal and result
in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shafts, etc.,
can also be damaged. Follow the cleaning directions listed in the procedures.
CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic beads.
Remove the foreign material and plastic beads with compressed air, hot high pressure water or steam before
placing them in tanks or cleaners. The foreign material and plastic beads can contaminate the tank and any
other engine parts cleaned in the tank. Contaminated parts may cause failures from abrasive wear.
Plastic bead blasting media, Part Number 3822735, can be used to clean all piston ring grooves. Do not sure any
bead blasting media on piston pin bores or aluminum skirts.
Follow the equipment manufacturer's cleaning instructions. Make sure to adjust the air pressure in the blasting
machine to the bead manufacturer's recommendations. Turning up the pressure can move material on the part and
cause the plastic bead media to wear out more quickly. The following guidelines can be used to adapt to
manufacturer's instructions:
1. Bead size: U.S. size Number 16 20 for piston cleaning with plastic bead media, Part Number 3822735
2. Operating Pressure 270 kPa (40 psi) for piston cleaning. Pressure should not cause beads to break.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning.
Rinse with hot water. Dry with compressed air.
Signature, ISX, and QSX15 Eng [...] General Cleaning Instructions
CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the engine
can be damaged due to increased parts clearance or inadequate surface finish on parts that move against
other parts.
When cleaning pistons, it is not necessary to remove all the dark stain from the piston. All that is necessary is to
remove the carbon on the rim and in the ring grooves. This is best done by directing the blast across the part as
opposed to straight at the part. If the machining marks are disturbed by the blasting process, then the pressure is too
high or the blast is being held on one spot too long. The blast operation must not disturb the metal surface.
Walnut shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell blasting
produces a great amount of dust particularly when the pressure if the air pressure on the blasting machine is increased
above media manufacturer's recommendation. Cummins Inc. recommends not using walnut shell media to clean
engine parts due to the risk media embedment and subsequent contamination of the engine.
Cummins Inc. now recommends glass bead media NOT used to clean any engine parts. Glass media is too easily
embedded into the material particularly in soft materials and when air pressures greater than media manufacturer's
recommend are used. The glass is an abrasive so when it is in a moving part, that part is abrading all the parts in
contact with it. When higher pressures are used the media is broken and forms a dust of a very small size that floats
easily in the air. This dust is very hard to control in the shop, particularly if only compressed air (and not hot water)
is used to blow the media after it is removed from the blasting cabinet (blowing the part off inside the cabinet may
remove large accumulations but never removes all the media).
Bead blasting is best used on stubborn dirt/carbon build-up that has not been removed by first steam/higher pressure
washing then washing in a heated wash tank. This is particularly true of pistons. Steam and soak the pistons first then
use the plastic bead method to safely remove the carbon remaining in the grooves (instead of running the risk of
damaging the surface finish of the groove with a wire wheel or end of a broken piston ring. Make sure the parts are
dry and oil free before bead blasting to prevent clogging the return on the blasting machine.
Always direct the bead blaster nozzle "across" rather than directly at the part. This allows the bead to get under the
unwanted material. Keep the nozzle moving rather than hold on one place. Keeping the nozzle directed at one-place
too long causes the metal to heat up and be moved around. Remember that the spray is not just hitting the dirt or
carbon. If the machining marks on the piston groove or rim have been disturbed then there has not been enough
movement of the nozzle and/or the air pressure is too high.
Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle across
the seat surface and radius rather than straight at them. The object is to remove any carbon build up and continuing
to blast to remove the stain is a waste of time.
Fuel System
When servicing any fuel system components, which can be exposed to potential contaminants, prior to disassembly,
clean the fittings, mounting hardware, and the area around the component to be removed. If the surrounding areas
are not cleaned, dirt or contaminants can be introduced into the fuel system.
The internal drillings of some injectors are extremely small and susceptible to plugging from contamination. Some
fuel injection systems can operate at very high pressures. High pressure fuel can convert simple particles of dirt and
rust into a highly abrasive contaminant that can damage the high pressure pumping components and fuel injectors.
Electrical contact cleaner can be used if steam cleaning tools are not available. Use electrical contact cleaner rather
than compressed air, to wash dirt and debris away from fuel system fittings. Diesel fuel on exposed fuel system parts
attracts airborne contaminants.
Choose lint free towels for fuel system work.
Cap and plug fuel lines, fittings, and ports whenever the fuel system is opened. Rust, dirt, and paint can enter the
fuel system whenever a fuel line or other component is loosened or removed from the engine. In many instances, a
good practice is to loosen a line or fitting to break the rust and paint loose, and then clean off the loosened material.
When removing fuel lines or fittings from a new or newly-painted engine, make sure to remove loose paint flakes/
chips that can be created when a wrench contacts painted line nuts or fittings, or when quick disconnect fittings are
removed.
Fuel filters are rated in microns. The word micron is the abbreviation for a micrometer, or one millionth of a meter.
The micron rating is the size of the smallest particles that will be captured by the filter media. As a reference, a human
hair is 0.003 mm [3/1000 in] in diameter. One micron measures 0.00004 mm [4/100,000 in]. The contaminants being
filtered out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope.
The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination. Like fuel
system parts, tools that are coated with oil or fuel attract airborne contaminants. Remember the following points
regarding your fuel system tools:
Fuel system tools are to be kept as clean as possible.

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

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

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

Section Contents
Page
Cylinder Head ....................................................................................................................................................2-5
Assemble........................................................................................................................................................2-32
Clean..............................................................................................................................................................2-10
Clean and Inspect for Reuse...........................................................................................................................2-21
Disassemble................................................................................................................................................... 2-17
Finishing Steps...............................................................................................................................................2-38
General Information..........................................................................................................................................2-5
Initial Check......................................................................................................................................................2-6
Inspect for Reuse..............................................................................................................................................2-9
Install..............................................................................................................................................................2-37
Leak Test........................................................................................................................................................2-11
Magnetic Crack Inspect...................................................................................................................................2-30
Measure..........................................................................................................................................................2-27
Preparatory Steps.............................................................................................................................................2-7
Remove............................................................................................................................................................2-8
Vacuum Test...................................................................................................................................................2-15
Injector Camshaft Scissor Gear ......................................................................................................................2-86
Install..............................................................................................................................................................2-87
Remove.......................................................................................................................................................... 2-86
Overhead Camshaft End Clearance, Valve .....................................................................................................2-81
Measure..........................................................................................................................................................2-81
Overhead Camshaft Bushings, Injector ..........................................................................................................2-69
Initial Check....................................................................................................................................................2-69
Inspect for Reuse............................................................................................................................................2-74
Install..............................................................................................................................................................2-74
Remove.......................................................................................................................................................... 2-69
Overhead Camshaft Bushings, Valve .............................................................................................................2-57
Initial Check....................................................................................................................................................2-57
Install..............................................................................................................................................................2-62
Remove.......................................................................................................................................................... 2-57
Overhead Camshaft End Clearance, Injector .................................................................................................2-83
Measure..........................................................................................................................................................2-83
Overhead Camshaft Gear, Valve .....................................................................................................................2-86
Install..............................................................................................................................................................2-86
Remove.......................................................................................................................................................... 2-86
Overhead Camshaft, Injector ..........................................................................................................................2-51
Finishing Steps...............................................................................................................................................2-55
Install..............................................................................................................................................................2-55
Preparatory Steps...........................................................................................................................................2-51
Remove.......................................................................................................................................................... 2-53
Overhead Camshaft, Valve ..............................................................................................................................2-47
Finishing Steps...............................................................................................................................................2-50
Install..............................................................................................................................................................2-50
Remove.......................................................................................................................................................... 2-48
Service Tools ....................................................................................................................................................2-1
.........................................................................................................................................................................2-1
Valve Guide Seal, Cylinder Head ....................................................................................................................2-39
Finishing Steps...............................................................................................................................................2-47
On-Engine Repair.........................................................................................................................................2-47
Off-Engine Repair.........................................................................................................................................2-47
General Information.........................................................................................................................................2-39
Install..............................................................................................................................................................2-43
Page 2-b Section 2 - Cylinder Head - Group 02
On-Engine Repair.........................................................................................................................................2-39
Off-Engine Repair.........................................................................................................................................2-40
Remove.......................................................................................................................................................... 2-40
Signature, ISX, and QSX15 Eng [...] Service Tools
Section 2 - Cylinder Head - Group 02 Page 2-1
Service Tools
Cylinder Head
The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.
Tool No. Tool Description Tool Illustration

Protective Plug Kit
Used to plug oil passages and drillings during a repair process.
4918319
Four-Valve Spring Compressor

Use to remove or install valve spring retainers, valve springs, and
4919358 valve seals.
Head Bolt Stretch Gauge

Use to measure head bolts.
3163162
Hydraulic Camshaft Bushing Installation and Removal Tool

Use to remove and install camshaft bushings.
3823621
Valve Camshaft Bushing Installation and Removal Tool

Use with the hydraulic camshaft bushing installation and removal
3164088 tool, Part Number 3823621.
Injector Camshaft Bushing Installation and Removal Tool

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

Cylinder Head Lifting Fixture
Use to remove the cylinder head from the cylinder block.
3400329
Scotch-Brite 7448
Use to clean carbon, rust, and corrosion from the engine block and
3823258 parts.
Air Impact Wrench

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

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

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

Use to remove the valve seal.
3163293
Valve Guide Installer

Use to press the valve guides into the cylinder head to the proper
3162892 assembled height.

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

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

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

Use to remove the intake valve seat from the cylinder head.
ST1279-1
Valve Guide Removal Tool

Use to remove the valve guides from the cylinder head.
3163321
Valve Vacuum Tester

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

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

Use to inspect cylinder heads and other ferrous castings that can
ST1166-1 not be magnafluxed for crack detection.

Valve Seat Grooving Tool
Use to cut a groove circumferentially in the inside diameter of a valve
3376405 seat to allow the seat extractor a suitable grip area.
Cylinder Head Fuel Passage Leak Test Kit

Use to test the fuel passages in the cylinder head. Use with leak test
3164943 kit, Part Number 3164231, purchased separately.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Cylinder Head (002-004)

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

Signature, ISX, and QSX15 engines. The design used in
a particular engine is dependent on the engine's
production vintage.
Engines assembled prior to engine serial number
14022615 have groove-top liners. They are characterized
by a groove machined into the top surface of the liner
flange.
Engines assembled with engine serial number 14022615
and higher have flat-top liners. They are characterized by
a cylinder liner flange that is flat, except for the fire dam.
CAUTION
Cylinder head gaskets are different depending on the
liner design. The cylinder head gasket designed to be
used with groove-top liners can not be used with flat-
top liners, and the head gasket designed to be used
with the flat-top liners can not be used with groove-
top liners.
Engines built with groove-top liners must use a cylinder
head gasket and fire rings.
Engines built with flat-top liners must use a one-piece
cylinder head gasket without the fire rings.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
Initial Check
WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
Use steam or high-pressure water to clean the exterior of
the engine.
Operate the engine at low idle.

Check for oil or coolant leaks between the cylinder head
and the engine block.
Listen for a chirping sound between the cylinder head and

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

and all related components.
Preparatory Steps
WARNING
Batteries can emit explosive gases. To reduce the possibility of
personal injury, always ventilate the compartment before
servicing the batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first and attach the negative
(-) battery cable last.
WARNING
Do not remove the pressure cap from a hot engine. Wait until the
coolant temperature is below 50C [120F] before removing the
pressure cap. Heated coolant spray or steam can cause personal
injury.
WARNING
Coolant is toxic. Keep away from children and pets. If not reused,
dispose of in accordance with local environmental regulations.
Disconnect the batteries or air supply to the air starter to prevent
accidental engine starting. Refer to the OEM service manual.
Drain the cooling system. Refer to Procedure 008-018 in Section
8.
Remove the turbocharger. Refer to Procedure 010-033 in Section
10.
Remove the exhaust manifold. Refer to Procedure 011-007 in
Section 11.
Remove the thermostat housing. Refer to Procedure 008-014 in
Section 8.
Remove the air intake connection.Refer to Procedure 010-080 in
Section 10.
Remove the integrated fuel system module. Refer to Procedure
005-073 in Section 5.
Remove the ECM. Use the following procedure for CM570
engines, in the Signature, ISX and QSX15 Electronic Control
System, Troubleshooting and Repair Manual, Bulletin 3666259.
Refer to Procedure 019-031 in Section 19.
engines, in the Signature and ISX CM870 Electronic Control
engines, in the ISX CM871 and ISM CM876 5 Electronic Control
Remove the air compressor air inlet hose.Refer to Procedure
Remove the rocker lever cover.Refer to Procedure 003-011 in
Section 3.
Remove the rocker lever shaft assemblies. Refer to Procedure
Remove the injectors. Refer to ProcedureRefer to Procedure
Remove the upper front gear cover. Refer to Procedure 001-079
in Section 1.
Remove the valve and injector camshaft gears.Refer to Procedure
Remove the retaining brace bracket. Refer to Procedure 001-081
in Section 1.
Remove the accessory bracket. Refer to Procedure 001-082 in
Section 1.
Remove the overhead valve camshaft. Refer to Procedure 002-024
in Section 2.
Remove the overhead injector camshaft. Refer to Procedure
Remove
WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Use a chip vacuum to remove the excess oil from the top
of the cylinder head.
Remove the cylinder head capscrews.
Use engine lifting fixture, Part Number 4919360 or
equivalent, to lift the cylinder head.
Remove the cylinder head. Remove and discard the
gasket.
Remove the fire rings from the cylinder liners, if equipped.
CAUTION
Immediately upon removal of the cylinder head, plugs
must be installed into the oil passage drillings in both
the cylinder head and the block. The plugs are
necessary to prevent debris from entering the
lubrication system during the repair. Failure to insert
the oil passage plugs can result in a connecting rod
bearing failure, crankshaft failure or both.
Reusable plugs, Part Number 4089255, are included in
the master plug kit, Part Number 4918319.
Install the plugs in the cylinder block and cylinder head oil
drillings.
NOTE: This step is not applicable if the engine has flat-

top liners and a single-piece head gasket, or when
upgrading from grooved-top liners and a 13-piece gasket
to flat-top liners and a single-piece gasket.
Prior to removing the cylinder head gasket and sealing
rings (if installed), examine the gasket for carbon tracks
across the sealing ring.
The pressure of carbon indicates a combustion leak.
Remove the cylinder head gasket.

Make sure the cylinder liner recession or protrusion
(based on liner style) is within specification.
Inspect for Reuse

Use depth gauge, Part Number 3164438, to measure the
valve recess in the cylinder head.
Service Valve Recession Specification (NEW)

mm in
Intake 0.88 MIN 0.035
1.21 MAX 0.048
Exhaust 0.43 MIN 0.017
0.77 MAX 0.030
Service Valve Recession Specification (USED)

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

inspect for a leak path between the cylinder and cylinder
head capscrew holes.

Inspect the cylinder head combustion surface for pitting
or erosion.
Pitting or erosion on the cylinder head combustion surface
located in the area where the cylinder liner fire dam
contacts the head is not acceptable.
Pitting or erosion on the cylinder head combustion surface
located inside the fire ring area is acceptable.
Clean
Prior to cleaning the combustion face of the cylinder head,
small rubber plugs, Part Number 4089255, and tape
must be used to plug or cover the oil supply holes at the
ends of the cylinder head to prevent debris from entering
the oil passages.
Use Scotch-Brite 7448, Part Number 3823258, or
equivalent, to clean the cylinder head combustion face.
Also make sure there is no loose debris sitting in the valve
pockets around the head of the valve.
Do not use power tools to clean the combustion face of
the cylinder head.

small rubber plugs, Part Number 4089255, and tape
must be used to plug or cover the oil supply holes at the
ends of the cylinder head to prevent debris from entering
the oil passages.
equivalent, to clean the cylinder head combustion face.
Also make sure there is no loose debris sitting in the valve
pockets around the head of the valve.
See the Leak Test section of this procedure for more
cleaning details.
CAUTION
If the oil passages are not plugged or covered before
cleaning, a crankshaft failure can occur.
Make sure the plugs are installed in the oil passages of
the cylinder block deck.
Plug or cover the coolant passages in the cylinder block
deck.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
Use a gasket scraper to clean the cylinder block deck
surface.
equivalent, and solvent to remove any residual gasket
material from the cylinder block deck surface.
Use a chip vacuum to remove the excess oil and coolant
from the capscrew holes.
Make sure the cylinder head capscrew holes are clean
and free of debris, oil, and coolant.
Do not use power tools to clean the combustion face.
Leak Test
Fuel Passage
NOTE: This task can be preformed either on or off-engine.
The fuel system is split into two banks.
The front bank is for cylinders one through three, and the
rear bank is for cylinders four through six.
The banks are tested independently of each other. Use
test kit, Part Number 3164943.
The left three male connectors on the plate are for the front
bank and the right three male connectors are for the rear
bank.
The three male connectors on the plate are:
Metering
Timing
Return.
Apply thread sealant to the male connectors and install

them into the plate, if they are not installed.
Install the gasket, plate, two short capscrews (5), and two
long capscrews (4).
Tighten the capscrews.
Torque Value: 27 Nm [ 239 in-lb ]
Install the injector cavity plug (3) into the appropriate

injector bores.
Center the injector cavity plugs in the injector bores.
Install the injector hold-down clamps and capscrews.
Torque Value: 41 Nm [ 30 ft-lb ]
Attach leak test kit, Part Number 3164231 or equivalent,

to one of the male connectors on the plate.
Apply 207 kPa [30 psi] of air pressure.
Verify the test hardware is not leaking.
Shut off the air pressure supply.
The air pressure must not drop below 193 kPa [28 psi] in
30 seconds.
If the fuel passages are leaking, the cylinder head must
be replaced.
Remove the test kit.
Coolant Passage
WARNING
NOTE: This task is preformed off-engine.
Place the cylinder head on a work bench with the intake
side down.
Install the gasket (2) onto the combustion face of the
cylinder head.
Install the plate (1), with the marking exhaust toward the
exhaust side of the cylinder head.
Install the cylinder head capscrews and nuts (5).

Apply thread sealant and install the male connector (7)

into the plate (3) if it is not installed.
Install the gasket (4) and plate (3) onto the cylinder head
at the thermostat location.
Install the capscrews (8) and washers (9).
Attach leak test kit, Part Number 3164231 or equivalent,
to the male connector.
Install the injector cavity plugs (6) into the injector bores.
Center the injector cavity plugs in the injector bores.
Install the injector hold-down clamps and capscrews.
WARNING
Place the cylinder head into a tank of water.
Apply 207 kPa [30 psi] of air pressure to the cylinder head.
Inspect for bubbles.
Make sure the test assembly is not leaking.
If bubbles are present, the cylinder head must be
replaced.
An alternate method to placing the cylinder head into a

tank of water is to use a water and soap solution.
Apply 207 kPa [30 psi] of air pressure to the cylinder head.
Spray the cylinder head with a mild water and soap
solution.
Inspect for bubbles.
Make sure the test assembly is not leaking.
If bubbles are present, the cylinder head must be
replaced.
Remove the test kit.
Valve Seat
NOTE: This task is performed off-engine.
Set the head down with the intake ports on the bottom.
Pour fuel into the exhaust port until it is full.
Start the timer.
If a drop of fuel drips or runs down the face of the head

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

Turn the head over so the exhaust port is on the bottom.
Pour fuel into the intake ports until full.
Start the timer.
If a drop of fuel drips or runs down the face of the head

within 30 seconds, the valve and valve seat interface
must be checked using the vacuum test procedure.
If a drop of fuel has not run down the face of the head in
30 seconds, it indicates that the valves and seats are
sealing properly.
Vacuum Test
NOTE: This task is preformed off-engine.
Use valve vacuum tester, Part Number ST-1257, to
inspect the seal between the valve and the valve seat. To
perform this test, the cylinder head must either be sitting
on its side or turned upside down so that the combustion
face can be accessed.
The valve vacuum tester can be used to test all Cummins
engine models. The seal ring, Part Number ST-1257-35,
and vacuum cup, Part Number ST-1251-6, are used to
seal the cylinder head inserts.
Install the seal ring and vacuum cup to the vacuum line
(hose).
The valves and valve seats must be clean and dry when
vacuum testing.
Make sure the combustion face of the cylinder head is
clean and dry and there is no loose debris in the valve
recess.
This will help to provide a good vacuum cup to cylinder
head sealing surface.
Move the toggle switch (1) to the ON position.

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

specified vacuum.
Valve to Valve Seat Vacuum

mm Hg in Hg
508 MIN 20
685 MAX 25
Turn the vacuum control valve to the closed position.
Turn the toggle switch (1) to the OFF position.
Use a stopwatch and start timing when the needle on the

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

following checks:
Repeat the test to be sure the equipment is operating
properly.
Use a mallet to hit the valve stem lightly to make sure
the valve is seated. Repeat the test.
Apply a thin layer of grease on the outside diameters
of the insert and the valve head. Repeat the test. The
grease pattern will show the point of leakage.
A break in the grease seal pattern will indicate leakage
between the valves and valve seat or the valve seat insert
and the cylinder head.
Disassemble
NOTE: This task is performed off-engine.
Prior to disassembly, make sure the valve recess has been
measured and recorded.
WARNING
Place the cylinder head combustion face down on a clean,
smooth and level work surface that is sturdy enough to
support the weight of the cylinder head.
WARNING
Valve springs are under tension and can act as
projectiles if improperly released. To reduce the
possibility of eye injury, wear safety glasses with side
shields. Before releasing the valve spring tension,
check that the collets are properly seated.
CAUTION
Do not use an impact tool for any part of this
procedure. Doing so can damage the tool and/or the
engine.
Use the four valve spring compressor, Part Number
4919358, to compress the valve springs.
The replacer screw pilots in the injector bore and is
secured using the injector hold-down clamp.
Position the replacer screw (1) in the injector hole with the
threaded end pointing up.
Secure the replacer screw (1) in the injector hole with the
injector clamp and capscrew.
Tighten the capscrew.
CAUTION
The side of the retainer plate with the larger diameter
chamfers faces down to accommodate the valve
springs. Failure to position the retainer plate properly
can result in damage to the engine and/or tool.
Position the compressor plate (2) over the replacer screw
(1) and onto the valve springs.
Install the washer (4) and forcing nut (3) on the replacer
screw (1).
Tighten hand-tight.
WARNING
Wear eye protection during this procedure. Springs
are under tension and can act as a projectile if
released, causing serious injury.
Turn the forcing nut (3) clockwise until the valve springs
start to compress.
CAUTION
Do not overtighten the forcing nut. Doing so can
damage the tool and/or springs.
Continue turning the forcing nut (3) clockwise until the
valve collets can be removed with a magnetic tool.
Discard the valve collets.
WARNING
Carefully turn the forcing nut (3) counterclockwise until
the tension is released from the valve springs.
Remove the forcing nut (3) and compressor plate (2) from
the replacer screw (1).
Remove the replacer screw (1) by removing the injector

hold-down bolt and injector hold-down clamp.
Remove the valve spring retainer.

Remove the valve spring.
Remove the valve spring guide.
WARNING
With the use of a lifting device, roll the head up on its side
to gain access to the valves.
Remove the valves.
Mark the valves with an electric pencil (engraving tool) for
location as they are removed.
The intake and exhaust valves are manufactured from
different materials and are not interchangeable.
Remove the valve seals from the valve guides.Refer to

Procedure 002-016 in Section 2.
NOTE: Only remove the valve guides if they were not

within specification criteria in the Clean and Inspect for
Reuse section.
Use valve guide removal tool, Part Number 3163321, to
remove the old valve guides.
It is preferable to drive the guides out with an air hammer,
but the use of a dead blow hammer is acceptable.
NOTE: Only remove the valve seats if they were not

within specification criteria in the Clean and Inspect for
Reuse section.
Use slide hammer assembly, Part Number 3376617, and
valve seat extractor, Part Number ST-1279-1, to remove
the intake valve seat inserts from the cylinder head.
The exhaust valve seat insert does not have a lower inside
diameter chamfer for the exhaust seat puller to grip. It will
be necessary to use the valve seat grooving tool to cut a
groove in the inside diameter of the exhaust valve seat
inserts.
Set up the cutting tool with the cutting edge 7.75 mm [0.3
in] from the base of the grooving tool motor.
When cutting the groove, make sure the base of the tool
remains flat on the cylinder head combustion face during
the entire cutting operation.
To cut, set the tool on the head surface with the cutter in
the valve bore.
Contact the valve seat insert inside diameter with the
grooving tool on.
Apply enough pressure to prevent tool chatter, but not so
much pressure that the tool or seat insert is overheated.
Follow the inside circumference in a clockwise direction
for three complete rotations.
Remove the tool and inspect the groove for uniformity of

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

Inspect the injector bores for wear, cracks, other damage,
or mis-drilled passages.
The cylinder head can not be used if wear, cracks, other
damage, or mis-drilled passages are detected in the
injector bores.
Inspect the insert bore for cracks or other damage, if the

valve seat insert was removed during disassembly.
The cylinder head can not be used if cracks or other
damage is detected in the insert bore.
WARNING
CAUTION
Do not use caustic or acid solutions to clean the
cylinder head capscrews. Damage to the capscrews
can occur.
Clean the cylinder head capscrews with a petroleum-
based solvent.
Clean the capscrews thoroughly with a wire brush, wire
wheel (soft), or nonabrasive bead blast to remove deposits
from the shank and threads.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
WARNING
Steam clean the cylinder head and dry with compressed
air.
Use a chip vacuum to clean out all capscrew holes.
WARNING
CAUTION
If the oil passages are not plugged or covered before
cleaning, a crankshaft failure can occur.
Do not use power tools to clean the combustion face of
the cylinder head.
small rubber plugs, Part Number 4089255, must be
inserted in the oil supply holes at the ends to prevent
debris from entering the oil passages.
Use Scotch-Brite 7448, Part Number 3823258 or
equivalent, and solvent to clean the cylinder head
combustion face.
Clean the exhaust manifold gasket surface.
Clean the air intake gasket surface.
WARNING
WARNING
personal injury.
Use a flexible brush and solvent to clean the valve guide
bores in the cylinder head.
Dry with compressed air.
WARNING
personal injury.
Use a wire brush and solvent to clean the deposits from
the valve seat insert bores.
Inspect the fuel drillings and water passages for

restrictions or foreign material.
Remove any obstructions.
Inspect the valves and valve springs for cracks, bent or

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

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

Wear in the area where the cylinder liner fire dam contacts
the head is acceptable.
Wear in the area where the fire ring combustion seal
contacts the head is not acceptable.
To distinguish the difference, use one of the inspection
gauges detailed below.

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

Install the inspection gauge, Part Number 3165071, on the
cylinder head combustion face with the dowel pin in the
injector bore for the cylinder being evaluated.
Inspect the area within the narrow slots cut into the tool.
Rotate the tool to view the entire wire ring area on the
cylinder head combustion face.
Any wear that can be felt by fingernail within these slots
is unacceptable, making the cylinder head not reusable.
Wear outside the slots will have not have an effect on
future combustion sealing and the usability of the cylinder
head.
Inspect the valve spring retainers and valve spring guides

for damaged or worn areas.
Discard damaged and worn parts.
The use of flange-head capscrews with the torque-plus-

angle method of installation places the capscrew beyond
the yield point and permanently stretches the capscrew.
These capscrews can be reused throughout the life of the
engine, unless the capscrew exceeds the specified free
length.
The free length must be checked to reduce the possibility
of bottoming in the block during installation.
Use the head bolt stretch gauge, Part Number 3163162,

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

the capscrew is too long and must be discarded.
If there is clearance between the end of the capscrew and

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

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

mm in
A to A 0.15 MAX 0.006
B to B 0.15 MAX 0.006
C to C 0.15 MAX 0.006
If the cylinder head is pitted, grooved, or is not within
specifications, the cylinder head must be replaced.
Use valve spring tester, Part Number 3375182, to

measure the valve spring load at the valve spring working
height.
Valve Spring Load at 61.75 mm [2.431 in]

N lbf
1511 MIN 339.5
1604 MAX 360.5
If the valve spring load for the working height is less than
the minimum specified, the valve spring must be
replaced.
Inspect the valves for damage and the collet grooves for
wear.
Measure the outside diameter of the valve stem.
Three measurements must be taken of each valve stem
at 40 mm [1.57 in], 90 mm [3.54 in], and 140 mm [5.51 in]
from the tip end.
Valve Stem Outside Diameter

mm in
9.593 MIN 0.378
9.627 MAX 0.379
If the valves are damaged or are not within specifications,
the valves must be replaced.
Inspect the valve guides for chips or cracks.

Measure the inside diameter of the valve guides in
locations 13 mm [ in] from each end and at the center
as shown.
Used Valve Guide Inside Diameter (Installed)

mm in
9.663 MIN 0.380
9.713 MAX 0.382
If the valve guide inside diameter is not within
specifications, it must be replaced.
Measure the valve guide installed height.
Valve Guide Height (Installed)

mm in
44.77 MIN 1.763
45.77 MAX 1.802
If damage is found or the valve guide is not within
Use depth gauge, Part Number 3164438, to measure the

valve recess in the cylinder head.
Service Valve Recession Specification (NEW)

mm in
1.21 MAX 0.048
0.77 MAX 0.030
Service Valve Recession Specification (USED)

mm in
If the valve recess is not within specifications, the valve
seat and the valve must be replaced.
Measure the inside diameter of the valve guide bore.
Valve Guide Bore Inside Diameter

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

head.
Insert Bore Depth

mm in
9.48 MAX 0.373
10.48 MAX 0.413
If the valve seat insert bore is not within specifications, the
cylinder head must be replaced.
Measure the inside diameter of the valve seat insert bore.
Insert Bore Inside Diameter

mm in
49.54 MAX 1.950
47.54 MAX 1.872
If the valve seat insert bore inside diameter is not within
specifications, the cylinder head must be replaced.
Magnetic Crack Inspect

CAUTION
Prior to magnetic crack inspection of the combustion
face of the cylinder head, small plugs, Part Number
4089255, must be used to cover the oil supply holes
at the ends of the cylinder head to prevent debris and
magnetic powder from entering the lubrication system
during magnetic crack inspection. Failure to insert the
oil passage plugs can result in a connecting rod
bearing failure, crankshaft failure, or both.
Use magnetic crack detector, Part Number ST-1166, to
find cracks in the combustion face, in areas around the
valve ports, and the injector bores.
Place the magnetizing head on the combustion face, as
illustrated, to check for cracks that run across the cylinder
head.
WARNING
personal injury.
Fill the powder spray bulb one-third (1/3) full with metal
powder.
Spray the powder lightly onto the combustion face.
Use compressed air to remove the excess metal powder.
Air Pressure 276 kPa [ 40 psi ]
The powder will remain in the cracks, if present, and show
as a white line.
Cracks are not allowable on the combustion face of the

cylinder head.
Place the magnetizing head on the combustion face, as

shown, to check for cracks that run lengthwise.
Repeat the procedure as outlined above.
WARNING
WARNING
personal injury.
CAUTION
Failure to insert the oil passage plugs can result in a
connecting rod bearing failure, crankshaft failure, or
both.
Remove the magnetizing head and use solvent to clean
the cylinder head. Dry with compressed air.
The cylinder head must be thoroughly cleaned after using
the magnetic crack detector to remove all of the iron
fragments.
Use the magnetic particle residual method to inspect the

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

A broad fuzzy pattern will appear at the welded joint on
the exhaust valves. If there is a distinct line in the pattern,
the valve must be replaced.
The intake valves contain only one type of metal, and

must be magnetized and inspected in two directions.
Use the magnetic coil method and inspect with residual
Magnaglo, the same as the exhaust valves.
Magnetize the intake valves again with a headshot at 500
to 700 amperes.
Inspect the valves with residual Magnaglo.
Assemble
Use valve guide installer (1), Part Number 3163294, to
install the new valve guides.
The valve guides can be driven in using a dead blow
hammer.
Measure the valve guide installed height above the

cylinder head top deck surface.
Valve Guide Height (Installed)

mm in
44.77 MIN 1.763
45.77 MAX 1.802
Measure the valve guide inside diameter.
New Valve Guide Inside Diameter (Installed)

mm in
9.66 MIN 0.380
9.71 MAX 0.382
If the valve guide is not within specifications, it must be
replaced.
The insert chamfer (1) must be installed toward the bottom

of the counterbore.
Use intake valve seat installer, Part Number 3163318, to
drive the intake seat insert into the counterbore.
Use exhaust valve seat installer, Part Number 3163319,
to drive the exhaust valve seat insert into the counterbore.
These two service tools pilot in the valve guide. Use a
dead blow hammer with the seat drivers to install the new
seat inserts.
Install new valve stem seals onto the valve guides. Refer
to Procedure 002-016 in Section 2.
Use clean 80W, or higher, gear lube with EP additives to

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

Install the valve springs.
Install the valve spring retainers.
CAUTION
procedure. Doing so can damage the service tool and/
or the engine.
The replacer screw pilots into the injector bore and is
secured with the injector hold-down clamp.
CAUTION
screw (1).
Tighten the nut hand-tight.
WARNING
start to compress.
CAUTION
Always use new collets when rebuilding the cylinder
head.
Install the new valve spring retainer collets.
Inspect the collets for proper seating and installation.
Once the cylinder head is assembled, it will be necessary
to run the vacuum test to make sure of a good valve to
seat sealing.
See the Vacuum Test section of this procedure.
WARNING

hold-down bolt and injector hold-down clamp.
Repeat the above steps for each cylinder as needed.
CAUTION
Before the cylinder head is assembled onto the block,
all oil passage plugs must be removed. Failure to
remove the oil plugs will result in extensive engine
damage.
Remove the oil plugs from the cylinder head and the
cylinder block.
Install
Two different styles of head gaskets are used on
Signature, ISX, and QSX15 engines, based on the style
of liner used in the engine. Correctly identify which style
of liner is used before installing the head gasket. Refer to
Install the cylinder head gasket.
WARNING
Use engine lifting fixture, Part Number 4919360 or
equivalent, to lift the cylinder head.
Two long cylinder head capscrews placed toward each
end of the cylinder head serve as convenient guides when
lowering the cylinder head into place.
Align the cylinder head over the dowel pins and lower into
position.
Use clean 15W-40 oil to lubricate the cylinder head

capscrews.
Allow the excess oil to drain from the threads.
Install the 26 capscrews into the cylinder head.
CAUTION
Make sure the four longer capscrews placed in the
correct location. Engine damage can occur if these
capscrews are not placed in the correct locations.
Tighten capscrews in sequence.
It is recommended to use an air impact wrench and
socket, Tool Number 3163059 and 3163484, to rotate the
capscrew 90 degrees.
Torque Value:
Step 1 203 Nm [ 150 ft-lb ]
Step 2 407 Nm [ 300 ft-lb ]
Step 3 Rotate 90 degrees.
Finishing Steps
NOTE: If the cylinder head or the cylinder head gasket is being replaced
due to a malfunction that caused an internal coolant leak, the external
crankcase breather element must be replaced, if the unit is equipped with
an external crankcase breather element.
WARNING
Coolant is toxic. Keep away from children and pets. If not reused,
dispose of in accordance with local environmental regulations.
WARNING
Batteries can emit explosive gases. To reduce the possibility of
personal injury, always ventilate the compartment before servicing
the batteries. To reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the negative (-) battery
cable last.
Install the overhead injector camshaft. Refer to Procedure 002-025 in
Section 2.
Install the overhead valve camshaft. Refer to Procedure 002-024 in
Section 2.
Install the accessory bracket. Refer to Procedure 001-082 in Section
1.
Install the retaining brace bracket. Refer to Procedure 001-081 in
Section 1.
Install the valve and injector camshaft gears. Refer to Procedure
Install the upper front gear cover. Refer to Procedure 001-079 in
Section 1.
Install the injectors. Refer to Procedure 006-026 in Section 6.
Install the rocker lever shaft assemblies.Refer to Procedure 003-009
in Section 3.
Adjust the overhead settings. Refer to Procedure 003-004 in Section
3.
Install the rocker lever cover. Refer to Procedure 003-011 in Section
3.
Install the air compressor air inlet hose. Refer to Procedure 012-014
in Section 12.
Install the ECM. Use the following procedure for CM570 engines, in
the Signature, ISX and QSX15 Electronic Control System,
Troubleshooting and Repair Manual, Bulletin 3666259. Refer to
the Signature and ISX CM870 Electronic Control System,
Procedure 019-031 in Section 19
the ISX CM871 and ISM CM876 5 Electronic Control System,
Install the integrated fuel system module.Refer to Procedure 005-073
in Section 5.
Install the air intake connection. Refer to Procedure 010-080 in
Section 10.
Install the thermostat housing. Refer to Procedure 008-014 in Section
8.
Install the exhaust manifold. Refer to Procedure 011-007 in Section
11.
Install the turbocharger. Refer to Procedure 010-033 in Section 10.
Fill the cooling system. Refer to Procedure 008-018 in Section 8.
Install the batteries or air supply to the air starter. Refer to the OEM
service manual.
If a malfunction resulted in coolant, oil, excessive fuel or excessive
black smoke entering the exhaust system, the aftertreatment system
must be inspected.Refer to Procedure 014-013 in Section 14.
Operate the engine and check for leaks.
Signature, ISX, and QSX15 Eng [...] Valve Guide Seal, Cylinder Head
Valve Guide Seal, Cylinder Head

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

built after, use a larger valve guide seal. These seals are
designed to be installed by hand without the seal driver.
The new seals snap into a groove machined on the valve
guide. The seals introduced into engines built after ESN
14010274 with the grooved valve guides are not
compatible with engines built with the non-grooved valve
guides and vice versa.
NOTE: The seals that mate with the grooved valve guides
had two iterations.
1. Engines built from May 15, 2000 to the end of
February, 2002 had separate intake and exhaust
valve guide seals which were color coded. Intake
valve guide seals had a brass-colored garter spring
and three raised dots molded into the rubber; the
exhaust valve guide seals had a silver-colored garter
spring and no raised dots.
2. Engines built after March, 2002 had only one valve
guide seal for both intake and exhaust valve guides.
These seals can be used on any engines built after
ESN 14010274.
Preparatory Steps
On-Engine Repair
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the coolant to below the cylinder head level.
Remove the rocker lever cover. Refer to Procedure
Disconnect the engine brake solenoid wiring
harness. Refer to Procedure 020-015 in Section 20.
Remove the injector for the cylinder to be repaired.
Valve Guide Seal, Cylinder Head Signature, ISX, and QSX15 Eng [...]
Bar the engine over so the cylinder you are working on is

at top-dead-center (TDC). Refer to Procedure 003-004 in
Section 3.
Repeat this step as needed for each cylinder.
Off-Engine Repair
WARNING
kg [50 lb]. To reduce the possibility of serious
personal injury, be sure to have assistance or use
appropriate lifting equipment to lift this component or
assembly.
Remove the cylinder head and set it on a bench or
table. Refer to Procedure 002-004 in Section 2.
Remove
WARNING
CAUTION
engine.
NOTE: This step can be preformed either on or off-engine.
Use valve spring compressor, Part Number 4919358, to
compress the valve springs.
Remove the spring retainer collets.
CAUTION
screw (1).
Tighten finger tight.
WARNING
Eye protection should be worn during this procedure.
Springs are under tension and can act as a projectile
if released, causing serious injury.
start to compress.
CAUTION
valve collets can be removed with a magnetic tool.
Discard the valve collets.
WARNING
Remove the replacer screw (1) by removing he injector

hold down bolt and injector hold down clamp.
Remove the valve spring retainer.

Remove the valve spring.
Remove the valve spring guide.
NOTE: It is not necessary to remove the valve spring
guides on cylinder heads that have the grooved style valve
guides. Valve guides that do not have the groove must
have the valve spring guides removed for use of the
installation tool.
Use the valve guide seal remover, Part Number 3163293,

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

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

Install the valve spring.
Install the valve spring guide.
WARNING
CAUTION
engine.
CAUTION
screw (1).
Tighten the nut finger tight.
WARNING
start to compress.
CAUTION
valve collets can be installed.
Always use new collets when rebuilding the cylinder
head.
Install the new valve spring retainer collets.
Inspect the collets for proper seating and installation.
WARNING

hold down bolt and injector hold down clamp.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Valve
Finishing Steps
On-Engine Repair
WARNING
Install the injectors. Refer to Procedure 006-026 in
Section 6.
Connect the engine brake solenoid wiring harness.
Install the rocker lever cover. Refer to Procedure
Fill the cooling system. Refer to Procedure 008-018
in Section 8.
If failure resulted in coolant, oil, excessive fuel or
excessive black smoke entering the exhaust system,
the aftertreatment system must be inspected. Refer
Operate the engine and check for leaks and proper
operation.
Off-Engine Repair
WARNING
kg [50 lb]. To reduce the possibility of serious
personal injury, be sure to have assistance or use
appropriate lifting equipment to lift this component or
assembly.
Install the cylinder head. Refer to Procedure 002-004
in Section 2.
operation.
Overhead Camshaft, Valve (002-024)

Preparatory Steps
Remove the upper gear cover. Refer to Procedure
001-079.
Overhead Camshaft, Valve Signature, ISX, and QSX15 Eng [...]

003-011.
Disconnect the engine brake wiring harness. Refer to

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

001-088.
Remove
Remove the retainer capscrews, retainer, seal, and o-ring.
Discard the seal and o-ring.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Valve
CAUTION
Use caution when removing the camshaft to avoid
damaging the camshaft bushings.
Remove the valve camshaft.
WARNING
WARNING
personal injury.
Clean the valve camshaft and the bore of the valve
camshaft gear with Envirosol 655 solvent, or equivalent,
and a lint-free cloth.
Check the valve camshaft and valve camshaft gear for

fretting damage.
The valve camshaft and valve camshaft gear must be
replaced if damaged.
Measure the outside diameter of the seven valve camshaft

bearing journals.
Valve Camshaft Bearing Journal Outside Diameter

mm in
64.987 MIN 2.5585
65.013 MAX 2.5596
If the camshaft journals are not within specifications, the
camshaft must be replaced.
Overhead Camshaft, Valve Signature, ISX, and QSX15 Eng [...]
Inspect the camshaft lobes for cracks, scratches, and

other damage. Refer to Camshaft Reuse Guidelines for
Cummins Engines with Roller Followers or Roller
Tappets, Bulletin 3666052, for further reuse guidelines.
Install
CAUTION
Use caution when installing the camshaft to avoid
Coat the inside of the valve camshaft bushings with
Lubriplate prior to installing camshaft.
Install the valve camshaft.
Install new o-rings onto the retainer plate.

Install the retainer plate and capscrews.
Finishing Steps
Install the valve camshaft gear. Refer to Procedure
001-088.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Injector
Install the rocker lever shafts. Refer to Procedure 003-009.

Connect the engine brake wiring harness. Refer to
Procedure 020-015.
Install the rocker lever cover. Refer to Procedure 003-011.
Install the upper gear cover. Refer to Procedure 001-079.
Operate the engine until it reaches normal operating

temperature and check for leaks.
Overhead Camshaft, Injector (002-025)

Preparatory Steps
001-079.
Overhead Camshaft, Injector Signature, ISX, and QSX15 Eng [...]

003-011.

003-009.
Remove the injector camshaft scissor gear. Refer to

Procedure 001-088.
Remove the integrated fuel system module. Refer to

Procedure 005-073.
Remove the camshaft sensor. Refer to Procedure 019-038

in the Troubleshooting and Repair Manual Electronic
Control System Signature, ISX and QSX15 Engines.
Remove
Remove the injector camshaft cover plate capscrews.
Remove the injector cover plate and gasket.
Discard the gasket.
Remove the two capscrews and the injector camshaft

retainer plate and o-rings.
Discard the o-rings.
CAUTION
Use caution when removing the camshaft to avoid
Remove the injector camshaft.
WARNING
WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
Clean the injector camshaft and the bore of the injector
camshaft scissor gear with Envirosol 655 solvent, or
equivalent and a lint-free cloth.
Check the injector camshaft and injector camshaft scissor

gear for fretting damage.
The camshaft and gear must be replaced if damaged.
Measure the seven injector camshaft bearing journals.
Injector Camshaft Bearing Journal Outside Diameter

mm in
84.987 MIN 3.3459
85.013 MAX 3.3469
If the camshaft bearing journals are not within
specifications, the camshaft must be replaced.
Inspect the camshaft lobes for cracks, scratches, or other

damage.
Refer to the Camshaft Reuse Guidelines for Cummins
Engines with Roller Tappets, Bulletin 3666052, for further
reuse guidelines.
Install
CAUTION
Use caution when installing the camshaft to avoid
Coat the inside of the injector camshaft bearings with
Lubriplate prior to installing camshaft.
Install the injector camshaft.
Install new o-rings on the retainer plate.

Install the retainer plate and capscrews.
Install the injector camshaft cover plate with new gasket.

Install the capscrews.
Finishing Steps
Install the integrated fuel system module. Refer to
Procedure 005-073.
Install the camshaft sensor. Refer to Procedure 019-038

in Troubleshooting and Repair Manual Electronic Control
System Signature, ISX and QSX15 Engines.
Install the injector camshaft scissor gear. Refer to

Procedure 001-088.


Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Valve
Operate the engine to normal operating temperature and

check for leaks.
Overhead Camshaft Bushings, Valve

(002-026)
Initial Check
Remove the valve camshaft. Refer to Procedure 002-024.
Inspect the amount of copper exposure on the camshaft

bushing. If it extends more than 180 degrees around the
bushing, the bushing must be replaced.
Remove
Use service tool, Part Number 3164088, for valve
camshaft bushing removal.
The hydraulic camshaft bushing tool kit, Part Number
3823621, consists of:
Item Part Number Description Qty.

1 3823622 Pump, air hydraulic 1
2 3823623 Center hole ram 1
3 3823624 Hydraulic hose 1
4 3823625 Puller shaft 1
5 3823626 Stop collar 2
Overhead Camshaft Bushings, Valve Signature, ISX, and QSX15 Eng [...]
NOTE:
For inner camshaft bushing removal, follow Steps 1,
2, 3, 4, 5, 6, 7, 8, 9, and 10.
For rear camshaft bushing removal, follow Steps 1,
2, 3, 4, 5, 6, 11, 12, and 13.
For front camshaft bushing removal, follow Steps 1,
2, 3, 4, 5, 6, 14, 15, and 16.
Step 1
CAUTION
Make sure to select the proper-size centering guides.
This kit contains different-size centering guides for
journals both with and without bushings installed.
Selection of incorrect centering guides can result in
damage to the journal and/or guides.
Install the centering guides in two of the camshaft bore
ends.
NOTE: The centering guide can be installed in any of the
holes, but keeping the wider distance is preferred.
Step 2
Install the puller shaft through both of the installed
centering guides.
Step 3
Position the receiver spacer on the puller shaft with the
open end facing the cylinder head.
NOTE: A receiver spacer has not been included in the
valve camshaft bushing replacer kit, Part Number
3164088. Use receiver spacer, Part Number 3824864, or
an appropriate-size spacer from another kit.
Step 4
Slide the center hole ram onto the puller shaft until it
touches the receiver spacer.
Step 5
Install the stop collar in the groove of the puller shaft
closest to the center hole ram.
Step 6
CAUTION
Make sure to install the proper-size bushing driver.
Selection of incorrect bushing driver can result in
damage to the camshaft bushing, journal cylinder
head bore, and tool equipment.
Position the bushing driver on the puller shaft next to the
bushing that is being removed.
Slide the bushing driver into the camshaft bushing until it
stops against the flange of the bushing driver.
Step 7 (for inner bushings only)

Install the stop collar into the groove on the puller shaft
closest to the end of the bushing driver.

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

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

Push down on the RELEASE side of the air/hydraulic
pump pedal. This will release the pressure.
Push the puller shaft forward until the stop collar is
touching against the center hole ram.
Remove the service tool from the engine.
Step 11 (for rear bushing only)

Install the bushing driver onto the puller shaft behind the
outer camshaft bushing.

WARNING
pedal.
pedal and hold until the rear camshaft bushing and
centering guide are out of the bore.

Step 14 (for front bushing only)

Install the bushing driver on the puller shaft so that the
larger end of the bushing driver is facing the front
camshaft bushing.

WARNING
pedal.
pedal and hold until the camshaft bushing and centering
guide are out of the bore.

Inspect for Reuse

Clean and inspect the camshaft bores in the cylinder head
for reuse. Use an emery cloth to remove any burrs and
sharp edges from the bore.
Install
Use service tool, Part Number 3164088, for valve
The hydraulic camshaft bushing tool Kit, Part Number

NOTE:
For inner camshaft bushing installation, follow Steps
1, 2, 5, 6, 7, 8, 9, 10, and 11.
For rear camshaft bushing installation, follow Steps
1, 3, 5, 6, 7, 12, 13, 14, and 15.
For front camshaft bushing installation, follow Steps
1, 4, 5, 6, 7, 16, 17, 18, and 19.
Step 1
CAUTION
Install the centering guides into both camshaft bore ends.
Step 2 (for inner bushing only)

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

Install the puller shaft through the two installed centering
guides.

the number 1 journal.
Place a camshaft bushing over the end of the puller shaft.
Continue to slide the puller shaft through the block and
opposite-end centering guide.
Step 5
Step 6
Step 7

CAUTION
damage to the camshaft bushing, journal, and tool
equipment.
Position the proper bushing driver on the puller shaft next
to the bushing being installed.
Slide the camshaft bushing over the bushing driver.

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

WARNING
pedal.
pedal to pull the cam bushing into the cylinder head. As
the camshaft bushing oil port comes close to the bore oil
port, let up on the pedal.
Lightly tapping the PRESS side of the air/hydraulic pump
pedal will provide control to stop the camshaft bushing in
the desired position.

Step 12 (for rear bushings only)

CAUTION
damage to the cam bushing, journal, and tool
equipment.
Place the camshaft bushing over the end of the puller
shaft.
Position the bushing driver on the puller shaft and slide
the camshaft bushing onto the bushing driver.

CAUTION
in the journal. Misalignment of camshaft bushing oil
port to journal oil port can result in damage to the
engine.
Push the bushing driver over until the camshaft bushing
just touches the cylinder head.

WARNING
pedal.
For front and rear bushing installation, move the centering
guides to journals 2 and 6.
pedal to pull the camshaft bushing into the cylinder head.
As the camshaft bushing oil port comes close to the bore
oil port, let up on the pedal.

Step 16 (for front bushings only)

CAUTION
equipment.
Position the proper bushing driver on the puller shaft.

CAUTION
engine.

WARNING
pedal.
NOTE: The centering guide will be forced into the receiver
spacer when the bushing and driver are pulled into the
bore.

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

Signature, ISX, and QSX15 Eng [...] Overhead Camshaft Bushings, Injector

check for leaks.
Overhead Camshaft Bushings, Injector

(002-027)
Initial Check
Remove the injector camshaft. Refer to Procedure
002-025.
Inspect the amount of copper exposure on the camshaft

bushing. If it extends more than 180 degrees around the
bushing, the bushing must be replaced.
Remove
Use service tool, Part Number 3164089, for injector

Overhead Camshaft Bushings, Injector Signature, ISX, and QSX15 Eng [...]
NOTE:
For inner camshaft bushing removal, follow Steps 1,
2, 3, 4, 5, 6, 7, 8, 9, and 10.
For rear camshaft bushing removal, follow Steps 1,
2, 3, 4, 5, 6, 11, 12, and 13.
For front camshaft bushing removal, follow Steps 1,
2, 3, 4, 5, 6, 14, 15, and 16.
Step 1
CAUTION
Install the centering guides in two of the camshaft bore
ends.
NOTE: The centering guide can be installed in any of the
holes, but keeping the wider distance is preferred.
Step 2
Install the puller shaft through both of the installed
centering guides.
Step 3
NOTE: A receiver spacer has not been included in the
injector camshaft bushing replacer kit, Part Number
3164088. Use receiver spacer, Part Number 3824864, or
an appropriate-size spacer from another kit.
Step 4
Step 5
Step 6
CAUTION
damage to the camshaft bushing, journal cylinder
head bore, and tool equipment.
Position the bushing driver on the puller shaft next to the
bushing that is being removed.
Slide the bushing driver into the camshaft bushing until it
stops against the flange of the bushing driver.


WARNING
pedal.
pedal and hold until the cam bushing is out of the bore.

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


Install the bushing driver onto the puller shaft behind the
outer camshaft bushing.

WARNING
pedal.
pedal and hold until the rear camshaft bushing and
centering guide are out of the bore.


Install the bushing driver on the puller shaft so that the
larger end of the bushing driver is facing the front
camshaft bushing.

WARNING
pedal.
pedal and hold until the camshaft bushing and centering
guide are out of the bore.

Inspect for Reuse

Clean and inspect the camshaft bores in the cylinder head
for reuse. Use an emery cloth to remove any burrs and
sharp edges from the bore.
Install
Use service tool, Part Number 3164089, for injector

NOTE:
For inner camshaft bushing installation, follow Steps
1, 2, 5, 6, 7, 8, 9, 10, and 11.
For rear camshaft bushing installation, follow Steps
1, 3, 5, 6, 7, 12, 13, 14, and 15.
For front camshaft bushing installation, follow Steps
1, 4, 5, 6, 7, 16, 17, 18, and 19.
Step 1
CAUTION
Install the centering guides into both camshaft bore ends.
Step 2 (for inner bushing only)

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

Install the puller shaft through the two installed centering
guides.

the number 1 journal.
Place a camshaft bushing over the end of the puller shaft.
Continue to slide the puller shaft through the block and
opposite-end centering guide.
Step 5
Step 6
Step 7

CAUTION
equipment.
Position the proper bushing driver on the puller shaft next
to the bushing being installed.

CAUTION
in the journal. Misalignment of cam bushing oil port to
journal oil port can result in damage to the engine.
Push the bushing driver over until the cam bushing just
touches the cylinder head.

WARNING
pedal.
pedal to pull the cam bushing into the cylinder head. As
the camshaft bushing oil port comes close to the bore oil
port, let up on the pedal.


CAUTION
damage to the cam bushing, journal, and tool
equipment.
Place the camshaft bushing over the end of the puller
shaft.
Position the bushing driver on the puller shaft and slide
the camshaft bushing onto the bushing driver.

CAUTION
engine.

WARNING
pedal.
For front and rear bushing installation, move the centering
guides to journals 2 and 6.


CAUTION
equipment.
Position the proper bushing driver on the puller shaft.

CAUTION
engine.

WARNING
pedal.
NOTE: The centering guide will be forced into the receiver
spacer when the bushing and driver are pulled into the
bore.

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

Signature, ISX, and QSX15 Eng [...] Overhead Camshaft End Clearance, Valve

check for leaks.
Overhead Camshaft End Clearance,

Valve (002-028)
Measure
003-011.

003-009.

001-079.
Overhead Camshaft End Clearance, Valve Signature, ISX, and QSX15 Eng [...]
Unload the injector camshaft scissor gear. Refer to

Procedure 001-088.
NOTE: End clearance can be checked without removing
the injector camshaft gear on engines equipped with a
non-scissor injector camshaft gear.
CAUTION
The rear camshaft cover plate must be installed.
Use a dial indicator to check the end clearance of the gear.
Push the camshaft to the rear and set the gauge at 0.
Pull the gear forward and measure the end clearance.
Valve Camshaft End Clearance

mm in
0.70 MAX 0.0276
If measurement exceeds specifications, replace the
overhead valve camshaft. Refer to Procedure 002-024.
NOTE: Before loading the injector camshaft scissor gear,

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

Signature, ISX, and QSX15 Eng [...] Overhead Camshaft End Clearance, Injector

check for leaks.
Overhead Camshaft End Clearance,

Injector (002-029)
Measure
003-011.
Overhead Camshaft End Clearance, Injector Signature, ISX, and QSX15 Eng [...]

003-009.

001-079.
Unload the injector camshaft scissor gear. Refer to

Procedure 001-088.
NOTE: End clearance can be checked without removing
the injector camshaft gear on engines equipped with a
non-scissor injector camshaft gear.
CAUTION
The rear camshaft cover plate must be installed.
Use a dial indicator to check the end clearance of the gear.
Push the camshaft to the rear and set the gauge at 0.
Pull the gear forward and measure the end clearance.
Injector Camshaft End Clearance

mm in
0.70 MAX 0.0276
If measurement exceeds specifications, replace the
injector overhead camshaft. Refer to Procedure 002-025.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft End Clearance, Injector
NOTE: Before loading the injector camshaft scissor gear,

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

Injector Camshaft Scissor Gear Signature, ISX, and QSX15 Eng [...]

check for leaks.
Overhead Camshaft Gear, Valve

(002-030)
Remove
Remove the valve camshaft gear. Refer to Procedure
001-088.
Install
Install the valve camshaft gear. Refer to Procedure
001-088.
Injector Camshaft Scissor Gear

(002-031)
Remove
Remove the injector camshaft concept gear. Refer to
Procedure 001-088.
Signature, ISX, and QSX15 Eng [...] Injector Camshaft Scissor Gear
Install
Install the injector camshaft concept gear. Refer to
Procedure 001-088.
Injector Camshaft Scissor Gear Signature, ISX, and QSX15 Eng [...]
Notes
Section 3 - Rocker Levers - Group 03 Page 3-a
Section 3 - Rocker Levers - Group 03

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

Section 3 - Rocker Levers - Group 03 Page 3-1
Service Tools
Rocker Levers
Repair Location.

Torque Wrench
Used to adjust the overhead settings.
3398105
Brake Feeler Gauge (7 mm)

Used to adjust the engine brake.
3163530
Overhead Setting Kit
3163167
Inch Pound Torque Wrench
3376592
Feeler Gauge (.014 inch)
3163171
Feeler Gauge (.027 inch)
3163172
Crankcase Breather (External) Signature, ISX, and QSX15 Eng [...]
Page 3-2 Section 3 - Rocker Levers - Group 03
Crankcase Breather (External)

(003-001)
Remove
Automotive with CM870
Remove the breather tube and rubber grommet from
engine.
Remove the four p-clips securing the hose to the front

cover and block.
Disassemble the breather tube.
Automotive With CM871

Disconnect the wiring connector from the breather
pressure sensor.
Loosen the two hose clamps on the inlet hose.
Disconnect hose from breather. Loosen outlet hose
clamp.
Disconnect the outlet hose.
Disconnect the breather oil drain line.
Remove the drain line inline with the connection nipple,
do not bend.
Remove the four mounting capscrews from the crankcase
breather element housing to the breather housing bracket
and remove the housing assembly.
Signature, ISX, and QSX15 Eng [...] Crankcase Breather (External)
Disassemble
Disassemble the crankcase breather assembly. Refer to
Procedure 003-019.
NOTE: All capscrews are captive capscrews.

WARNING
WARNING
personal injury.
Use solvent to clean the inside of the crankcase breather
tube, and dry with compressed air.
Use air pressure to blow through the vent tube.
Replace the vent tube if it is clogged.
WARNING
personal injury.
Do not use solvent to clean the rubber grommet.
Clean the rubber grommet with soapy water. Dry with
compressed air.
Crankcase Breather (External) Signature, ISX, and QSX15 Eng [...]
Inspect the breather tube, hose and rubber grommet for

cracks or other damage. Replace if necessary.
WARNING
personal injury.
Clean breather crankcase housing and breather
crankcase cover with solvent.
Check for cracks in crankcase breather element housing
and crankcase breather cover. Replace if necessary.
Assemble
Assemble the crankcase breather assembly. Refer to
Procedure 003-019.
Install
Assemble the breather tube as shown.
Signature, ISX, and QSX15 Eng [...] Crankcase Breather (Internal)
Two p-clips attach the vent hose to the gear housing and
two p-clips attach the vent hose to the side of the block.
With the breather hose installed on the new cover, the
hose (3) must extend lower than the flywheel housing.
Install the crankcase vent hose (1). Use the four p-clips
(2), to secure the crankcase vent hose to the engine.

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

(003-002)
Preparatory Steps
Remove the breather tube. Refer to Procedure
003-001 (Crankcase Breather (External)) in Section
3.
Inspect the breather tube for sludge or debris on or
in the tube.
NOTE: Inspect the tube more frequently in icy conditions.
Crankcase Breather (Internal) Signature, ISX, and QSX15 Eng [...]
Remove
Remove the breather tube assembly from the seal carrier.
Remove the breather oil seal (1) from the upper gear
cover.
Remove the upper gear cover.

Refer to Procedure 001-079 (Gear Cover, Upper) in
Section 1.
Remove the four capscrews from the crankcase breather

and remove the breather.

Clean and inspect the crankcase breather for reuse.
If the filter element is plugged, replace the filter element.
Signature, ISX, and QSX15 Eng [...] Crankcase Breather (Internal)
Install
Make sure the spacer and cam gear have been torqued.
Refer to Procedure 002-024 (Overhead Camshaft, Valve)
in Section 2.
Position the crankcase breather over the spacer.

Pre-start the four crankcase breather capscrews.
Torque the capscrews in a crisscross pattern.
Lubricate the breather shaft with clean engine oil.

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

The groove side (1) must be installed toward the engine.
Make sure the seal carrier is tight in the front cover. If not,
tighten the seal carrier.
Install the breather tube assembly into the seal carrier.
Torque to the breather tube assembly.
Overhead Set Signature, ISX, and QSX15 Eng [...]
Finishing Steps
Install the crankcase breather tube. Refer to
Procedure 003-001 (Crankcase Breather (External))
in Section 3.
Operate the engine until it reaches normal operating
temperature and check for leaks.
Overhead Set (003-004)

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

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

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

Remove the oil fill connector from the lower gear case
cover.
Insert a 3/4-inch drive ratchet and extension into the air
compressor drive.
Rotate the air compressor drive clockwise, as viewed
from the front of the engine.
WARNING
Do not pull or pry on the fan to manually rotate the
engine. To do so can damage the fan blades.
Damaged fan blades can cause premature fan failures
which can result in serious personal injury or property
damage.
The crankshaft rotation is clockwise, as viewed from the
front of the engine.
The cylinders are numbered from the front of the engine
(1-2-3-4-5-6).
The engine firing order is 1-5-3-6-2-4.
If the engine is not equipped with an air compressor:

Loosen the cover plate capscrews and rotate the cover or
remove the oil fill tube, if equipped.
Use a 1 inch socket to push the barring gear into the

gear mesh and rotate the barring adapter
counterclockwise to bar the engine.
Rock the barring device back and forth until it disengages.
Each cylinder has four rocker levers:

The exhaust valve rocker lever (1)
The injector rocker lever (2)
The intake valve rocker lever (3)
The engine brake rocker lever (4).
The intake valve rocker lever is always the long lever on
the valve rocker lever shaft.
The valves, brakes, and the injectors on the same cylinder
are adjusted at the same index mark on the vibration
damper.
Injector and Valve Adjustment Sequence

Bar Engine
Set Set Set
in Pulley
Cylinder Cylinder Cylinder
Direction Position
Injector Valve Brake
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing Order: 1-5-3-6-2-4
NOTE: For illustrative purposes, position A is shown as

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

if both intake and exhaust valves are closed.
Both sets of valves are closed when the rocker levers and
the brake lever are loose. If both sets of valves are not
closed, rotate the compressor drive gear one complete
revolution, and align the A mark on the front damper with
the pointer again.
Valve Lash
Use feeler gauges to measure the amount of clearance
(lash) between the crosshead and the rocker lever nose.
Measure and record the intake, exhaust, and brake valve
lash. If the valve lash is not within the specifications listed
below, the valve must be adjusted. See the adjust step in
this procedure.
Press the brake lever down to verify the camshaft follower
is in contact with the camshaft prior to measurement of
the brake lash.
ISX, QSX Series Valve Lash Recheck Limits

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

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

mm in
0.635 MIN 0.025
2.79 MAX 0.110
Injector Lash
There is no service procedure to check the injector free
load.
Install the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
Preparatory Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
(-) battery cable first and attach the negative (-) battery
cable last.
Disconnect the battery.
Remove the rocker lever cover and gasket. Refer to

Procedure 003-011 (Rocker Lever Cover) in Section 3.
Make sure the engine base timing is properly set before
attempting to adjust/set the overhead. Refer to Procedure
001-088 (Engine Base Timing) in Section 1.
All overhead valve, injector, and brake adjustments
must be made when the engine is cold (any stabilized
coolant temperature at 60C [140F] or below).
Adjust
Read the entire procedure for overhead adjustment before
attempting to perform this operation.
Valves, injectors, and engine brakes (if equipped) must
be correctly adjusted for the engine to operate efficiently.
Valve, injector, and engine brake adjustment must be
performed using the values listed in this section.
After an engine rebuild or any major repair where the
injector and valve setting must be disturbed, set all of the
valves, injectors, and brakes.
Valve, Brake, and Injector Adjustment Values

Injector Adjustment is 8 Nm [70 in-lb]
Intake Valve 0.35 mm [0.014 in]
Exhaust Valve 0.68 mm [0.027 in]
Engine Brake 7.00 mm [0.276 in]

damper.
Two complete revolutions are required to set all valves,
engine brakes, and injectors.
If the engine is equipped with an air compressor:

cover.
compressor drive.
WARNING
damage.
The crankshaft rotation is clockwise as viewed from the
(1-2-3-4-5-6).
If the engine is not equipped with an air compressor:

Loosen the capscrews and rotate the cover or remove the
oil fill tube, if equipped.
Use a 1 inch socket to push the barring gear into the

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

The intake valve rocker lever is always the long lever on
the valve rocker lever shaft.
The valves, brakes, and injectors on the same cylinder are
adjusted at the same index mark on the vibration damper.

Bar Engine
Set Set Set
in Pulley
Direction Position
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4

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

the pointer again.
Loosen the injector adjusting screw locknut on the

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

Back the adjusting lever screw out 1 or 2 turns.
Tighten the injector lever adjusting screw.
Hold the injector lever adjusting screw and tighten the

adjusting screw locknut.
After setting the injector on a cylinder, set the valves and

engine brakes on the same cylinder.
with only A, B, or C, and are adjusted with the valve and
With the set mark aligned with the pointer on the gear
cover and both sets of valves closed on the cylinder,
loosen the locknuts on the intake and exhaust valve
adjusting screws.
Back out the adjusting screws one or two turns.
Select a feeler gauge for the correct valve lash

specification.
Valve Lash Specification

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

Torque Value: 0.6 Nm [ 5 in-lb ]
Use a torque wrench and crows foot adapter to tighten the

locknut.
Hold the adjusting screw in this position. The adjusting
screw must not turn when the locknut is tightened.
After tightening the locknut to the correct torque value,

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

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

the pointer again.
Press the engine brake lever down to verify the camshaft

follower is in contact with the camshaft.
Loosen the locknut on the brake lever adjusting screw,

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

mm in
7.00 NOM 0.276
Tighten the adjusting screw until drag on the feeler gauge

is felt. Proper drag means that there is no motion of the
brake lever camshaft follower against the cam lobe.
Hold the engine brake lever adjusting screw and tighten

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

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

Bar Engine
Set Set Set
in Pulley
Direction Position
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Finishing Steps
Install the rocker lever cover and gasket. Refer to
Procedure 003-011 (Rocker Lever Cover) in Section
3.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Assembly
WARNING
cable last.
Connect the battery.
If coolant, oil, excessive fuel, or excessive black smoke,
has entered the exhaust system, Refer to Procedure
014-013 (Aftertreatment Testing) in Section 14..
Rocker Lever Assembly (003-009)

Preparatory Steps
Remove the engine brake solenoid valve wiring harness.
003-011.
Remove the engine brake wiring harness. Refer to
Procedure 020-015.
Remove
There are four rocker lever shafts:
Front - valve and brake rocker lever shaft
Rear - valve and brake rocker lever shaft
Front - injector rocker lever shaft
Rear - injector rocker lever shaft.
CAUTION
Some valves will not be loose. Do not tighten or
bottom adjusting screw against lever. Engine damage
can occur.
Loosen the valve and injector adjusting screw locknuts on
each rocker lever.
Turn the adjusting screws counterclockwise until the
rocker levers are loose.
Rocker Lever Assembly Signature, ISX, and QSX15 Eng [...]
CAUTION
Use care when handling shafts. Rocker levers can fall
off the shaft during removal and damage the levers.
Remove the valve and brake, rocker lever shaft
capscrews, and the rocker lever shaft assemblies.
Remove the injector, rocker lever shaft capscrews, and
the rocker lever shaft assemblies.
Remove the valve crossheads.
To prevent increased wear, mark each crosshead and
rocker lever shaft assembly as it is removed so it can be
installed back in its original location.
Remove the rocker levers and brake levers from the

shafts.
Remove the rocker lever spacers from the shaft.
Remove the locknuts and the adjusting screws from the
rocker levers.
To prevent increased wear, mark each adjusting screw as
it is removed so it can be installed back in its original
rocker lever.
WARNING
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the rocker lever shaft.
Be sure to blow out the oil passages.
WARNING
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the valve crossheads,
rocker lever adjusting screw, and nuts.
Inspect the valve and brake rocker lever shaft for cracks
or damage.
Measure the valve and brake rocker lever shaft outside
diameter in the bushing wear area.
Valve and Brake Rocker Lever Shaft Outside Diameter

mm in
34.950 MIN 1.3760
35.000 MAX 1.3780
If the valve or brake rocker lever shaft is not within
Inspect the valve and brake rocker lever shaft for wear in
the brake detent pockets.
A raised edge on one side of the detent pocket is normal
and does not need replaced.
An elongated detent pocket, typically toward the cam
follower end of the brake rocker lever, is excessive wear
and must be replaced.
Measure the injector rocker lever shaft outside diameter

in the bushing wear area.
Injector Rocker Lever Shaft Outside Diameter

mm in
44.950 MIN 1.7697
45.000 MAX 1.7717
If the rocker lever shaft is not within specifications, it
must be replaced.
Inspect the rocker levers for cracks or unusual wear and

thread condition.
Measure the valve and brake rocker lever bushing bore

inside diameter.
Valve and Brake Rocker Lever Bushing Bore Inside

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

diameter.
Injector Rocker Lever Bushing Bore Inside Diameter

mm in
45.037 MIN 1.7731
45.138 MAX 1.7771
If the injector rocker lever bushing is not within
specifications, the rocker lever must be replaced.
Inspect the valve crossheads and crosshead guide pins

for damage.
The contact area on the crossheads must be smooth with

an even seating pattern.
If any distortions or cracks are found on the valve
crossheads or adjusting screws, they must be replaced.
Inspect the injector rocker lever adjusting screw socket for

excessive wear.
If excessive wear is found, the injector rocker lever
adjusting screw must be replaced.
Measure the intake and exhaust valve adjusting screws

for wear. Be sure the adjusting screw is perpendicular for
measurement.
Intake and Exhaust Valve Adjusting Screw Length

mm in
46 MIN 1.81
Measure the rocker lever spacers for wear.
Rocker Lever Spacer Width

mm in
11.5 MIN 0.453
If the rocker lever spacer is not within specification, it
must be replaced.
Install
Install the adjusting screw and locknut into each rocker
lever. Do not tighten the locknuts.
Install the injector rocker levers on the shaft.

Install the exhaust (1), intake (2), and engine brake (3)
rocker levers onto the shaft.
WARNING
Clear the rocker lever assembly mounting capscrew
holes of oil and debris. Extensive engine damage can
result if this warning instruction is not followed.
Install the valve crossheads.
Position the valve/brake rocker lever assemblies onto the
cylinder head.
CAUTION
To reduce the possibility of valve rocker shaft damage
due to inadequate brake rocker lever running
clearance, follow the specified procedure to seat the
valve rocker shafts on the cylinder head pedestals (1).
Each valve rocker shaft must be seated in the cylinder
head pedestals prior to tightening the rocker shaft
capscrews.
The front and rear rocker lever shaft assemblies will seat
separately as the engine is rotated in the clockwise
direction.

viewed from the front of the engine.
Align the A mark on the vibration damper with the timing
mark on the gear cover.
Either the front or the rear rocker shaft assembly will be

fully seated on the cylinder head pedestals at this point.
Check the position of the front and rear valve rocker shaft
assemblies to determine which one is fully seated.
Lubricate the capscrews of the fully seated rocker shaft
with clean 15W-40 oil.
CAUTION
because of inadequate brake rocker lever running
clearance, follow the specified capscrew torque
procedure. The valve rocker lever shaft has a
machined flat on the front of the shaft to provide
proper brake rocker lever position. Therefore, the
front rocker shaft capscrew (1) must be tightened first
to control brake rocker lever position. Brake lever
running clearance must always be checked after valve
rocker lever shaft installation.
Check the brake running clearance. Refer to Procedure
003-004.
Tighten the front mounting capscrew for the fully seated
valve rocker lever shaft to the initial torque value to locate
the shaft.
Tighten all the capscrews to the final torque value using
the torque plus angle method. Tighten the capscrews from
the center out.
Torque Value: Step1 30 Nm [ 22 ft-lb ]
Step2 Rotate 60 degrees

viewed from the front of the engine.
Align the B mark on the vibration damper with the timing
mark on the gear cover.
The remaining rocker shaft will be fully seated at this point.
Lubricate the capscrews of the fully seated rocker shaft
with clean 15W-40 oil.
CAUTION
because of inadequate brake rocker lever running
clearance, follow the specified capscrew torque
procedure. The valve rocker lever shaft has a
machined flat on the front of the shaft to provide
proper brake rocker lever position. Therefore, the
front rocker shaft capscrew must be tightened first to
control brake rocker lever position. Brake lever
running clearance must always be checked after valve
rocker lever shaft installation.
Check the brake running clearance. Refer to Procedure
003-004.
Tighten the front mounting capscrew for the remaining
valve rocker lever shaft to the initial torque value to locate
the shaft.
Tighten all the capscrews to the final torque value using
the torque plus angle method. Tighten the capscrews from
the center out.
Position the injector rocker lever assemblies onto the

cylinder head.
Lubricate the injector rocker lever shaft capscrews with
clean 15W-40 oil. Install the capscrews and washers.
Tighten all the mounting capscrews.
Loosen capscrews one at a time 360 and tighten again,

using the torque-plus-angle method. Tighten capscrews
from center out.
Adjust the valve, injectors, and brake.
Refer to Procedure 003-004.
Rocker Lever Cover Signature, ISX, and QSX15 Eng [...]
Finishing Steps
Install the engine brake wiring harness. Refer to
Procedure 020-015.
Install the engine brake solenoid valve wiring harness.
Rocker Lever Cover (003-011)

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

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

Clean the contaminated lube oil from the cylinder head
cavities.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Cover
WARNING
WARNING
personal injury.
Steam clean the cover. Dry with compressed air.
CAUTION
Do not use solvent to clean the rocker lever cover
gasket. Solvent will damage the gasket material and
cause it to swell. Prolonged exposure can also cause
degradation of the gasket material.
Clean the reusable gasket with a dry, lint-free cloth,
making sure no oil remains between the sealing beads.
NOTE: Engines built before September 7, 2006, have the
separate rocker lever cover and a separate cover gasket,
make certain that no lubricating oil remains between the
sealing beads.
Inspect the rocker lever cover for cracks or damage.

Replace if necessary.
Inspect the cover gasket beads for cuts, missing beads,

kinks, twists, wear, or other damage.
A gouged hole is acceptable if the bead is not damaged.
Crankcase Breather Element Signature, ISX, and QSX15 Eng [...]
Install
NOTE: Engines built after September 7, 2006, or engines
that have the cover gasket embedded in the rocker lever
cover.
If the cover gasket was removed, install the cover
gasket as soon as possible to avoid swelling of the
cover gasket as the cover gasket swells due to its
prior exposure to lubricating oil.
If a new cover gasket is required, use P80
lubriplate, Part Number 3163086, or soapy water to
lubricate the cover gasket.
If the cover gasket was removed or requires replacement,
start the installation of the cover gasket at each bolt hole
and press the cover gasket into the groove in the rocker
level cover around each bolt hole.
After the cover gasket is in place around all bolt holes,
press the cover gasket into the grove of the rocker level
cover starting from the bolt holes moving to the center of
each span.
Inspect and make certain that there are no kinks, twists or
other damage.
Align the capscrew holes in the cylinder head to the cover

gasket, and rocker lever cover prior to installing the
capscrews and isolator assemblies.
Install the eight capscrews and isolator assemblies.
NOTE: Engines built before September 7, 2006, have the
separate cover and a separate gasket, install the eight
capscrews and isolator assemblies.
Tighten capscrews in sequence shown.
Crankcase Breather Element (003-019)

Remove
Loosen the eight cover mounting captive capscrews.
Remove the element cover.
NOTE: Discard the crankcase breather element in
accordance with local environmental regulations.
Remove and discard the crankcase breather element.
Wipe out any excess dirt or oil from the inside of the cover.
Signature, ISX, and QSX15 Eng [...] Crankcase Breather Element
Install
Install the new crankcase breather element in the breather
housing.
Make sure the element is properly seated in the housing
so its seal will not be cut, crimped, or otherwise
compromised when installing the housing cover.
Install the cover.
Tighten the eight captive mounting capscrews.
Crankcase Breather Element Signature, ISX, and QSX15 Eng [...]
Notes
Section 5 - Fuel System - Group 05 Page 5-a
Section 5 - Fuel System - Group 05

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

Stall Speed Check List....................................................................................................................................5-28
Stall Speed Too Low.................................................................................................................................... 5-28
Stall Speed Too High....................................................................................................................................5-29
Time Speed Check..........................................................................................................................................5-27
Section 5 - Fuel System - Group 05 Page 5-1
Service Tools
Fuel System
Repair Location.

Vacuum Gauge (0-30 in. Hg)
Used to check intake air restriction, and also check fuel filter
ST-434 restriction on the suction side of the gear pump. Fuel restriction
adapters, Part Number ST-434-1, 3375845, and 3376922, are
required and must be ordered separately.
Hose Adapter
Used with vacuum gauge Part Number ST-434. Use Part Number
ST-434-1 ST-434-1 with Number 8 hose. Use Part Number ST-434-2 with
ST-434-2 Number 10 hose.
Sight Glass
ST-998 Check for air in fuel suction line. Use Part Number ST-998 with
3375362 Number 10 hose. Use Part Number 3375362 with Number 12 hose,
3375808 and Part Number 3375808 with Number 16 hose.
Slack Tube Manometer

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

Used to remove carbon from the top of the piston.
3164019
Pressure Gauge and Hose (0 to 300 psi)

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

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

Turn engine on and off from a remote location.
3376506
Filter Wrench
Used to remove or tighten spin on fuel filters.
3398145
Pressure Gauge (0 to 100 psi)

Used to measure fuel pressure during cranking.
3375388
Safety Solvent
Used to clean parts and tools safely.
3824510
Optical Tachometer
Measure engine rpm.
3377462
Pressure/Vacuum Module
Used with 3377161 Digital Multimeter or 3824648 Automotive Meter.
3824645 The pressure transducer range is 500 psi and the vacuum range is
29.92 in Hg.
Signature, ISX, and QSX15 Eng [...] Fuel Consumption
Fuel Consumption (005-010)

Maintenance Check
Refer to the Fuel Consumption Checklist sheets in the
back of Section TS.
NOTE: The most accurate method to check the fuel
consumption is to weigh the fuel used. Use a scale
capable of measuring within 0.045 kg [0.1 lb] to weigh the
fuel tank. Use a remote-mount tank with enough capacity
to run 80 km [50 mi].
Fill the fuel tank. Weigh the tank with the fuel. The weight
on No. 2 diesel fuel is nominally 0.844 kg per l [7.03 lb per
gal].
Install the remote tank (1).
Measure the distance traveled with an accurate odometer.

The odometer accuracy can be checked by using
measured miles or kilometers.
After traveling the route, remove the tank and weigh the
remaining fuel. Compute the fuel used in liters [gallons] as
required.
Fuel Pump Signature, ISX, and QSX15 Eng [...]
Compute the kilometers per liter or miles per gallon.
Fuel Pump (005-016)

Pressure Test
Monitor the rail fuel pressure, use INSITE electronic
service tool or connect a pressure gauge, Part Number
3824877, on the Compuchek fitting (as shown), and read
the rail fuel pressure.
The rail pressure while cranking at 130 rpm for at least 10
seconds is 689 kPa [100 psi]. Make sure the fuel system
is primed for at least 30 seconds.
The rail fuel pressure with EGR must be 1585 to 1889 kPa
[230 to 274 psi] at engine idle.
The rail fuel pressure with EGR must be 1896 to 2068 kPa
[275 to 300 psi] at 2100 rpm.
The rail fuel pressure without EGR must be 1551 to 1889
kPa [225 to 274 psi] at engine idle.
The rail fuel pressure without EGR must be 1758 to 1999
kPa [255 to 290 psi] at 2100 rpm.
If the rail fuel pressure is below 689 kPa [100 psi], check
to make sure there is fuel supply to the pump and that it
is not restricted.
Leak Test
Clean the area surrounding the fuel pump. Run the engine
at idle rpm.
Inspect for fuel leakage at the ECM cooling plate supply
and return lines and fittings. If a leak is detected, stop the
test immediately and replace the damaged o-ring(s) or
ECM cooling plate supply or return line(s).
Inspect for fuel or oil leakage at the fuel pump weep hole
and integrated fuel system module. If leaks are detected
at the fuel pump weep hole or integrated fuel system
module, stop the test immediately and replace the failed
component.
Inspect for fuel or oil leakage at the fuel pump mounting
gasket and o-rings. If leaks are detected in these areas,
stop the test immediately and replace the damaged
component.
Inspect the head gasket for leaks.
Signature, ISX, and QSX15 Eng [...] Fuel Pump
Preparatory Steps
WARNING
cable last.
Disconnect the batteries and cables. Refer to
Remove
Automotive with CM870 and CM871
Clean the area surrounding the pump.
Disconnect the ECM cooling plate return line from the
back of the fuel pump.
Remove the four fuel pump capscrews and remove the
fuel pump from the integrated fuel system module.
Remove and discard the gasket.
Automotive, Industrial with CM570 and Power

Generation without CM570
Remove the fuel control cover.
Clean the area surrounding the pump.
Remove the four fuel pump capscrews and remove the
fuel pump from the integrated fuel system module.
Discard the o-ring seals or gasket.

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

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

Install and tighten the four fuel pump capscrews in the
sequence.
Tighten the four fuel pump capscrews in the sequence
shown.
Signature, ISX, and QSX15 Eng [...] Fuel Pump
Connect the ECM cooling plate return line to the back of

the fuel pump.

Replace the o-ring seals or gasket.
Install the pump onto the integrated fuel system module.
Install and tighten the four fuel pump capscrews in the

sequence.
Tighten the four fuel pump capscrews in sequence.
Install the fuel control cover.
Finishing Steps
WARNING
cable last.
Connect the batteries and cables. Refer to Procedure
Prime
With Fuel Lift Pump
NOTE: Several different versions of the priming pump
exist. All versions are covered in this step.
The integrated (Integrated Fuel System Module mounted)
and the automotive and industrial timing module priming
pumps are activated by turning the ignition switch to the
ON position. The pump will shut off automatically after two
minutes.
The engine can then be started.
The manual switch priming pump can be activated by

either the toggle switch on the priming pump or by
cranking the engine.
If the fuel system has lost prime, hold the switch on the
pump to the ON position.
Run the priming pump for two minutes, then turn it off.
The engine can then be started.
The engine will possibly run rough for several minutes
until the air is out of the system.
Without Fuel Lift Pump

The Signature, ISX, or QSX15 fuel system can require
priming.
If the engine is equipped with a priming pump, see the
priming pump equipped procedure above.
CAUTION
Fuel system damage can occur if debris is introduced
into the clean side of the filter during the prefilling
procedure.
Prefill the filter with a clean source of fuel.
Signature, ISX, and QSX15 Eng [...] Fuel Pump Pulsation Damper
Remove the top outboard M14 pressure side plug using a

6-mm Allen wrench.
NOTE: Later versions of the integrated fuel system
module have a 19-mm external hex plug at this location.
Crank the engine until fuel begins to flow from the top
plug. Retighten the plug.
Crank the engine for 20 seconds. If the engine does not
start within 20 seconds, wait 2 minutes. If necessary,
repeat these steps until the engine starts.
The engine will possibly run rough for several minutes
until the air is out of the system.
Fuel Pump Pulsation Damper

(005-031)
Preparatory Steps
All Applications
Remove the integrated fuel system module. Refer to
Procedure 005-073.
Remove
There are two pulsation dampers.
Remove the top two capscrews and fuel pulsation
dampers.
Fuel Pump Pulsation Damper Signature, ISX, and QSX15 Eng [...]

There are three pulsation dampers.
Remove three torx screws, cover, and dampers.

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

Remove the housing from the cover. Remove the steel
diaphragm. Discard the o-rings. Inspect the nylon washer
and discard it if it is damaged.
Check for corrosion, wear, or cracks in the cover or the
diaphragm. Replace the damaged parts.
To check the diaphragm for hidden cracks, drop it on a
flat, hard surface. It must have a clear ring. If it produces
a flat sound, replace the diaphragm.
Install
Assemble the fuel pulsation damper with new o-rings, a
new steel diaphragm, and a new nylon washer, if needed.
Install the lower fuel pulsation damper capscrew.
Torque Value:
Lower 9.5 Nm [ 84 in-lb ]
Verify the seal (1) is in the groove of the fuel pulsation
damper (2) and add Lubriplate to hold the seal in place.
Attach the fuel pulsation damper (2) with capscrews (3).
Signature, ISX, and QSX15 Eng [...] Fuel Shutoff Valve

Assemble the fuel pulsation damper with new o-rings, a
new steel diaphragm, and a new nylon washer, if needed.
Install the lower fuel pulsation damper capscrew.
Torque Value:
Screws A and B 9.5 Nm [ 84 in-lb ]
Screw C 5.5 Nm [ 48 in-lb ]
Finishing Steps
All Applications
Install the integrated fuel system module. Refer to
Procedure 005-073.
Fuel Shutoff Valve (005-043)

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

Remove the coil (1) and the fuel shield (2).
Remove the valve spring washer (3), valve disc (4), and
actuator disc (5) from the actuator housing (7) from the
IFSM (8).
Discard the o-rings (6).
Fuel Shutoff Valve Signature, ISX, and QSX15 Eng [...]
Inspect for Reuse
WARNING
WARNING
Use mineral spirits. Clean all of the parts except the coil
assembly.
NOTE: Do not get solvent on the coil. Clean the coil with
a dry cloth. Use a 200-grit emery cloth and a flat surface
to polish the coil surface.
Check the valve disc, valve seat, and actuator disc for dirt,
metal parts, bonding separation, corrosion, cracks, or
wear. Replace if necessary.
Use a wire brush to clean any corrosion from the coil

terminal.
Check the coil assembly with a multimeter. Replace the

solenoid if the resistance is not to specification.
Fuel System Shutoff Valve Solenoid Specifications

Voltage Resistance Resistance
Minimum (Ohms) Maximum (Ohms)
6 VDC 1 5
12 VDC 6 15
24 VDC 24 50
32 VDC 42 80
36 VDC 46 87
48 VDC 92 145
74 VDC 315 375
115 VAC 645 735
NOTE: If the coil assembly shows 0 ohm, there is an

electrical short in the coil.
Signature, ISX, and QSX15 Eng [...] Fuel Shutoff Valve
Install
Assemble the shutoff valve as shown. Install these parts
as follows.
Install a new o-ring between the spacer and the electronic
control valve body.
Install the spacer o-ring groove toward the coil.
Install the actuator disc with the cup side toward the coil.
Install the spring washer with the cup side toward the coil.
Align the actuator disc, spacer, and valve disc on the

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

Install the nut onto the threaded post of the coil.
Use a wrench to hold the nut at the base of the post firmly
while tightening the connection nut.
Fuel Lift Pump Signature, ISX, and QSX15 Eng [...]
Fuel Lift Pump (005-045)

Initial Check
Inspect the engine harness, the lift pump power
connector, the lift pump relay power connector, and the
lift pump relay pins for the following:
Loose connector
Corroded pins
Bent or broken pins
Pushed back or expanded pins
Moisture in or on the connection
Missing or damaged connector seals
Dirt or debris in or on the connector pins
Connector shell broken
Wire insulation damage
Damaged connector locking tab.
See the service manual for the proper procedure for
replacing or repairing connectors, pins, or harnesses.
Resistance Check
CAUTION
Do not use probes or leads other than Part Number
3822758 and Part Number 3822917. The connector
will be damaged. The leads must fit tightly in the
connector without expanding the pins in the
connector.
Check for an open circuit in the fuel lift pump return circuit.
Disconnect the 2-pin fuel lift pump power connector at the
fuel lift pump.
Disconnect the fuel lift pump relay power connector where
the OEM harness connects to the engine harness.
Measure the resistance of the fuel lift pump return
between these two connectors.
The resistance must be 10 ohms or less.
If the resistance is greater than 10 ohms, repair or replace
the engine harness.
Signature, ISX, and QSX15 Eng [...] Fuel Lift Pump
CAUTION
3164572. The connector will be damaged. The leads
must fit tightly in the connector without expanding the
pins in the connector.
Check for an open circuit in the fuel lift pump relay return
line.
Measure the resistance from the fuel lift pump relay return
pin in the engine harness relay connector to engine block
ground.
The resistance must be 10 ohms or less.
If the resistance is greater than 10 ohms, repair or replace
the engine harness ground.
Measure the resistance of the fuel lift pump relay.

Measure the resistance between the fuel lift pump relay
signal pin and the fuel lift pump relay return pin on the
relay.
The resistance must be between 70 and 80 ohms.
If the resistance is not between 70 and 80 ohms, replace
the fuel lift pump relay.
Voltage Check
CAUTION
3822758 and Part Number 3822917. The connector
will be damaged. The leads must fit tightly in the
connector without expanding the pins in the
connector.
Remove the fuel lift pump power connector at the fuel lift
pump.
Turn the keyswitch to the ON position.
Measure the voltage between the fuel lift pump supply pin
and the fuel lift pump return pin on the harness connector.
The voltage must be battery voltage.
If voltage is not present, check the fuse on the fuel lift
pump relay supply line. Replace if necessary.
If the voltage is not correct, disconnect the 2-pin
connector between the OEM harness and the engine
harness that supplies the fuel lift pump relay with
unswitched battery power.
Measure the voltage at the 2-pin connector on the OEM
harness.
If voltage is not present, repair or replace the OEM wiring
or contact a Cummins Authorized Dealer.
Check the fuel lift pump relay for proper operation.

Unplug the fuel lift pump relay from the engine harness
connector.
Check the voltage at the fuel lift pump relay supply pin.
If voltage is not present, recheck the fuses and the OEM/
engine harness for shorts and open circuits.
With the keyswitch in the ON position, measure the
voltage at the fuel lift pump relay signal pin on the engine
harness relay connector.
A measurement of 12-VDC must be indicated.
If 12-VDC is not indicated, check the ECM for the proper
calibration and contact a Cummins Authorized Repair
Location.
Test
Unplug the fuel lift pump relay from the engine harness
connector.
Connect the 2-pin fuel lift pump power connector to the
fuel lift pump.
Insert a jumper wire between the fuel lift pump relay
supply pin and the fuel lift pump supply pin in the engine
harness relay connector.
If the fuel lift pump is functioning correctly, the fuel lift
pump will operate.
If the lift pump does not operate when using the jumper
wire, Refer to Procedure 019-396 in the CM870 Electronic
Control System, Signature and ISX Engines
Troubleshooting and Repair Manual, Bulletin 4021334, for
replacing the lift pump.
Pressure Test
Turn the ignition switch to the ON position to activate
integrated fuel system mounted, automotive, or industrial
timing module priming pumps. Repeat if necessary.
Measure the fuel pressure at the gear pump inlet
Compuchek fitting.
If 69 kPa [10 psi] or greater is indicated, the lift pump is
operating correctly.
If less than 69 kPa [10 psi] is indicated, check the pressure
while drawing fuel from a bucket.
Preparatory Steps
WARNING
cable last.
CAUTION
If the unit has recently switched to Bio-diesel or Ultra
Low Sulfur diesel and has a fuel leak, the entire lift
pump must be replaced, not only the gasket.
Remove or disconnect the following:
Battery cables. Refer to Procedure 013-009.
Engine wiring harness from the fuel lift pump.
EGR differential pressure sensor tubes. Refer to
Procedure 011-026.
EGR differential pressure sensor. Refer to Procedure
019-043 in the CM870 Electronic Control System,
Signature and ISX Engines Troubleshooting and
Repair Manual, Bulletin 4021334.
Remove
Automotive Engine Mounted
NOTE: The fuel lift pump is bolted to a mounting plate and
must be removed as an assembly.
Remove the four capscrews.
Remove the fuel lift pump.

Industrial Engine Mounted

Disconnect the fuel pump wiring harness and the power
supply connections at the starter.
Tag the wires for location at installation.
Disconnect the fuel outlet line from the top of the

Integrated Fuel System Module (IFSM).
Disconnect the fuel inlet line from the rear of the IFSM.
Remove the fuel lift pump assembly mounting capscrews

and the fuel lift pump assembly.
Remote Mounted
Disconnect the ground wire from the cylinder block.
Disconnect the fuel pump wiring harness and the power

supply connections at the starter.
Tag the wires for location at installation.
Disconnect the fuel inlet and outlet lines from the fuel
pump.
Remove the mounting capscrews and mounting plate.

Remove the fuel pump assembly.
Remove the large internal hex plug from the fuel pump.
Remove the filter screen and the gasket.

Clean the mounting surfaces.
Inspect the fuel lift pump mounting plate for leaks, cracks,
and other damage.
If any damage is found, replace the fuel lift pump.
Remote Mounted
WARNING
WARNING
WARNING
personal injury.
Use solvent to clean the parts.
Flush debris from the filter screen.
Clean the mounting surfaces.
Inspect the fuel lift pump mounting surface for cracks or

other damage.
If any damage is found, replace the fuel lift pump.
Use an Allen wrench to check for free movement of the
check valve.
Replace the check valve assembly, if damaged.
Replace
CAUTION
The fuel lift pump is extremely sensitive to debris. A
small amount of debris in the lift pump can cause the
lift pump to fail, causing it to need replacement. Only
service the lift pump in clean areas and use care not
to allow debris into the system.
CAUTION
The lift pump contains many loose parts. Use care
when removing the lift pump body from the adaptor
and keep the lift pump vertical.
This step includes the method for removing and installing
the fuel lift pump gasket.
Remove the three bolts that connect the adapter to the lift
pump body.
Replace the fuel lift pump gasket.

Connect the adapter and lift pump assembly.

Tighten the bolts.
Install
Install a new gasket between the fuel lift pump mounting
plate and the IFSM.
Install the fuel lift pump and the four capscrews.

To verify the lift pump is not leaking, turn the keyswitch to
the ON position with the engine off, operate the lift pump
for three minutes, and check for leaks.
Industrial Engine Mounted

Install the fuel lift pump assembly and mounting
capscrews.
Be sure both copper washers are in place on the top fitting

when installing the fuel outlet line.
Install two new sealing washers on the fuel outlet line.
Install the fuel outlet line.
Install the fuel inlet line to the IFSM.
Connect the wiring harness connectors to the starter.
Remote Mounted
Install a new filter sealing ring.
Install the clean filter.
Install the large plug with a new o-ring.
Tighten the plug.
Install the fuel lift pump, mounting plate, and capscrews.

Install the fuel inlet and outlet lines.
Install the ground wire to the cylinder block.
Install the power supply connections to the starter.
Finishing Steps
Install or connect the following:
EGR differential pressure sensor. Refer to Procedure
019-043 in the CM870 Electronic Control System,
Signature and ISX Engines Troubleshooting and
Repair Manual, Bulletin 4021334.
Procedure 011-026.
Engine wiring harness to the fuel lift pump.
Battery cables. Refer to Procedure 013-009.
Prime the fuel system. Refer to Procedure 005-016 in
Section 5.
Start the engine and check for leaks.
Signature, ISX, and QSX15 Eng [...] Stall Speed Test
Stall Speed Test (005-054)

Stall Speed Check
The stall speed is the engine speed (rpm) obtained at full
throttle when the converter output shaft is locked.
NOTE: It is possible that the vehicle brakes will not hold
an electronically controlled transmission.
CAUTION
Do not exceed 120C [250F] converter oil
temperature. Overheating can result and converter
damage can occur. If the oil temperature exceeds
120C [250F], put the transmission in NEUTRAL and
operate the engine until the oil temperature is below
120C [250F].
Check the converter oil level.
The following equipment is needed for this check:

Stopwatch
Optical tachometer, Part Number 3377462 or
INSITE
Equipment manufacturer's stall speed and time-to-
stall specifications.
Place the gear selector in the highest gear or full forward.

Stall Speed Test Signature, ISX, and QSX15 Eng [...]
Make certain the vehicle has good brakes and air pressure
in the brake system.
NOTE: The brakes must prevent the vehicle from moving
when the engine is at full throttle. Engage the vehicle
brakes to keep the vehicle from moving.
Operate the engine until the converter temperature is 80

C [180F] or above.
Bring the engine speed back to low idle.
CAUTION
Do not exceed 120C [250F] converter oil
temperature. Overheating can result and converter
damage can occur. If the oil temperature exceeds
120C [250F], put the transmission in NEUTRAL and
operate the engine until the oil temperature is below
120C [250F].
Quickly move the throttle to the full-open position.
Check the engine speed (rpm) at the point of stall:

Always hold the speed until it is stable.
Take several readings.
Make certain the readings are accurate.
Check the speed (rpm) against the specifications for the

equipment, converter, or automatic transmission.
NOTE: The stall speed for the engine and converter/
transmission can vary 8 percent from the
If the stall speed is not within the specifications, refer to

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

Perform the previous Stall Speed Check procedure
through the "check the engine speed (rpm) at the point of
stall" step, then:
Quickly move the throttle to the full-open position
and start the stopwatch at the same time.
Stall Speed Test Signature, ISX, and QSX15 Eng [...]
When the engine speed is 90 percent of the stall

speed rpm, stop the stopwatch.
Example: Stall speed rpm 2089 [2089 x 0.90 = 1880
rpm].
NOTE: The type of unit and the stall speed rpm can make
the stall speed time a maximum of 10 seconds.
Refer to the equipment manufacturer's specifications for

the time to stall or the acceleration time.
Stall Speed Check List

Stall Speed Too Low
If the Stall Speed is too low, check the following:
1. The tachometer is in error.
a. Yes
b. No
2. The engine is up to or above 70C [160F].
a. Yes
b. No
3. The converter oil is up to 80C [180F].
a. Yes
b. No
4. The stall has been held long enough for the engine to accelerate to full power.
a. Yes
b. No
5. The match curve stall speed was recorded correctly.
a. Yes
b. No
6. The converter oil meets the converter manufacturer's recommendation (SAE 30 rather than SAE 10, for
instance).
a. Yes
b. No
7. The engine-driven accessory power requirements exceed 10 percent of the gross engine power. Check for
abnormal accessory horsepower losses such as hydraulic pumps, large fans, oversize compressors, and so on.
Either remove the accessory or accurately determine the power requirement and adjust accordingly.
a. Yes
b. No
8. The unit is operating at an altitude high enough to affect the engine power.
a. Yes
b. No
9. The converter charging pressure is correct.
a. Yes
b. No
10. The converter blading is interfering, or in a stage of failure. Check the sump or filter for particles.
a. Yes
b. No
11. The converter stators are freewheeling rather than locking up.
a. Yes
b. No
12. The engine is set for power other than that specified on the power curve.
a. Yes
b. No
13. The converter is wrong due to improper build or rebuild of unit.
a. Yes
b. No
14. The converter is performing to the published absorption curve.
a. Yes
b. No
15. The engine and converter match is correct. Check the engine and converter models for the proper match.
a. Yes
b. No
16. The engine is matched to too large of a converter. If this condition is believed to exist, please report the engine-
converter accessory information to the factory.
a. Yes
b. No
17. The engine power is down. Perform a cylinder performance test to find the cylinder with low power.
a. Yes
b. No
Stall Speed Too High
If the Stall Speed is too high, check the following:
1. The engine is high in power.
a. Yes
b. No
2. The tachometer is in error.
a. Yes
b. No
3. The accessory power requirements are less than 10 percent of the gross engine power.
a. Yes
b. No
4. The converter oil is aerating or foaming. Check for low oil level, air leaks in suction line, lack of foam inhibitor in
the oil, or suction screen or filter. Would be accompanied by a noticeable loss of machine performance.
a. Yes
b. No
5. The converter is being held at full stall. Check for slipping front disconnect clutch or a rotating output shaft. On
the converter-transmission package, this can be impossible to check.
a. Yes
b. No
6. The converter turbine element is beginning to fail and lose blades, or the converter was originally built with the
wrong size element.
a. Yes
b. No
7. The engine and converter match is correct due to a revision in the engine rating or the converter performance.
a. Yes
b. No
8. If the oil level is too high on the transmission-converter units with the oil sump in the transmission, it can cause
severe aeration due to parts dipping in the oil.
a. Yes
b. No
9. The converter is performing to the published absorption curve.
a. Yes
b. No
10. The converter charging pressure is correct.
a. Yes
b. No
Integrated Fuel System Module (IFSM) Signature, ISX, and QSX15 Eng [...]
The reasons for abnormal stall speeds listed above are some that have been encountered by Cummins representatives
and probably do not include all possible causes. The correction of the problem is either covered in the vehicle service
manual, the converter service manual, or is self-explanatory.
Integrated Fuel System Module (IFSM)

(005-073)
Preparatory Steps
With CM870
WARNING
cable last.
Disconnect the battery cables. Refer to Procedure
Remove the EGR mixer. Refer to Procedure 011-021
in Section 11.
Disconnect the air intake connection. Refer to
Remove engine wiring harness from all temperature
and pressure sensors, fueling and timing actuators,
the fuel shutoff valve, the water-in-fuel sensor, and the
fuel lift pump.
Remove the EGR differential pressure sensor tubes.
Remove the EGR differential pressure sensor. Use the
following procedure in the Troubleshooting and Repair
Manual, CM870 Electronic Control System,
Signature and ISX Engines, Bulletin 4021334. Refer
Remove the EGR differential pressure sensor adapter.
Remove the customer accessory bracket.
Disconnect the fuel supply and fuel drain lines. Refer
Remove the lift pump. Use the following procedure in
the Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature and ISX
Engines, Bulletin 4021334. Refer to Procedure
Remove the ECM cooling plate fuel supply line
(bottom) from the IFSM and the ECM cooling plate fuel
return line (top) from the fuel pump. Refer to Procedure
Remove the fuel filter. Refer to Procedure 006-015 in
Section 6.
Remove the accessory bracket located above the
integrated fuel system module (IFSM). Refer to
Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
CM570
WARNING
cable last.
Disconnect the battery cables. Refer to Procedure
Remove the air inlet piping. Refer to Procedure
Disconnect the engine wiring harness from all
pressure and temperature sensors, fueling and timing
actuators, the fuel shut off valve, the water-in-fuel
sensor, and the fuel lift pump.
Remove the fuel control covers.
Disconnect the air intake connection. Refer to
Remove the customer accessory bracket.
Remove the fuel supply and fuel drain lines. Refer to
Section 5.
Remove
WARNING
Remove two mounting capscrews from the IFSM.
Install two guide studs.
Remove the remaining capscrews, IFSM, and gasket.
Discard the gasket, if damaged.
Disassemble
With CM870
Remove all components:
Sensors
Regulators
Check valve
Fuel and timing actuators
Fuel shut-off valve
Gear pump (Only remove the four long capscrews, as
shown in the illustration.)
Fuel inlet and drain fittings
Fuel dampers (Only remove the two top capscrews of
the damper assembly, as shown in the illustration.)
All threaded plugs, o-rings, and gaskets.
CM570
Remove all components:
Sensors
Regulators
Check valve
Fuel and timing actuators
Fuel shut-off valve
Gear pump (Only remove the four long capscrews, as
shown in the illustration.)
Fuel inlet and drain fittings
Fuel dampers (Only remove the two top capscrews of
the damper assembly, as shown in the illustration.)
All threaded plugs, o-rings, and gaskets.

With CM870
Inspect the anti-drain back valve for damage or improper
sealing. Replace if necessary.
Verify that the anti-drain back valve seats properly and is
free of damage or debris. If damage is found, replace the
valve.
Inspect the mounting capscrew holes for cracks. Inspect

the IFSM for leaks or cracks. Replace the module if cracks
are found.
Inspect the 1724 kPa [250 psi] and the 2620 kPa [380 psi]
fuel regulators for debris or damage (including the spring
inside the regulators). Replace the regulator if damage is
found.
CM570
Inspect the mounting capscrew holes for cracks.
Remove the 1724 kPa [250 psi] fuel pressure regulator.

Inspect for debris or other damage. Replace the regulator,
if necessary.
Install the fuel pressure regulator and tighten.
Remove the 2206 kPa [320 psi] fuel pressure regulator.

Inspect for debris or other damage. Replace the regulator,
if necessary.
Install the fuel pressure regulator and tighten.
Remove the check valves located in the fuel inlet and fuel
filter head.
Verify both seat properly and are free of damage or debris.
Install both check valves and tighten.
Check the inlet filter screen for debris. Clean the filter, or
replace if necessary.
Install the inlet filter screen.
Assemble
With CM870
Verify the seal (1) is in the groove of the fuel control
damper (2) and add Lubriplate multi-purpose lubricant to
hold the seal in place.
Attach the fuel control damper (2) with capscrews (3) and
tighten.
Install the o-rings (2 and 3) onto the pressure regulator (1).

Install the (2620 kPa) [380 psi] pressure regulator (1) into
the IFSM housing and tighten.

Install the (1724 kPa) [250 psi] fuel pressure regulator into
Install the o-ring seal (2) onto the fuel pressure sensor (1).
Install the fuel pressure sensor (1) into the IFSM housing
and tighten.
Install the o-ring seal (2) onto the fuel temperature sensor
(1).
Install the fuel temperature sensor into the IFSM housing
and tighten.
Install the o-ring (2) onto the Compuchek fitting (1).

Install both Compuchek fittings (1) into the IFSM housing
and tighten.
Install the o-ring (2) onto the anti-drain back valve (1).
Install the anti-drain back valve (1) into the housing and
tighten.
Install the o-ring (2) onto the cooling plate fuel supply
fitting (1).
Install the cooling plate fuel supply fitting (1) into the
housing and tighten.
Install the o-ring (3) onto the front face of the cooling plate
fuel supply fitting.
Install the o-ring (2) onto the fuel drain fitting (1).
Install the fuel drain fitting (1).
Turn the nut all the way to the top of the fitting.
Thread the fitting all the way into the IFSM housing, until
it stops.
Turn the fitting back until the threaded end is oriented
directly over the regulator.
Lock the fitting into position and tighten the locking nut.
Maintain the correct orientation.
Use a small amount of Lubriplate multi-purpose lubricant

in the grooves on the bottom of the metering actuators (2).
Install the actuator gasket (3) onto each actuator. Make
sure to align each properly.
Install the actuators (2) onto the IFSM housing.
Use three capscrews (1) to mount each actuator to the
housing and tighten the capscrews.

in the grooves on the bottom of the timing actuators (2).
Install the actuator gasket (3) onto each actuator. Make
Use three capscrews (1) to mount each actuator to the
housing and tighten the capscrews.
Etch the same part number of the original IFSM on the

data tag (1).
Attach the tag to the housing by pressing the screws (2)
into the housing.
Install the seal (1) into the groove in the IFSM housing.
Place the actuator disc (2) over the seal (1), small diameter
down.
Place the valve disc (3) onto the actuator disc (2) with the
sealing surface down (spring pilot diameter up).
Place the valve spring (4) into the actuator housing (5) with
the inside diameter on the valve disc pilot (3).
Place the actuator housing (5) over the actuator disc (2).
Install the seal (1) into the groove in the actuator housing
(5).
Place the shutoff valve shield (6) over the actuator housing
(5).
Align the hole pattern of the shutoff valve shield (6).
Place the solenoid (7) over the shutoff valve shield (6)
taking care to align the holes and not pinch any seals.
Orient the terminal facing the gear pump.
Use four capscrews (8) to attach the assembly to the
housing and use an x pattern.
Install the o-ring (2) onto the threaded plug (1).

Install the three threaded plugs (1) into the housing.
Install the o-ring (4) onto the large threaded plug (3).
Install the large threaded plug (3) into the housing.
Install the o-rings (2) onto the threaded plugs (1).

Install the two threaded plugs (1) into the housing.
Install the o-ring (4) onto the fuel supply fitting (3).
Install the fuel supply fitting (3) into the housing.
Install the o-ring (1) onto the fuel inlet fitting ( 2) from the
ECM cooling plate.
Install the fitting (2) into the fuel gear pump and tighten.
Install the o-ring (3) onto the fuel inlet fitting (2).
Install the o-ring (3) onto the fuel gear pump (2).
Apply Lubriplate multi-purpose lubricant to the o-ring (3).
Install the gasket (4) onto the gear fuel pump.
Use four capscrews (1) to install the pump to the IFSM
housing.
Install the lift pump gasket (1) onto the lift pump (2).
Use four capscrews (3) to install the lift pump to the
housing.
CM570
Verify the seal (1) is in the groove of the fuel control
damper (2) and add Lubriplate multi-purpose lubricant to
hold the seal in place.
Attach the fuel control damper (2) with capscrews (3) and
tighten.

Install the 2206 kPa [320 psi] pressure regulator (1) into

Install the 1724 kPa [250 psi] fuel pressure regulator into
Install the o-rings (2) onto the fuel pressure sensor (1).
Install the fuel pressure sensor (1) into the IFSM housing
and tighten.
NOTE: Some IFSMs contain an additional fuel pressure
sensor.
Install the air bleed (2) onto the air bleed orifice into the
IFSM (1) through the opening for the Compuchek fitting.
Install the o-ring (2) onto the Compuchek fitting (1).

Install both Compuchek fittings (1) into the IFSM housing
and tighten.
Install the anti-drain back valve (1) into the housing and
tighten.
Install the anti-drain back valve (1) for the fuel filter into
the housing and tighten.
Install the filter screen (1), compression spring (2) , o-ring

(3), and filter cap (4) into the housing.
Install the o-ring seal (2) onto the fuel drain fitting (1).
Install the fuel drain fitting (1).
Turn the nut all the way to the top of the fitting.
Thread the fitting all the way into the IFSM housing until
it stops.
Turn the fitting back until the threaded end is oriented
directly over the regulator.
Lock the fitting into position and tighten the locking nut.
Maintain the correct orientation.

in the grooves on the bottom of the metering actuators (2).
Install the actuator gasket (3) onto each actuator, making
Mount each actuator to the housing using three
capscrews (1) and tighten the capscrews.

in the grooves on the bottom of the timing actuators (2).
Install the actuator gasket (3) onto each actuator, making
Mount each actuator to the housing using three
capscrews (1) and tighten the capscrews.
Etch the same part number of the original IFSM on the

data tag (1).
Attach the tag to the housing by pressing the screws (2)
into the housing.
Install the seal (1) into the groove in the IFSM housing.
Place the actuator disc (2) over the seal (1), small diameter
down.
Place the valve disc (3) onto the actuator disc (2) with the
sealing surface down (spring pilot diameter up).
Place the valve spring (4) into the actuator housing (5) with
the inside diameter on the valve disc pilot (3).
Place the actuator housing (5) over the actuator disc (2).
Install the seal (1) into the groove in the actuator housing
(5).
Place the shutoff valve shield (6) over the actuator housing
(5).
Align the hole pattern of the shutoff valve shield (6).
Place the solenoid (7) over the shutoff valve shield (6),
taking care to align the holes and not pinch any seals.
Orient the terminal facing the gear pump.
Attach the assembly to the housing using four capscrews
(8) and tighten using an x pattern.
Install the o-ring (2) onto the threaded plug (1).

Install the three threaded plugs (1) into the housing.
Install the o-ring (4) onto the large threaded plug (3).
Install the larger threaded plug (3) into the housing.
Install the o-ring onto the fuel supply fitting.

Install the fuel supply fitting into the housing.
Install the o-ring onto the fuel inlet fitting.
Install the o-ring (3) onto the fuel gear pump (2).
Apply Lubriplate multi-purpose lubricant to the o-ring (3).
Install the gasket (4) onto the gear fuel pump.
Use four capscrews (1) and install the pump to the IFSM
housing.
Install the lift pump gasket (1) onto the lift pump (2).
Install the lift pump to the housing using three capscrews
(3).
NOTE: Some early engines were not equipped with a lift
pump. These engines use a hand priming pump or they
have been fitted with an auxilary lift pump.
Install
Install two guide pins into the mounting holes on the
cylinder head.
Install a new gasket onto the guide pins.

WARNING
Install the IFSM on the guide pins.
Install and tighten the capscrews.
Remove the guide pins.
Install and tighten the remaining capscrews.
Finishing Steps
With CM870
WARNING
cable last.
Install the accessory bracket. It is located above the
IFSM. Refer to Procedure 001-082 in Section 1.
Install the ECM cooling plate fuel supply line (bottom)
to the IFSM and ECM cooling plate fuel return line (top)
to the fuel pump. Refer to Procedure 006-006 in
Section 6.
Install the lift pump. Use the following procedure in the
Troubleshooting and Repair Manual, CM870
Install the customer accessory bracket. Tighten to 18
Nm [159 in-lb].
Connect the fuel supply and fuel drain lines. Refer to
Install the EGR differential pressure sensor adapter.
Install the EGR differential pressure sensor. Use the
Manual, CM870 Electronic Control System,
Signature and ISX Engines, Bulletin 4021334. Refer
Install the EGR differential pressure sensor tubes.
Connect the engine wiring harness to all temperature
and pressure sensors, fueling and timing actuators,
the fuel shutoff valve, the water-in-fuel sensor, and the
fuel lift pump.
Connect the air intake connection. Refer to Procedure
Connect the EGR mixer to the air intake connection.
Connect the battery cable. Refer to Procedure 013-009
in Section 13.
Install the fuel filter. Refer to Procedure 006-015 in
Section 6.
Prime the fuel system.
Operate the engine to normal operating temperature
and check for leaks.
Signature, ISX, and QSX15 Eng [...] Fuel Inlet Pre-Filter
CM570
WARNING
cable last.
Section 5.
Connect the fuel supply and fuel drain lines. Refer to
Install the customer accessory bracket. Tighten to 18
Nm [159 in-lb]).
Connect the air intake connection. Refer to Procedure
Install the fuel control covers.
Connect the engine wiring harness from all pressure
and temperature sensors, fueling and timing actuators,
the fuel shut off valve, the water-in-fuel sensor, and the
fuel lift pump.
Connect the air inlet piping. Refer to Procedure
Connect the battery cables. Refer to Procedure
Fuel Inlet Pre-Filter (005-096)

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

filter located in a housing at the Integrated Fuel System
Module fuel inlet.
Some engines are not equipped with a pre-filter.
Remove
Remove the fuel supply line to the Integrated Fuel System
Module. Refer to Procedure 006-024.
Remove the fuel inlet fitting, pre-filter snap ring, and pre-
filter.
Remove the fuel pump screen cap (36-micron screen).

Discard the screen.
Signature, ISX, and QSX15 Eng [...] Fuel Inlet Pre-Filter
Remove the large pre-filter from the Integrated Fuel

System Module.
Clean
Disassemble the inlet pre-filter.
NOTE: The filter media is not removable from the inlet
fitting.
WARNING
WARNING
personal injury.
Use solvent to back-flush the pre-filter element.
Assemble the inlet pre-filter.

Fuel Inlet Pre-Filter Signature, ISX, and QSX15 Eng [...]
Install
Install the pre-filter on the Integrated Fuel System Module.
NOTE: Do not use a new style inlet screen combined with

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

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

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
Finishing Steps.................................................................................................................................................6-5
Install................................................................................................................................................................6-5
Remove............................................................................................................................................................6-3
Fuel Drain Line Restriction ...............................................................................................................................6-6
Measure............................................................................................................................................................6-6
Fuel Filter (Spin-On Type) .................................................................................................................................6-6
Clean................................................................................................................................................................6-9
Initial Check......................................................................................................................................................6-6
Install................................................................................................................................................................6-9
Remove............................................................................................................................................................6-8
Fuel Inlet Restriction .......................................................................................................................................6-11
Measure..........................................................................................................................................................6-11
With Pressurized Fuel Filtering.....................................................................................................................6-11
With Vacuum Fuel Filtering.......................................................................................................................... 6-12
Fuel Supply Lines ............................................................................................................................................6-13
Remove.......................................................................................................................................................... 6-13
Injector .............................................................................................................................................................6-14
Assemble........................................................................................................................................................6-23
Disassemble................................................................................................................................................... 6-19
Finishing Steps...............................................................................................................................................6-27
Install..............................................................................................................................................................6-27
Leak Test........................................................................................................................................................6-14
Remove.......................................................................................................................................................... 6-17
Service Tools ....................................................................................................................................................6-1
.........................................................................................................................................................................6-1
Page 6-b Section 6 - Injectors and Fuel Lines - Group 06

Section 6 - Injectors and Fuel Lines - Group 06 Page 6-1
Service Tools
Repair Location.

Manometer
Used to measure fuel drain line restriction.
ST-1111-3
Sight Glass
Check for air in fuel suction line. Use Part Number ST-998 with
ST-998 Number 10 hose.
Injector Leak Test Kit

Use in conjunction with a manometer (ST1111-3) to test injectors for
3164001 leaks that cause an engine to exhibit slow shutdown or excessive run-
on after a key-off condition.
Filter Wrench
Used to remove or tighten spin-on fuel filters.
3376807
Chip Removing Unit

Used to remove carbon from the top of the piston.
3823461
Pressure/Vacuum Module
Used with 3377161 Digital Multimeter or 3824648 Automotive Meter.
3824645 The pressure transducer range is 500 psi and the vacuum range is
29.92 in Hg.
ECM Cooling Plate, Fuel Cooled Signature, ISX, and QSX15 Eng [...]
Page 6-2 Section 6 - Injectors and Fuel Lines - Group 06
Air in Fuel (006-003)

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

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

(006-006)
Preparatory Steps
NOTE: Some chassis will allow the ECM to be moved
aside with the wiring harness attached, for access to the
cooling plate.
Disconnect the engine wiring harness and OEM
harness connectors, if necessary. Refer to
Procedure 019-031 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
Signature, ISX, and QSX15 Eng [...] ECM Cooling Plate, Fuel Cooled
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.
WARNING
WARNING
personal injury.
Clean the cooling plate mounting surfaces with solvent.
ECM Cooling Plate, Fuel Cooled Signature, ISX, and QSX15 Eng [...]
WARNING
personal injury.
NOTE: If the sealing bead or groove is dirty, a leak can
result.
Clean the ECM cooling plate gasket sealing bead with a
dry cloth.
Make sure no rust or soot has accumulated in the grooves
on either side of, or on top of, the sealing bead.
Use compressed air to remove debris from the grooves, if
necessary.
Inspect the five insulating washers and the one ground

washer for cracks or other damage.
Replace any washer that is damaged.
Check for cracks or damage to the cooling plate.

Replace the cooling plate if cracks or damage is found.
Check the cooling plate fuel supply and return line fittings
on the ECM cooling plate, integrated fuel system module,
and fuel pump to make sure the o-rings are installed
properly and are not damaged.
Replace the o-ring, fitting, or cooling plate if damaged.
Signature, ISX, and QSX15 Eng [...] ECM Cooling Plate, Fuel Cooled
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.
Install the ECM.
Install and tighten the five ECM mounting capscrews.
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.
Finishing Steps
Connect the ECM harness and engine wiring
harness. Refer to Procedure 019-031 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
Start the engine and check for fuel leaks.
Fuel Filter (Spin-On Type) Signature, ISX, and QSX15 Eng [...]
Fuel Drain Line Restriction (006-012)

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

mm Hg in Hg
With Check Valve 165 MAX 6.5
Without Check Valve 229 MAX 9
If restriction exceeds specifications, inspect the drain lines
for the cause of the restriction. Fuel coolers and fuel
heaters can cause excessive drain line restriction.
Excessive restriction can cause low power and poor fuel
economy.
Remove the adapter and pressure gauge. Install the fuel
drain hose.
If damage resulted in coolant, oil, excessive fuel or
excessive black smoke entering the exhaust system, the
aftertreatment system must be inspected. Refer to
Fuel Filter (Spin-On Type) (006-015)

Initial Check
With Pressurized Fuel Filtering
Install a pressure gauge, Part Number 3824877 (2758 kPa
[400 psi]), on the fuel pump Compuchek fitting, to
measure the fuel pressure before the fuel filter.
Start the engine and operate at high idle and no load.

Measure and record the fuel pressure.
Shut the engine off.
Remove the pressure gauge from the fuel pump.
Signature, ISX, and QSX15 Eng [...] Fuel Filter (Spin-On Type)
Install a pressure gauge, Part Number 3824877 (275 kPa

[400 psi]), on the rail fuel pressure Compuchek fitting
located on the IFSM to measure the fuel pressure after the
filter.
Start the engine and operate at high idle and no load.

Measure and record the fuel pressure.
Remove the pressure gauge from the rail fuel pressure
Compuchek fitting.
The pressure difference between the rail fuel pressure and
fuel pump pressure is the differential pressure.
Fuel Filter Restriction

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

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

the IFSM. Insert a Compuchek fitting in this location and
run a line to a catch container.
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
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.
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.
Disconnect the wiring harness from the water-in-fuel
sensor, if equipped.
3400158.
Signature, ISX, and QSX15 Eng [...] Fuel Filter (Spin-On Type)
Clean
All Applications
Use a clean, lint-free cloth to clean the filter head gasket
surface.
Install
Use the correct filter(s) for your engine. It must remove a
minimum of 95 percent of free and emulsified water. It
must also have a minimum of 98.7 percent 15-micron
particle-removal efficiency.
Refer to Procedure 018-024 in Section V.
Apply a thin coating of clean engine oil to the filter gasket
surface.
CAUTION
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
NOTE: Engines equipped with priming pumps do not
require the fuel filter to be filled prior to installation, if the
following filling procedure is followed:
Install the filter onto the filter head. Turn the filter until the
gasket contacts the filter head surface.
Tighten the filter an additional of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.
To perform the priming procedure, use the following

ittems to fabricate a fuel bypass hose:
2- Quick-disconnect fittings, Part Number 3376859
Clear tubing (capable of 2758 kPa [400 psi])
Install the fuel bypass hose fabricated above between the
suction-side Compuchek fitting at the top of the IFSM
and the fuel pump Compucheck fitting located on the head
of the fuel pump.
Connect the clear hose and the shutoff valve normally
used to check for air in fuel to the rail Compuchek fitting.
Refer to Procedure 006-003 in Section 6. Place the open
end of the tube in a suitable container and fully open the
shutoff valve in the hose.
Fill the fuel filter by turning the ignition switch to the ON

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

must also have a minimum of 98.7 percent at 25-micron
surface and the center seal.
CAUTION
Tighten the filter an additional 3/4 of a turn after the gasket
manufacturer.
If the filter is equipped with a water-in-fuel sensor, rotate
the sensor to the desired location and connect the wiring
harness.
NOTE: The engine will, perhaps, run rough for several

minutes until the air is out of the system.
Fill the fuel filter by turning the ignition keyswitch to the
ON position. The priming pump will operate for 2 minutes,
which will adequately fill the fuel filter. The engine can
then be started.
Some engines utilize a manual, remote mount priming
pump. Flip the priming pump mounted toggle switch to the
ON position. Operate the pump for 2 minutes and shut it
off. The engine can then be started.
Signature, ISX, and QSX15 Eng [...] Fuel Inlet Restriction
With Vacuum Fuel Filtering and Without Priming

Pump
must also have a minimum of 98.7 percent at 25-micron
surface and the center seal.
CAUTION
Tighten the filter an additional 3/4 of a turn after the gasket
manufacturer.
If the filter is equipped with a water-in-fuel sensor, rotate
the sensor to the desired location and connect the wiring
harness.
NOTE: The engine will, perhaps, run rough for several

minutes until the air is out of the system.
Fill the fuel filter by turning the ignition switch to the ON
position. The priming pump will operate for 2 minutes,
which will adequately fill the fuel filter. The engine can
then be started.
Fuel Inlet Restriction (006-020)

Measure
Connect a vacuum gauge to the suction side Compuchek
fitting on top of the integrated fuel system module.
Fuel Inlet Restriction Signature, ISX, and QSX15 Eng [...]
Operate the engine at rated speed no load.

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

Install a vacuum gauge, Part Number ST434, using
adapter, Part Number ST434-2.
Hold the vacuum gauge at the same level as the fuel inlet
connection.
Operate the engine at rated speed no load.
Observe the reading on the gauge.
Maximum Inlet Restriction (With Clean Suction Filter)
127 mm Hg [ 5 in Hg ]
If the restriction exceeds the specifications, correct the
restriction in the suction filter, lines, heaters, or fuel tank.
Refer to the OEM troubleshooting and repair manual.

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

integrated fuel system module connection.
Operate the engine at high idle and no load.

Observe the reading on the vacuum gauge.

mm Hg in Hg
Without remote fuel 76 MAX 3
filter
With remote fuel filter 254 MAX 10
If the inlet restriction measured at the fuel supply
connection is above specification, the OEM fuel supply
lines, remote mount filter, or remote mount priming pump
(if equipped) is obstructed.
If the inlet restriction at the fuel supply connection is below
specification, the inlet pre-filter should be inspected for
debris and/or the fuel filter changed.
Fuel Supply Lines (006-024)

Remove
Remove the fuel supply hose to the integrated fuel system
module.
Inspect for Reuse

Inspect the inside of the hose.
The inner lining of the hose can be separate from the
center hose section.
A separation or flap can cause a restriction in the fuel
flow.
Replace the fuel hose if damage is found.
Injector Signature, ISX, and QSX15 Eng [...]
Injector (006-026)
Leak Test
This test checks for combustion gas leaks back through the injector rail check valve, or other conditions that will allow
gas leakage through the injector into the fuel rail.
When the engine is barred over, back pressure is created against the injector by the piston coming up on the
compression stroke.
During the test, if the rail check valve is leaking, air is pushed through the rail check valve and into the fuel rail, where
pressure is sensed at the test fixture which is in place of the metering actuator. If a manometer is connected to the
test fixture, pressure will be measured as air escapes through the leaking rail check valve. If a container of water is
used instead of a manometer, bubbles will be seen as air escapes through the leaking rail check valve.
The overhead set marks on the damper are used to identify which cylinder is on the compression stroke, and therefore
which injector has malfunctioned, if a change in manometer pressure or bubbles are seen.
Verify the run-on after key OFF complaint.
If the engine exhibits an excessive amount of run-on after
key OFF (greater than 3 seconds), continue with this
procedure.
The complaint must be verified to continue the

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

Signature, ISX, and QSX15 Eng [...] Injector
The fuel-metering actuators are the actuators located on

each end of the unit.
Remove the fuel-metering actuator for the front three
cylinders. Use the ISX Fuel System Troubleshooting and
Repair Manual, Bulletin 3666259. Refer to Procedure
Install the Injector Leak Test Kit, Part Number 3164001, in
place of the fuel-metering actuator.
Connect the flexible tubing to the hose fitting on the
mounting plate.
Place the flexible tubing into a container of water.
Bar the engine over while watching for bubbles in the

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

Determine the leaking injector by following the diagram.
If bubbles occur between:
A and B (number 3 injector is leaking)
B and C (number 1 injector is leaking)
C and A (number 2 injector is leaking).
Remove the mounting plate connected to the port for the

front three cylinders. Install the fuel-metering actuator
removed previously. Use the ISX Fuel System
Troubleshooting and Repair Manual, Bulletin 3666259.
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.
Repeat the above procedure for the rear three cylinders.
Bar the engine over and note between which two timing
marks the bubbles occur.
If the bubbles occur between:
A and B (number 4 injector is leaking)
B and C (number 6 injector is leaking)
C and A (number 5 injector is leaking).
Replace the leaking injector(s). Go to the remove section

in this procedure.
Preparatory Steps
WARNING
WARNING
Drain the coolant to below the cylinder head level.
Disconnect the engine brake solenoid wiring harness.
Remove
CAUTION
Do not bottom out adjusting screws. Engine damage
can occur if adjusting screws are bottomed out.
Remove only the valve and injector shaft for the injector
(s) being removed.
Loosen the injector rocker lever adjusting screws.
Remove the six capscrews and injector rocker lever shaft.
Do not let the rocker levers come off of the shaft during
removal.
Rotate the engine to the valve set mark for the injector
being removed. Refer to Procedure 003-004 in Section 3.
Loosen and back off the valve lash adjusting screws

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

side of the engine to allow the injector to be removed.
Loosen the injector clamp capscrew.

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

Inspect the injector for missing or damaged o-rings.
Replace o-rings as necessary.
Inspect the injector cup for missing plug balls. Replace the
injector if necessary.
Disassemble
Oil Seals, Roll pin retained load ring
Thoroughly clean the oil and dirt from the outside of the
injector.
Place the injector into the injector holding fixture.
Place the injector holding fixture into a vise. Tighten the
vise to hold the fixture in place.
Align the load ring capscrew bracket with the cutout in the
fixture plate.
Use a T45 Torx drive (long version) to loosen the injector

coupling retainer capscrew.
Make certain the injector remains upright; this will prevent

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

The load ring drilling is designed to remove and install the
roll pin in only one direction. Remove in the direction
shown.
Use a 5/32 inch punch to lightly tap the roll pin loose and
remove it from the load ring.
Discard the roll pin.
Remove the load ring from the injector body.
Install the coupling/plunger assembly into the injector

body bore to prevent debris from entering the bore.
The base of the oil seal is visible through the four

machined holes in the side of the injector body.
CAUTION
Its very important that a 3/32 inch punch be used so
the barrel is not damaged during oil seal removal.
Use a 3/32 inch punch. Place the punch at an upward
angle, as shown in the illustration, against the base of the
oil seal.
Use a hammer to gently tap the punch against the base
of the oil seal. To prevent damage to the seal bore in the
barrel, alternate between the four holes in the barrel so
that the seal comes out evenly and does not score the
barrel.
WARNING
personal injury.
Slide the oil seal up the plunger.
Use a can of safety solvent to blow debris away from the
oil seal area before removing the plunger.
Make certain the injector remains upright.

Remove the oil seal and plunger assembly from the
injector.
Remove the old oil seal from the plunger.
Remove the injector holding fixture and the injector from
the vise.
Place the fixture and injector onto the arbor press table.
Oil Seals, Clip retained load ring

Thoroughly clean the oil and dirt from the outside of the
injector.
Place a clean, lint free shop towel folded in quarters over
the edge of a work bench.
While holding the injector firmly in one hand, place the
upper plunger against the outer edge of the work bench
with the load ring just above the working surface of the
bench.
Lean in on the injector to partially compress the upper
spring and plunger. Use care not to come in contact with
the nozzle of the injector.
Use a pick to remove the injector load ring retaining clip.

Slowly, remove pressure from the injector, releasing the

upper spring.
Stand the injector upright and remove the load ring, the
upper plunger/coupling assembly, and the spring.
NOTE: Some of the injector parts are not
interchangeable.
Place each of the individual injector assembly parts
together on a lint free cloth.
Place the injector in the holding fixture, mounted in a

bench vise.
Locate the outer edge of the upper seal.

Use a punch, held at a slight angle, as shown in the
illustration, to carefully fold the edge of the seal in and
down.
Fold the edge of the seal in, 180 degrees from the first
fold.
Use care not to damage the injector body.
When the seal begins to rotate in the bore of the injector

body, carefully insert a small pry bar into the center of the
seal.
Carefully pry the seal out of the injector body bore.
Use care not to damage the injector body.
Assemble
Oil Seals, Roll pin retained load ring
CAUTION
Do not install the oil seal upside down. Failure to
install the seal correctly will cause damage to the oil
seal.
The oil seal will fit on the tool tightly if installed correctly.
The spring side of the oil seal (as shown) faces up when
installed in the injector.
Install a new oil seal onto the installation tool.
With the new oil seal positioned on the tool, position the
tool over the seal bore.
Use the arbor press to gently place pressure onto the
installation tool until the outer diameter face of the tool
contacts the injector body.
When properly installed, the seal height will not be flush
with the injector body. The height will be approximately
0.5 mm [0.020 in] above the injector.
Place the injector holding fixture with injector into the vise.
Tighten the vise to hold the fixture in place.
Install the load ring on the injector. Align the load ring
capscrew hole end with the cutout on the injector fixture.
Install a new roll pin into the load ring. By design, the roll
pin holes are a different size on each side, so the roll pin
must be installed in the correct direction, as illustrated.
Use a 5/32 inch punch to gently tap the roll pin into both
holes in the load ring. Continue driving the roll pin into the
load ring until the pin is centered evenly in both holes and
is an equal distance from both sides.
Inspect the oil seal and plunger bore for debris. If debris
is present, clean with a lint free cloth.
Clean the injector coupling spring with a lint free cloth.
Assemble the spring onto the load ring.
Clean the plunger and coupling assembly with a lint free
cloth.
Lubricate the plunger with clean calibration fluid.
Slightly angle and rotate the upper plunger while installing

the plunger into the oil seal.
Hold the plunger vertically and rotate while installing the
plunger into the injector bore.
Use a flashlight to view through the coupling spring.

Inspect the oil seal to verify the garter spring (1) is still in
the correct location around the seal.
Install the spring retainer bracket.

Tighten the retainer capscrew.
Install new injector o-rings.
Oil Seals, Clip retained load ring
CAUTION
Do not install the oil seal upside down. Failure to
install the seal correctly will cause damage to the oil
seal.
The oil seal will fit on the tool tightly, if installed correctly.
The spring side of the oil seal (as shown) faces up when
installed in the injector.
Install a new oil seal onto the installation tool.
With the new oil seal positioned on the tool, position the
tool over the seal bore.
Use the arbor press to gently place pressure onto the
installation tool until the outer diameter face of the tool
contacts the injector body.
When properly installed, the seal height will not be flush
with the injector body. The height will be approximately
0.5 mm [0.020 in] above the injector.
Lubricate the plunger with clean calibration fluid.

Carefully install the spring and load ring on the upper
plunger.
Holding the injector up right in one hand, slightly angle

and rotate the upper plunger while installing the plunger
into the oil seal.
Hold the plunger vertically and rotate while installing the
plunger into the injector bore.
Use a flashlight to view through the coupling spring.

Inspect the oil seal to verify the garter spring (1) is still in
the correct location around the seal.
Place a clean, lint free shop towel folded in quarters over

the edge of a work bench.
While holding the injector firmly in one hand, place the
upper plunger against the outer edge of the work bench
with the load ring just above the working surface of the
bench.
Lean in on the injector to partially compress the upper
spring and plunger. Use care not to come in contact with
the nozzle of the injector.
Install the clip onto the injector load ring.

Slowly, remove pressure from the injector, releasing the
upper spring against the load ring.
Install new injector o-rings.
Install
Use clean 15W-40 lubricating oil to lubricate the o-rings.
CAUTION
Make sure the injector hold down clamp is properly
aligned before tightening the capscrew. It is possible
for the clamp to contact a nearby ledge, and result in
low clamp load.
Install the injector into the cylinder head.
Install the injector clamp and the capscrew with washer.
Install the crossheads.
Finishing Steps
Install the injector rocker lever and valve rocker lever
assemblies. Refer to Procedure 003-009 in Section 3.
Connect the engine brake solenoid wiring harness, if
equipped. Refer to Procedure 020-015 in Section 15.
Adjust the overhead set as needed. Refer to Procedure
Fill the cooling system. Refer to Procedure 008-018 in
Section 8.
Notes
Section 7 - Lubricating Oil System - Group 07 Page 7-a
Section 7 - Lubricating Oil System - Group 07

Section Contents
Page
Centinel System ............................................................................................................................................7-58
Lubricating Oil and Filter Analysis .................................................................................................................7-58
Inspect............................................................................................................................................................7-58
Lubricating Oil..............................................................................................................................................7-58
Lubricating Oil Filter.....................................................................................................................................7-59
Lubricating Oil Cooler .......................................................................................................................................7-4
Finishing Steps...............................................................................................................................................7-10
Install..............................................................................................................................................................7-10
Leak Test..........................................................................................................................................................7-8
Automotive, Industrial with CM570 and Power Generation without CM570......................................................7-5
Remove............................................................................................................................................................7-5
Lubricating Oil Cooler Element .......................................................................................................................7-11
Assemble........................................................................................................................................................7-14
Single-Element.............................................................................................................................................7-14
Dual-Element............................................................................................................................................... 7-14
Disassemble................................................................................................................................................... 7-11
Single-Element.............................................................................................................................................7-11
Dual-Element............................................................................................................................................... 7-11
Finishing Steps...............................................................................................................................................7-15
Pressure Test..................................................................................................................................................7-13
Lubricating Oil Dipstick ...................................................................................................................................7-15
Calibrate.........................................................................................................................................................7-15
Lubricating Oil Dipstick Tube .........................................................................................................................7-16
Install..............................................................................................................................................................7-16
Automotive With CM871...............................................................................................................................7-17
Remove.......................................................................................................................................................... 7-16
Lubricating Oil Fill Tube ................................................................................................................................. 7-52
Install..............................................................................................................................................................7-55
Remove.......................................................................................................................................................... 7-52
Lubricating Oil Filter (Spin-On) .......................................................................................................................7-17
Install..............................................................................................................................................................7-19
Measure..........................................................................................................................................................7-18
Remove.......................................................................................................................................................... 7-19
Lubricating Oil Filter Bypass Valve ................................................................................................................7-20
Page 7-b Section 7 - Lubricating Oil System - Group 07
Clean..............................................................................................................................................................7-21
Install..............................................................................................................................................................7-22
Remove.......................................................................................................................................................... 7-20
Lubricating Oil Filter Head Adapter ................................................................................................................7-23
Finishing Steps...............................................................................................................................................7-25
Install..............................................................................................................................................................7-24
Remove.......................................................................................................................................................... 7-23
Lubricating Oil High Pressure Relief Valve ....................................................................................................7-25
Install..............................................................................................................................................................7-26
Remove.......................................................................................................................................................... 7-25
Lubricating Oil Leaks ......................................................................................................................................7-27
Lubricating Oil Pan ..........................................................................................................................................7-29
Finishing Steps...............................................................................................................................................7-31
Install..............................................................................................................................................................7-30
Remove.......................................................................................................................................................... 7-30
Lubricating Oil Pressure Gauge ......................................................................................................................7-32
Test................................................................................................................................................................ 7-32
Lubricating Oil Pump ......................................................................................................................................7-32
Assemble........................................................................................................................................................7-40
Disassemble................................................................................................................................................... 7-33
Finishing Steps...............................................................................................................................................7-44
Install..............................................................................................................................................................7-42
Remove.......................................................................................................................................................... 7-32
Lubricating Oil Suction Tube (Block-Mounted) ..............................................................................................7-45
Finishing Steps...............................................................................................................................................7-46
Install..............................................................................................................................................................7-46
Remove.......................................................................................................................................................... 7-45
Lubricating Oil System ....................................................................................................................................7-47
Drain...............................................................................................................................................................7-47
Fill...................................................................................................................................................................7-49
Prime..............................................................................................................................................................7-47
Lubricating Oil Thermostat .............................................................................................................................7-50
Install..............................................................................................................................................................7-51
Remove.......................................................................................................................................................... 7-50
Service Tools ....................................................................................................................................................7-1
.........................................................................................................................................................................7-1
Section 7 - Lubricating Oil System - Group 07 Page 7-1
Service Tools
Lubricating Oil System
Repair Location.

Pressure Gauge
Used to measure engine intake manifold pressure.
ST-1273
Battery Black Light/Lamp (100 Watt)

Used in conjunction with Part Number 3376891 and Part Number
3163337 3377438, fluorescent tracers, for fuel, oil, and coolant leaks.
Battery Black Light/Lamp (50 Watt)

Use in conjunction with Part Number 3376891 and Part Number
3163338 3377438, fluorescent tracers, for fuel, oil, and coolant leaks.
Silicone Sealant
Used for sealing tee-joints. Replaces silicone sealant, Part Number
3164067 3823494.
Filter Head Adapter Replacer

Used to remove and install the lubrication oil filter head adapter
3165082 (Service Tool Kit 3165074 includes both lubrication oil filter head
adapter and seal Loctite 2760).
Sealing/Retaining Compound
Loctite 2760 or Loctite 277 is used to secure the lubrication oil filter
3165083 head adapter to the lubricating oil filter head (Service Tool Kit
3165074 includes both lubrication oil filter head adapter and seal
Loctite 2760).
Page 7-2 Section 7 - Lubricating Oil System - Group 07

Tube Filter Cutter
Used for inspection of the filter element.
3376579
Fluorescent Tracer Dye

Added to oil. Used with black light to find leaks.
3376891
Female Quick Connect Coupler

Used to connect the priming pump to the engine.
3376859
Oil Filter Wrench

Used to remove spin-on filter. Replaces oil filter wrench, Part Number
3400157 3397929.
Silicone Sealant
Used for sealing tee-joints.
3823494
Oil Cooler Leak Test Kit

Used to pressurize the oil cooler assembly in order to check for leaks.
4918200 Used with air pressure regulator, Part Number 3164231 or
equivalent.
Filter Head Adapter Replacer

Used to remove and install the lubrication oil filter head adapter
4918222 (Service Tool Kit 3165074 includes both lubrication oil filter head
adapter and seal Loctite 2760). This filter head adapter replacer is
equivalent to the filter head adapter replacer, Part Number 3165082.
Remote Filter Head Adapter Replacer

Used to remove and install the remote lubrication oil filter head
4919518 adapter.

Protective Plug Kit
Used to plug oil passages and drillings during a repair process.
4918319
Lubricating Oil Cooler Signature, ISX, and QSX15 Eng [...]
Lubricating Oil Cooler (007-003)

Preparatory Steps
WARNING
WARNING
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
Drain the cooling system. Refer to Procedure
008-018 (Cooling System) in Section 8.
Remove the lubricating oil filter. Refer to Procedure
007-013 (Lubricating Oil Filter (Spin-On) in Section
7.
Remove the variable geometry turbocharger. Refer
to Procedure 010-033 (Turbocharger) in Section 10.
Remove the EGR valve. Refer to Procedure 011-022
(EGR Valve) in Section 11.
Remove the EGR cooler connection. Refer to
Procedure 011-024 (EGR Cooler Connection) in
Section 11.
Remove the EGR cooler. Refer to Procedure
011-019 (EGR Cooler) in Section 11.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Cooler

WARNING
WARNING
WARNING
WARNING
008-018 (Cooling System) in Section 8.
007-013 (Lubricating Oil Filter (Spin-On)) in Section
7.
Remove the turbocharger. This step is not required
with a die cast oil cooler. Refer to Procedure 010-033
(Turbocharger) in Section 10.
Remove the alternator. Refer to Procedure 013-001
(Alternator) in Section 13.
Remove
All Applications
Remove two oil cooler mounting capscrews and install the
guide pins.
Clean the area above the oil cooler to prevent debris entry
into the oil passages.
WARNING
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.

All Applications
Inspect the oil thermostat seat depth.
Remove the oil thermostat. Refer to Procedure 007-039
(Lubricating Oil Thermostat) in Section 7.
Measure from the spot face to the oil thermostat seat.
Reference graphic for measurement points. If the
measured diminsion for lubricating oil cooler housing with
integrated filter head is less than the minimum dimension,
the oil cooler housing will need to be replaced.
Lubricating Oil Cooler Housing Seat Depth

mm in
123.47 MIN 4.861
Install the oil thermostat. Refer to Procedure 007-039
(Lubricating Oil Thermostat) in Section 7.
CAUTION
Do not reuse an oil cooler core after a debris related
engine failure since there is no practical method for
cleaning the cooler core. Metal particles which can
circulate through the lubricating system can remain in
the cooler core and cause engine damage. Do not
allow dirt to enter the oil passages when cleaning the
oil cooler.
WARNING
for use. Wear goggles and protective clothing to avoid
personal injury.
WARNING
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
passages in the cylinder block when cleaning the
gasket sealing surfaces. Connecting rod bearing
failures can be caused if debris is introduced into the
cylinder block or lubricating oil cooler housing oil
passages. Therefore, use of power tools combined
with abrasive pads to clean gasket surfaces is not
recommended.
Plug the oil passages in the cylinder block with rubber
plugs.
Clean the oil cooler to cylinder block gasket surface with
Scotch-Brite 7448 abrasive pad.
Remove the rubber plugs when cleaning is complete.
Leak Test
All Applications
It is important to leak test the oil cooler assembly as a unit,
so leaks at the mounting joints can be identified. These
leaks can not be found when testing individual elements
that have been removed from the assembly. An element
is replaced only if it is found to be leaking.
This procedure is most effective when the oil cooler
assembly is tested in water below 7C [44F].
Use the mounting capscrews from the lubricating oil
cooler to attach the two plates and corresponding o-rings
from oil cooler leak test kit, Part Number 4918200, to the
lubricating oil cooler housing.
Remove the threaded male union that connects to the

turbocharger oil supply.
Install the threaded plug, Part Number 3089567.
Insert the o-ring from the oil filter into the filter head cap,
Part Number 4918204.
Use engine oil to lubricate the gasket surface and install
the filter head cap.
Attach air pressure regulator, Part Number 3164231, to

the outlet plate air fitting and pressurize the assembly to
689 kPa [100 psi].
WARNING
Place the oil cooler assembly under water.
If bubbles are observed, carefully determine the source of
the bubbles and replace the components as necessary.
If the element is suspected of leaking, refer to Procedure
007-007 (Lubricating Oil Cooler Element) in Section 7. for
leak testing individual elements. Mounting joint leaks are
much more common than element leaks. Do not replace
components that do not leak.
If no leaks are found and the engine serial number is in
the range of 14023600 to 1405000 and 7900000 to
79012457, replace the capscrews and gaskets if the
elements are to be reused.
If no leaks are found and the engine serial number is not
in the above ranges, the element does not get removed,
but the capscrew torque is to be checked and then
tightened to the specified torque.
Install
All Applications
WARNING
When installing a new two-element oil cooler on an older
engine, be sure the cooler element mounting capscrews
do not interfere with the cylinder block.
Install the guide pins.
Remove the protective plugs from the oil passages. Make
sure no debris enters the lubrication system. Using a clean
shop towel, carefully wipe out the oil passages and inspect
to make sure no debris is left in these passages.
Install a new mounting gasket and the oil cooler housing
assembly.
Install the 18 capscrews.
Remove the guide pins and install the two capscrews.

Tighten the capscrews in a circular motion from the center
out.
Finishing Steps
Install the EGR cooler. Refer to Procedure 011-019
(EGR Cooler) in Section 19.
Install the EGR cooler connections. Refer to
Procedure 011-024 (EGR Cooler Connection ) in
Section 11.
Install the EGR valve. Refer to Procedure 011-022
(EGR Valve ) in Section 11.
Install the lubricating oil filter. Refer to Procedure
007-013 (Lubricating Oil Filter (Spin-On)) in Section
7.
Install the variable geometry turbocharger. Refer to
Procedure 010-033 (Turbocharger) in Section 10.
(Cooling System) in Section 8.
Prime the lubricating oil system. Refer to Procedure
007-037 (Lubricating oil System) in Section 7.
Fill the engine with clean oil.
Operate engine to normal operating range and check
for oil and coolant leaks.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Cooler Element

Install the oil filter. Install the alternator. Refer to
Procedure 013-001 (Alternator) in Section 13.
Install the turbocharger. Refer to Procedure 010-033
Fill the engine with clean oil.
Operate the engine to normal operating range and
check for oil and coolant leaks.
Lubricating Oil Cooler Element

(007-007)
Preparatory Steps
Remove the lubricating oil cooler. Refer to Procedure
007-003.
Disassemble
Single-Element
Remove the element from the lubricating oil filter head.
Discard the gaskets.
Dual-Element
Remove the elements from the lubricating oil filter head.
Remove the oil cooler tube.
Lubricating Oil Cooler Element Signature, ISX, and QSX15 Eng [...]
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.
WARNING
WARNING
personal injury.
CAUTION
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.
Inspect the oil cooler tube for cracks. Replace the cooler
tube if cracks are found.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Cooler Element
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.
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
personal injury.
CAUTION
Do not allow dirt or foreign material to enter the oil
cooler element passages when cleaning. Engine
damage can result.
Remove the cooler element from the tank.
Remove the test equipment and dry with compressed air.
Lubricating Oil Cooler Element Signature, ISX, and QSX15 Eng [...]
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 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.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Dipstick
Finishing Steps
Install the lubricating oil cooler. Refer to Procedure
007-003.
check for leaks.
Lubricating Oil Dipstick (007-009)

Calibrate
NOTE: This procedure must begin with the oil pan
drained and the vehicle on level ground.
Install the dipstick into the dipstick tube housing.
Use the correct volume of clean 15W-40 oil to fill the oil
pan to the specified LOW oil level. Refer to Lubricating Oil
System - Specifications in this section for the correct
engine oil capacity for your application.
CAUTION
Use care when marking the dipstick, or the dipstick
will break if the scribe mark is too deep.
Remove the dipstick and scribe a mark across the stick at
the oil level. Label the mark with an L to indicate the LOW
oil level.
If a new blank dipstick is being used, cut the dipstick off
approximately 38 mm [1.5 in] below the LOW oil level
mark.
Wipe off the dipstick and install it into the dipstick tube
housing.
Use the correct volume of oil to fill the oil pan to the
specified HIGH oil level. Refer to Lubricating Oil System
Specifications in this section for engine oil capacity.
Lubricating Oil Dipstick Tube Signature, ISX, and QSX15 Eng [...]
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
Remove the dipstick tube clamp capscrew, nut, and
clamp.
Remove the dipstick and dipstick tube.

Remove the dipstick tube clamp capscrew, nut, and
clamp.
Remove the dipstick and dipstick tube.
Install
Install the dipstick tube and tighten the nut finger-tight.
Install the dipstick tube clamp, capscrew, and nut.
Tighten the dipstick tube nut.
Tighten the clamp.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Filter (Spin-On)

Install the dipstick tube and tighten the nut finger-tight.
Install the dipstick tube clamp, capscrew, and nut.
Tighten the dipstick tube nut.
Tighten the clamp.
Lubricating Oil Filter (Spin-On)

(007-013)
General Information
A combination oil filter is present on the engine. The upper
portion of the combination filter contains the full-flow filter
element while the lower portion contains the bypass filter
element.
The venturi design has been optimized to distribute oil
flow during normal engine operation; however during
extreme engine oil conditions (additive dropout,
contamination, soot etc.) the improvements increase the
overall filtration effectiveness.
Oil circulates through the full-flow portion of the filter, into
the oil cooler housing, and is directed to the engine oil
rifles.
A smaller portion of the oil circulates through the lower
bypass portion of the filter and is directed to the engine oil
rifles.
Lubricating Oil
Use Valvoline Premium Blue 15W-40 multiviscosity oil,
or its equivalent, which meets CES 20081 and CES 20078
oil classifications for turbocharged engines.
Refer to Cummins Engine Oil and Oil Analysis
Recommendations, Bulletin 3810340, for additional oil
information.
Lubricating Oil Filter (Spin-On) Signature, ISX, and QSX15 Eng [...]
CAUTION
Limited use of oils such as 5W-30 or 10W-30 can aid
in starting the engine and providing sufficient oil flow
at ambient temperatures below -5C [23F]. However,
the continuous use of low-viscosity oils can decrease
engine life.
See the accompanying chart to determine the best weight
of oil for the engine operating conditions.
Measure
Remove the oil plugs from the lubricating oil cooler
housing at the filter inlet (2) and outlet (1) pressure ports
and install manual gauges.
The following parts, or equivalent, are available for use:
Part Number Description
3824844 Compuchek fitting for port size
M14x1.5
3376920 Compuchek coupling (1/4-inch pipe
thread
3164491 Electronic pressure adapter for
multimeter (1/4-NPT pipe)
3164488 or Electronic digital multimeter
3164489
Start and operate the engine until the oil temperature

reaches or exceeds 70C [160F].
Engine Information
Oil filter type:
Miles on filter:
Oil type:
Operate the engine at each rpm called for and record the
corresponding pressure values:
Oil Temperature
Start of test:
End of Test
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Filter (Spin-On)
Engine Oil Pressure Filter Oil Pressure Filter Inlet - Outlet = INSITE electronic
RPM Inlet Outlet Differential Pressure service tool
Low Idle
High Idle
A pressure drop greater than 172 kPa [25 psi], at operating temperature using 15W-40 oil, indicates the filter is
plugged.
Identify the causes of a plugged filter. Verify the Cummins Inc. maintenance guidelines are being met.
Refer to Procedure For possible fluid contamination, 007-083 (Lubricating Oil Filter and Filter Analysis) in Section 7.
Change both the lubricating oil and lubricating oil filter, if plugged.
Reference symptom tree t103-56 (Lubricating Oil Filter Plugged) in Section TS.
For additional information about lubricating oil filter plugging, refer to Cummins Engine Oil and Oil Analysis
Recommendations, Bulletin 3810340.
Remove
WARNING
WARNING
NOTE: If the lubricating oil filter head adapter comes off
during the removal of the lubricating oil filter, then reinstall
the oil filter head adapter. Use a small amount of Loctite
on the threads of the oil filter head adapter and tighten.
Refer to Procedure 007-018 (Lubricating Oil Filter Head
Adaptor) in Section 7.
Use oil filter wrench, Part Number 3375049, 3397929, or
3400157 to remove the oil filter.
Install
NOTE: The o-ring can stick onto the filter head. Make sure
it is removed before installing a new filter.
Clean the oil filter head surface.
Use clean engine oil to lubricate the gasket surface of the
filter.
Lubricating Oil Filter Bypass Valve Signature, ISX, and QSX15 Eng [...]
CAUTION
Mechanical overtightening can distort the threads or
damage the filter element seal.
Fill the oil filter with clean 15W-40 oil.
Install the oil filter onto the oil filter head. Tighten the filter
until the gasket contacts the filter head surface.
Use oil filter wrench, Part Number 3375049, 3397929, or
3400157 to tighten the filter an additional 3/4 to 1 turn, or
follow the instructions supplied with the filter.
Confirm that the oil level in the pan is to the full mark.
Operate the engine until the water temperature reaches
82C [180F].
Check the oil pressure and for leaks.
Lubricating Oil Filter Bypass Valve

(007-014)
General Information
Whenever the pressure drop across the lubricating oil
filter exceeds 862 kPa [125 psi], the oil filter bypass valve
opens and allows lubricating oil to bypass the lubricating
oil filter.
This condition can occur during cold ambient (cold
lubricating oil) engine start-ups.
The purpose of the bypass valve is to maintain lubricating
oil flow to the engine and prevent an oil filter collapse.
Remove
WARNING
WARNING
Loosen the retaining plug with a 7-millimeter Allen wrench.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Filter Bypass Valve
Remove the retaining plug (1), spring (2), and plunger (3)
from the lubricating oil cooler housing (4).
Clean
WARNING
WARNING
personal injury.
WARNING
bodily injury.
Clean the spring, plunger, and retaining plug with solvent.
Inspect for Reuse

Inspect the o-ring on the retaining plug for cuts or tears.
Replace the o-ring if damaged.
Lubricating Oil Filter Bypass Valve Signature, ISX, and QSX15 Eng [...]
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.

007-037.

check for leaks.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Filter Head Adapter
Lubricating Oil Filter Head Adapter

(007-018)
Preparatory Steps
WARNING
WARNING
NOTE: The lubricating oil filter head housing assembly
does not need to be removed to replace the oil filter head
adapter.
Remove
WARNING
To reduce the possibility of personal injury or
equipment damage. Use only a 3/4-inch drive
extension and ratchet for the removal of the adapter.
NOTE: If the engine is equipped with a remote filter, first
remove the remote lubricating oil filter head adapter from
the lubricating oil filter head. Use service tool, Part
Number 4919518, or equivalent, to remove the remote
lubricating oil filter head.
If the pinned adapter has come loose or if the staking pin
is missing, and the oil filter head adapter can be removed
by hand or without damaging the threads in the housing,
then follow the procedure as described below for cleaning
and installing the adapter. The missing staking pin will
not be replaced.
NOTE: If the housing threads are found damaged, the
housing must be replaced.
Use service tool, Part Number 3165082 or Part Number

4918222, to remove the adapter from the housing.
Lubricating Oil Filter Head Adapter Signature, ISX, and QSX15 Eng [...]
WARNING
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.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil High Pressure Relief Valve
Finishing Steps
Fill the new oil filter with clean lubricating oil.
Install the lubricating oil filter. Refer to Procedure
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
WARNING
Remove and disassemble the lubricating oil pump. Refer
to Procedure 007-031.
Lubricating Oil High Pressure Relief Valve Signature, ISX, and QSX15 Eng [...]
Inspect for Reuse

Inspect the ball. A slight ring around the ball from contact
with the pump body and spring is acceptable.
Measure the spring free length.
High Pressure Relief Valve Spring Free Length

mm in
68.91 NOM 2.713
Use a spring compression tester to determine if the spring

is defective.
Replace the spring with a new spring if it is defective.
High Pressure Relief Valve Spring (Compressed

Length) Load at 45.82 mm [1.804 in]
N lbf
281.47 MIN 63.277
298.87 MAX 67.189
Install
Assemble and install the lubricating oil pump. Refer to
Procedure 007-031.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Leaks

check for leaks.
Lubricating Oil Leaks (007-024)

General Information
The cause of external oil leaks is hard to diagnose and correct because of the potential number of factors involved.
Although the location of a leak can sometimes seem obvious, it can also be difficult to isolate the exact location due
to fan blast and road grime that would cause the leak to migrate.
Before doing any repairs, it is important to locate the exact root cause of the leak to prevent misdiagnosis and further
downtime. Please use the diagrams below to troubleshoot any external oil leaks.
Begin by determining which quadrant of the engine the leak is located in. It will be necessary to start out by steam
cleaning the engine and then operating it on a dynamometer to look for the leak. Keep in mind where the oil looks the
most concentrated before the steam clean, as this will give a good indication of where to start looking for leaks.
Once the quadrant has been determined, look at the following diagram to get a good indication of where the leak can
be coming from on the exhaust side of the engine.
1. Lower front gear cover gasket leak 6. Oil spill from oil filter change
2. Gear housing gasket leak 7. Oil slobber from exhaust manifold
3. Oil pan gasket leak 8. Cam cover gaskets leaks
4. Flywheel housing gasket leak 9. Valve cover gasket leak
5. Lube cooler gasket leak
Lubricating Oil Leaks Signature, ISX, and QSX15 Eng [...]
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
CAUTION
Protect all electrical components, openings, and
wiring from the full force of the cleaner spray nozzle.
Use a steam cleaner or a high-pressure washer to clean
the engine.
Check the engine crankcase breather element, hose, and

tube for restriction. Refer to Procedure 003-001.
Add fluorescent dye tracer, Part Number 3376891, to the
oil.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pan
Check for a loose or missing oil dipstick tube, dipstick, or

oil filler cap.

82C [180F]. Inspect the exterior of the engine for
leaking gaskets, seals, o-rings, pipe plugs, or fittings.
Use a black light, Part Number 3377394, to locate leaks.
Follow the manufacturer's operating instructions to use
the black light.
NOTE: Before removing and replacing any gaskets, check
the capscrews to make sure they are tightened to the
correct torque values.
Lubricating Oil Pan (007-025)

Preparatory Steps
WARNING
WARNING
Drain the lubricating oil. Refer to Procedure 007-037
(Lubricating Oil System) in Section 7.
Lubricating Oil Pan Signature, ISX, and QSX15 Eng [...]
Remove
Remove the oil pan mounting capscrews, oil pan, and
gasket.
Discard the oil pan gasket.
WARNING
WARNING
bodily injury.
Steam clean and dry with compressed air.
Inspect the inside and the outside of the oil pan for cracks.
Replace the oil pan if cracked or broken.
Install
Apply a 1.97 mm [1/8 in] bead of silicon sealant, Part
Number 3164067, to each of the four T-joints where the
front gear housing and flywheel housing gaskets intersect
the oil pan gasket.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pan
Install a new oil pan gasket.

Install the oil pan onto the cylinder block. Install one of the
13 mm oil pan mounting capscrews, hand tight, on each
side of the oil pan, halfway between the front and the rear
of the oil pan.
Finger-tighten all or the mounting capscrews.
Tighten the thirty-two 13 mm capscrews in the sequence

shown.
At the end of the sequence, loosen and tighten capscrew
number 1again.
Install the oil drain plug.
Finishing Steps
Fill the lubricating oil pan. Refer to Procedure 007-037
(Lubricating Oil System) in Section 7.
82C [180F], and check for leaks.
Lubricating Oil Pump Signature, ISX, and QSX15 Eng [...]
Lubricating Oil Pressure Gauge

(007-028)
Test
1. Check for the following:
Electrical wiring broken
Oil pressure sensor malfunction (refer to step
No. 2)
Plumbing loose, leaking, or broken.
2. Use a master gauge of known accuracy to verify the
reading of the suspect sensor or gauge.
3. Replace the oil pressure sensor or gauge if it is
defective.
NOTE: The arrow points to a combination oil pressure and
oil temperature sensor on the cylinder block below the
integrated fuel system module.
Lubricating Oil Pump (007-031)

Preparatory Steps
WARNING
WARNING
ingestion and prolonged contact with used engine oil.
If not reused, dispose of in accordance with local
Drain the lubricating oil. Refer to Procedure 007-037 in
Section 7.
Remove the lubricating oil pan. Refer to Procedure
Remove the lubricating oil suction tube. Refer to
Remove
CAUTION
Do not discard shims, if equipped. They must be
installed in the original location. Failure to do so can
result in engine damage.
Remove four capscrews, oil pump, and shims if equipped.
When installing a new oil pump, new shims will possibly
be needed to acquire acceptable lash.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pump
Disassemble
WARNING
The pressure regulator spring is under compression.
Slowly remove the cap to reduce the possibility of
personal injury.
Remove the lubricating oil pressure regulator and spring
by removing the split pin that secures the spring cap to the
lubricating oil pump.
Discard the o-ring.
The external idler gear retaining capscrew has a left-hand

thread. capscrew.
Remove the external idler gear from the lubricating oil
pump.
Save the retaining capscrew for reuse.
WARNING
The high pressure relief valve is under compression.
Apply pressure to the cover while removing the
capscrews. Slowly release the pressure to reduce the
possibility of personal injury.
Remove the six assembly capscrews and the lube pump
cover.
Press off the external drive gear from the internal drive
gear shaft.
Remove the high-pressure relief spring and ball.
Remove the idler pumping gear from the shaft in the

lubricating oil pump body.
WARNING
WARNING
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
WARNING
personal injury.
Use a steam cleaner to rinse the components.
Inspect the following areas of the lubricating oil pump for

damage or blockage.
Lubricating oil pump body gear cavity
Inlet and outlet ports
Internal oil passages
Lubricating oil pump housing body
Pressure regulator bore
High pressure relief bore and seat.
If the lubricating pump housing is damaged, it must be
replaced.
Inspect the lubricating oil pump cover for damage.

Inspect the bushing for scuffing and wear.
If the marks on the lubricating pump cover can be felt with
a fingernail, the part must be replaced.
Measure the regulator bore for beat-in.
Regulator Bore Depth Specification

mm in
186.95 MIN 7.3602
187.45 MAX 7.380
If the regulator bore depth is not within the specifications,
the housing must be replaced.
Inspect the pressure regulator spool for scuffing.

Minor spool scuff is acceptable. If the scuff can be felt by
a fingernail, the spool will need to be replaced.
Insert the spool in the bore and check for smooth
movement in and out of the bore. If any hesitation is felt,
the spool must be replaced and the bore inspected for
burrs.
Remove any burrs found in the bore before installing a
new spool.
Inspect the pressure regulator spring for a broken coil or

rust.
Measure the free length of the pressure regulator spring.
Oil Pressure Regulator Spring Free Length

mm in
109.55 NOM 4.313

to measure the pressure regulator valve spring at working
height, 70 mm [2.756 in].
Lubricating Oil Pressure Regulator Spring Load at 70

mm [2.756 in]
N lbf
131.8 MIN 29.6
135.3 MAX 30.4
If the regulator spring is not within the specifications, the
spring must be replaced.
Inspect the high pressure relief spring for a broken coil or

rust.
Measure the free length of the high pressure relief spring.
High Pressure Relief Valve Spring Free Length

mm in
68.91 NOM 2.713

to measure the high pressure relief spring at working
height, 45.82 mm [1.804 in].
High Pressure Relief Valve Spring (Compressed

Length) Load at 45.82 mm [1.804 in]
N lbf
281.5 MIN 63.3
298.9 MAX 67.2
If the pressure relief valve spring is not within the
specification, the spring must be replaced.
Inspect the high pressure relief ball. A slight ring around

the ball from contact with the pump body and spring is
acceptable.
Inspect the external idler gear retainer.

Minor retainer scuff is acceptable. If the scuff can be felt
by a fingernail, replace the retainer.
Inspect the external idler gear for cracks, chips, and

broken teeth.
If the external idler gear is damaged, the gear must be
replaced.
Check the idler gear bushing for wear and scuffing.
Measure the inside diameter of the bushing in the external

idler gear.
External Idler Gear Bushing Inside Diameter

mm in
32.044 MIN 1.2616
32.069 MAX 1.2626
If the external idler gear bushing is not within
specifications, the bushing must be replaced.
Inspect the external drive gear for cracks, chips, and

broken teeth.
If the external drive gear is damaged, the gear must be
replaced.
Check the drive gear bushing for wear and scuffing.
Measure the inside diameter of the external drive gear.
External Drive Gear Inside Diameter (No Bushing)

mm in
24.909 MIN 0.9807
24.935 MAX 0.9817
If the external drive gear is not within specifications, the
gear must be replaced.
Inspect the lubricating oil pump internal gears for

excessive wear, cracks, or broken teeth.
Erosion and pitting on the tip and root of the gear tooth is
not acceptable. The gear must be replaced.
Measure the inside diameter of the internal idler gear.
Internal Idler Gear Inside Diameter

mm in
24.909 MIN 0.9807
24.935 MAX 0.9817
If the internal idler gear is not within specifications, it
must be replaced.
Inspect the internal idler shaft for damage. Measure the

outside diameter of the idler shaft.
Internal Idler Shaft Outside Diameter

mm in
24.858 MIN 0.9787
24.871 MAX 0.9792
If the idler shaft is not within specifications, it must be
replaced.
Inspect the internal drive gear and shaft assembly for

damage. Measure the outside diameter of the internal
drive gear shaft.
Internal Drive Gear Shaft Outside Diameter

mm in
24.858 MIN 0.9787
24.871 MAX 0.9792
If the drive shaft is not within specifications, it must be
replaced.
Assemble
Lubricate the drive shaft with clean 15W-40 lubricating oil.
Install the internal idler gear onto the shaft.
Insert the internal drive gear and shaft assembly into the
lubricating oil pump cover.
Press the external drive gear onto the shaft.
Install the ball first, then the spring.

Install the high pressure relief ball and spring into its bore
in the lube pump housing.
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.
Install the external idler gear.

Insert the external idler gear retainer such that the holes
are at the 3 and 9 o'clock position.
The idler gear retaining capscrew has left-hand threads.
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
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.
Use a dial indicator, check the oil pump idler gear back
lash.
Oil Pump Idler Gear Backlash

mm in
0.18 MIN 0.008
0.46 MAX 0.018
0.32 NOM 0.013
CAUTION
Improper gear lash can cause damage to the gear train
and the lubricating oil pump.
Shims will be available in six different thicknesses in order
to provide correct lash. The various thicknesses are
identified by the color of the shim. Identify the number
stamped on the pump (1) and the letter on the block (2).
Use the following table to determine which shim should be
used according to the stamped number and letter.
If a lube pump or cylinder block is replaced, the block and pump will not be stamped. In that instance, a shim must
be chosen and installed. The oil pump idler gear backlash must be checked. If the backlash is not within the
specification, choose another size shim and recheck the backlash. Do this until the backlash is within specification.
Block
Pump A B C D
1 0.000 mm [0.000 in]-None- 0.45 mm [0.018 in]-Black- 0.55 mm [0.022 in]- 0.35 mm [0.014 in]-
Purple- Yellow-
2 0.45 mm [0.018 in]-Black- 0.65 mm [0.026 in]-Red- 0.75 mm [0.030 in]-Blue- 0.55 mm [0.022 in]-Purple-
3 0.55 mm [0.022 in]-Purple- 0.75 mm [0.030 in]-Blue- 0.85 mm [0.033 in]-Green- 0.65 mm [0.026 in]-Red-
4 0.35 mm [0.014 in]-Yellow- 0.55 mm [0.022 in]- 0.65 mm [0.026 in]-Red- 0.45 mm [0.018 in]-Black-
Purple-
If the lubricating oil pump is not within specifications, the
shims must be changed to proper thickness to give proper
backlash.
Finishing Steps
Install the lubricating oil suction tube. Refer to
Install the lubricating oil pan. Refer to Procedure
Fill the engine with lubricating oil. Refer to Procedure
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Suction Tube (Block-Mounted)
Lubricating Oil Suction Tube (Block-

Mounted) (007-035)
Preparatory Steps
WARNING
WARNING
Drain the lubricating oil. Refer to Procedure 007-037.
Remove the lubricating oil pan. Refer to Procedure
007-025.
Remove
Remove the lubricating oil suction tube capscrews,
suction tube, and o-ring. Discard o-ring.
Inspect for Reuse

Inspect the oil suction tube for cracks or damage.
Inspect the o-ring grooves for cavities or damage.
If cracks, damage, or cavities are found, the oil suction
tube must be replaced.
Lubricating Oil Suction Tube (Block-Mounted) Signature, ISX, and QSX15 Eng [...]
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.
Finishing Steps
Install the lubricating oil pan. Refer to Procedure 007-025.
Fill engine with oil. Refer to Procedure 007-037.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System
Lubricating Oil System (007-037)

Drain
WARNING
WARNING
60C [140F].
Shut off the engine.
Remove the oil drain plug.
Drain the oil immediately to make sure all the oil and
suspended contaminants are removed from the engine.
If lubricating oil element failure occurs resulting in
contamination of the lubricating oil, the following is
recommended:
Inspect the lubricating oil filter by cutting it open and
inspecting for debris. Refer to Procedure 007-083.
If debris is not found, drain the lubricating oil and
remove the lubricating oil pan. Clean and reinstall
the lubricating oil pan. Refer to Procedure 007-025.
Remove the valve cover and clean the contaminated
lubricating oil from the cylinder head cavities. This
can be done using a siphoning device. Refer to
Procedure 003-011.
If debris is found, refer to the Cummins Warranty
Administration Manual, Bulletin 4021290.
Prime
CAUTION
The lubricating oil system must be primed before
operating the engine after any internal engine repairs
or extended engine storage (beyond 6 months) to
avoid internal component damage.
Bar the engine during oil priming.
Lubricating Oil System Signature, ISX, and QSX15 Eng [...]
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.
Check the oil level on the dipstick before adding additional

oil.
If necessary, fill the engine with lubricating oil.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System
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.
82C [180F], and check for leaks.
Shut off the engine. Wait 15 minutes for the oil to drain
back to the oil pan.
Check the oil level. Add oil as necessary to bring the level
up to the H (high) mark on the dipstick.
Lubricating Oil Thermostat Signature, ISX, and QSX15 Eng [...]
Lubricating Oil Thermostat (007-039)

Remove
WARNING
WARNING
Remove the alternator. Refer to Procedure 013-001
Remove the water pump. Refer to Procedure 008-062
(Water Pump) in Section 8.
Remove the thermostat plug.
Remove the tapered snap ring.
Remove the thermostat from the lubricating oil cooler
housing.
Inspect for Reuse
WARNING
The flash point of new lubricating oil is approximately
221C [430F]. Do not allow the oil temperature in the
container to exceed 149C [300F]. Do not allow
water droplets to enter the container of hot oil. Water
droplets will cause a violent reaction that can cause
personal injury.
Suspend the thermostat and a 127C [260F]
thermometer in a container of new lubricating oil. Do not
allow the thermostat or the thermometer to touch the sides
of the container.
Heat the lubricating oil.
Write down the temperature at which the valve is fully

extended. The valve must be fully extended to at least 6
mm [0.250 in] from the closed position when the
temperature reaches 127C [260F].
Replace the thermostat if it does not operate as
described.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Thermostat
Inspect the valve for damage. Any damage to the front

face of the valve will allow oil to constantly bypass the oil
cooler.
If cracks are found on the oil thermostat, inspect the oil
cooler housing for the correct seat depth. Refer to
Procedure 007-003 (Lubricating Oil Cooler) in Section 7.
Install
Install the thermostat into lubricating oil cooler housing.
Install the tapered snap ring with the tapered side facing
away from the lubricating oil cooler housing.
Install and tighten the thermostat plug.
Install the alternator. Refer to Procedure 013-001
Install the water pump. Refer to Procedure 008-062 (Water
Pump) in Section 8.


check for leaks.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Eng [...]
Lubricating Oil Fill Tube (007-065)

Remove
CAUTION
Removal of the oil fill tube without loosening the tube
brace capscrew is likely to cause fill tube thread
breakage.
Loosen the tube brace capscrew (1).
Remove the tube brace capscrew from the gear cover (2).
Remove the oil fill tube (1) and the tube brace (2) from the
oil fill tube connection (3).
A smooth, rounded end bar can be used for leverage to

rotate the oil fill tube connection.
Rotate the oil fill tube connection counterclockwise to
remove.
Remove the ring seals from the oil fill connection, the oil
fill tube, and the oil fill tube cap.
Discard the ring seals.
Ring seals:
1. Oil fill connection ring seal
2. Oil fill tube ring seal
3. Oil fill cap ring seal.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Fill Tube
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.

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.

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.
Install
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.
Install and tighten the tube brace gear cover capscrew (2).
Tighten the tube brace capscrew (1).

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.
Install the oil fill tube cap and the oil fill tube.
Install and tighten the tube brace gear cover capscrews.

Lubricating Oil and Filter Analysis Signature, ISX, and QSX15 Eng [...]
Centinel System (007-075)

General Information
NOTE: Fleetguard Extended Service (ES) System
lubrication oil and fuel filters are required with Centinel.
These filters provide the filtration performance needed for
extended service intervals.
Centinel is an onboard continuous oil replenishment
system that operates as a function of fuel rate. The
Centinel valve is controlled by the ECM and is actuated
proportional to the amount of fuel consumed. The oil burn
rate has been designed for continued reliability and
durability of the engine. The continuous oil replenishment
process stabilizes engine oil quality and allows extended
oil and filter change intervals. The extended intervals are
a 844,907 km [525,000 mi] oil drain interval and 160,935
km [100,000 mi] oil filter change interval. The calibration
setting is a 0.33-percent blend rate. This rate uses 3.8
liters [1 gal] of oil for every 1136 liters [300 gal] of fuel
consumed (3.8/1136 = 1/300 = 0.33 percent).
The basic Centinel system can operate on vehicles
whose engines are equipped with either 12- or 24-VDC
electrical systems. Though the Centinel control valve
operates on 12-VDC, the valve is compatible with either
12- or 24-VDC engines because both engine ECMs (12- or
24-VDC) provide 12-VDC to the valve.
In addition to the valve and mounting hardware, it is
necessary to obtain an oil makeup tank and plumbing.
Tanks are available through Cummins Inc. with a capacity
between the high and low mark of 15.142 liter [4 gal], or
24.605 liters [6.5 gal].
Refer to Centinel Master Repair Manual, Bulletin
3666231, for detailed repair procedures on Centinel
equipped engines.
Lubricating Oil and Filter Analysis

(007-083)
Inspect
Lubricating Oil
An analysis of used oil can help diagnose internal engine
damage and determine if it was caused by one of the
following:
Intake air filter malfunction
Coolant leaks
Oil diluted with fuel
Metal particles causing wear.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil and Filter Analysis
For additional oil analysis information, refer to Cummins

Engine Oil Recommendations, Bulletin 3810340.
NOTE: Do not disassemble an engine for repair based
only on the results of an oil analysis. The oil filter must
also be inspected. If the oil filter shows evidence of
internal damage, find the source of the problem and repair
the damage. Refer to the appropriate procedure(s) based
on the following oil filter inspection.
Lubricating Oil Filter
WARNING
Carefully cut open the upper section of the
combination filter. The filter element spring is under
compression and can cause personal injury.
Use the tube cutter, Part Number 3376579, to open the
upper section of the combination filter.
Inspect the filter element for evidence of moisture or metal

particles.
Metal Probable Source

Copper Bearings and bushings
Chromium Piston rings
Iron Cylinder liners
Lead Bearing overlay material
Aluminum Piston wear or scuffing
Lubricating Oil and Filter Analysis Signature, ISX, and QSX15 Eng [...]
Notes
Section 8 - Cooling System - Group 08 Page 8-a
Section 8 - Cooling System - Group 08

Section Contents
Page
Belt Tensioner, Automatic (Water Pump) .......................................................................................................8-68
CM570.........................................................................................................................................................8-72
Finishing Steps...............................................................................................................................................8-74
Drives Alternator.......................................................................................................................................... 8-74
Initial Check....................................................................................................................................................8-68
Install..............................................................................................................................................................8-72
Automotive Applications...............................................................................................................................8-72
Industrial and Power Generation...................................................................................................................8-73
Remove.......................................................................................................................................................... 8-69
Automotive Applications...............................................................................................................................8-69
Coolant Filter .....................................................................................................................................................8-5
General Information..........................................................................................................................................8-5
Install................................................................................................................................................................8-6
Remove............................................................................................................................................................8-6
Coolant Filter Valve ...........................................................................................................................................8-7
Clean................................................................................................................................................................8-8
Install................................................................................................................................................................8-8
Remove............................................................................................................................................................8-7
Coolant Thermostat ..........................................................................................................................................8-9
Finishing Steps...............................................................................................................................................8-14
Out-of-Chassis Opening Temperature Test...................................................................................................8-12
Install..............................................................................................................................................................8-13
Leak Test..........................................................................................................................................................8-9
In-Chassis Opening Temperature Test..........................................................................................................8-11
Remove.......................................................................................................................................................... 8-11
Coolant Thermostat Housing ..........................................................................................................................8-15
Finishing Steps...............................................................................................................................................8-21
Install..............................................................................................................................................................8-18
Single Thermostat........................................................................................................................................8-18
Dual Thermostat...........................................................................................................................................8-19
Remove.......................................................................................................................................................... 8-16
Single Thermostat........................................................................................................................................8-16
Dual Thermostat...........................................................................................................................................8-16
Coolant Thermostat Seal ................................................................................................................................ 8-21
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
Page 8-b Section 8 - Cooling System - Group 08
Drain...............................................................................................................................................................8-23
Fill...................................................................................................................................................................8-26
Flush...............................................................................................................................................................8-24
Pressure Test..................................................................................................................................................8-31
Cooling System - Air or Combustion Gas Test ..............................................................................................8-32
Initial Check....................................................................................................................................................8-32
Air in Cooling System...................................................................................................................................8-32
Leak Test........................................................................................................................................................8-34
Fan, Shutter, or Heater Air Control Valve......................................................................................................8-34
Air Compressor............................................................................................................................................8-34
Combustion Gas Leak..................................................................................................................................8-35
Overflow Method..........................................................................................................................................8-38
Drive Belt, Cooling Fan .....................................................................................................................................8-3
Drives Alternator............................................................................................................................................8-3
Install................................................................................................................................................................8-3
Remove............................................................................................................................................................8-3
Drive Belt, Water Pump ....................................................................................................................................8-4
Adjust...............................................................................................................................................................8-5
Install................................................................................................................................................................8-5
Remove............................................................................................................................................................8-4
Fan Clutch, On-Off ..........................................................................................................................................8-39
Initial Check....................................................................................................................................................8-39
With Low Temperature Fan-On Control.........................................................................................................8-39
With High Temperature Fan On....................................................................................................................8-40
Fan Drive Idler Pulley Assembly .....................................................................................................................8-42
Finishing Steps...............................................................................................................................................8-43
Install..............................................................................................................................................................8-42
Remove.......................................................................................................................................................... 8-42
Fan Hub, Belt Driven .......................................................................................................................................8-43
Finishing Steps...............................................................................................................................................8-46
Industrial CM570 and Power Generation without CM570...............................................................................8-47
Install..............................................................................................................................................................8-45
Remove.......................................................................................................................................................... 8-44
Fan Pulley ........................................................................................................................................................8-78
Install..............................................................................................................................................................8-79
Remove.......................................................................................................................................................... 8-78
Fan Shroud Assembly .....................................................................................................................................8-47
Initial Check....................................................................................................................................................8-47
Fan Support .....................................................................................................................................................8-75
Finishing Steps...............................................................................................................................................8-78
Section 8 - Cooling System - Group 08 Page 8-c

Install..............................................................................................................................................................8-76
Remove..........................................................................................................................................................8-76
Fan, Cooling ....................................................................................................................................................8-48
Install..............................................................................................................................................................8-49
Remove..........................................................................................................................................................8-48
Radiator ...........................................................................................................................................................8-49
Initial Check....................................................................................................................................................8-49
Radiator Hoses ................................................................................................................................................8-50
Radiator Pressure Cap ....................................................................................................................................8-50
....................................................................................................................................................................8-50
Radiator Shutter Assembly .............................................................................................................................8-51
Service Tools ....................................................................................................................................................8-1
Cooling System.................................................................................................................................................8-1
Water Inlet Connection ...................................................................................................................................8-74
Finishing Steps...............................................................................................................................................8-75
Install..............................................................................................................................................................8-75
Remove..........................................................................................................................................................8-75
Water Pump .....................................................................................................................................................8-51
Assemble........................................................................................................................................................8-60
Clean..............................................................................................................................................................8-55
Disassemble...................................................................................................................................................8-56
Finishing Steps...............................................................................................................................................8-67
Install..............................................................................................................................................................8-63
Measure..........................................................................................................................................................8-59
Remove..........................................................................................................................................................8-53
Water Pump Cartridge .....................................................................................................................................8-80
Finishing Steps...............................................................................................................................................8-81
Install..............................................................................................................................................................8-81
Remove..........................................................................................................................................................8-80
Page 8-d Section 8 - Cooling System - Group 08

Section 8 - Cooling System - Group 08 Page 8-1
Service Tools
Cooling System
Repair Location.

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.
Page 8-2 Section 8 - Cooling System - Group 08

Combustion Gas Leak Test Kit
Used to detect combustion gas leaks. Includes test fluid, Part
3822985 Number 3822986, adapter, Part Number 3822987, and instructions,
Part Number 3877612.
Thermocouple Extension Wire Kit

Used with fluke digital temperature measuring instrument kit.
3822988 Includes adapter, Part Number 3822989, thermocouple, Part Number
3822990, thermocouple wire assembly, Part Number 3822991, and
bushing (1/8 NPT), Part Number 3822992.
Cooling System Test Kit - Fleetguard

Used to measure supplemental coolant additive (SCA) concentration.
CC-2602
Refractometer
Used to measure glycol (antifreeze) concentration.
CC-2800
Signature, ISX, and QSX15 Eng [...] Drive Belt, Cooling Fan
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.

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
Pivot and hold the belt tensioner.
Install the drive belt and release the tensioner.
Drive Belt, Water Pump Signature, ISX, and QSX15 Eng [...]
Drive Belt, Water Pump (008-003)

Remove
CAUTION
The belt tensioner is spring-loaded and must be
tensioner.
Using a 1/2-inch square drive, lift the tensioner to relieve
tension in the belt and remove the belt.
Inspect for Reuse

Inspect the idler and the water pump pulley for cracks or
broken grooves. Replace if necessary.
Inspect and replace the belt for the following

characteristics:
Cracks
Glazing
Tears or cuts
Excessive wear.
Inspect the pulley alignment. Pulley misalignment must

not exceed 0.5 mm per cm [0.0625 in per ft] of distance
between the pulley centers.
Replace the water pump if the pulleys are not in
alignment. Refer to Procedure 008-062.
Signature, ISX, and QSX15 Eng [...] Coolant Filter
Install
CAUTION
The belt tensioner is spring-loaded and must be
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
Coolant Filter Signature, ISX, and QSX15 Eng [...]
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
Remove the cooling system pressure cap.
WARNING
Turn the coolant on/off valve to the OFF position.
Do not use force to open or close the on/off valve. If the
valve does not turn freely, refer to Procedure 008-082.
Remove and discard the coolant filter. Clean the gasket
surface on the filter head.
Install
CAUTION
Mechanical overtightening can distort the threads or
damage the filter head.
Apply a thin film of clean engine oil, or its equivalent, to
the coolant filter gasket sealing surface before installing
the coolant filter.
Tighten the coolant filter to of a turn after initial
gasket contact, or as specified by the manufacturer.
Turn the coolant on/off valve to the ON position.
Signature, ISX, and QSX15 Eng [...] Coolant Filter Valve
Install the radiator pressure cap.
WARNING
Operate the engine until the coolant temperature is above
82C [180F], and check for coolant leaks.
After the air has been purged from the system, check the
coolant level again.
Coolant Filter Valve (008-009)

Remove
Drain the coolant. Refer to Procedure 008-018.
Remove the coolant valve retaining capscrew and large

flat washer.
Coolant Filter Valve Signature, ISX, and QSX15 Eng [...]
Remove the coolant filter valve and o-ring.
Clean
WARNING
Use skin and eye protection when handling caustic
solutions to reduce the possibility of personal injury.
Clean the coolant filter valve and valve bore in the water
inlet connection with a filter brush and solvent.
Inspect for Reuse

Inspect the valve for corrosion or other damage. Replace
if necessary.
Install
Install a new o-ring onto the valve.
Install the valve into the water inlet connection.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat
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.
Turn the valve to the ON position.
Fill the cooling system. Refer to Procedure 008-018.

Operate engine and check for leaks.
Coolant Thermostat (008-013)

Leak Test
Signature, ISX, and QSX engines use two engine coolant
thermostats.
The engine thermostat and thermostat seal must operate
properly in order for the engine to operate in the most
efficient heat range. Overheating or overcooling will
shorten engine life.
Refer to Procedure 008-016 to inspect the thermostat seal.
Coolant Thermostat Signature, ISX, and QSX15 Eng [...]
WARNING
WARNING
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.
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
WARNING
Coolant is toxic. If not reused, dispose of in
Drain the cooling system. Refer to Procedure 008-018.
Remove
Remove the upper radiator hose from the thermostat
housing cover.
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.
Suspend the thermostat and a 100C [212F]

thermometer into a container of water. Do not allow the
thermostat or the thermometer to touch the sides of the
container.
Heat the water.
Record the temperatures at which the thermostat begins
to open and when it is fully open.
The nominal operating temperature is stamped on the

thermostat.
The thermostat must begin to open within 1C [2F]
of nominal temperature.
The thermostat must be fully open to at least 11 mm
[0.435 in] within 12C [22F] above nominal
temperature.
Replace the thermostat if it does not operate as
described.
Install
Install the two thermostats into the thermostat housing
cover by pushing on the outer rims.
Install the thermostat housing cover, gasket, and four

capscrews on the cylinder head.
Tighten the capscrews to the values shown.
Torque Value:
Short Capscrews 34 Nm [ 25 ft-lb ]
Long Capscrews 56 Nm [ 41 ft-lb ]
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.
Install the upper radiator hose. Tighten the hose clamp.

Finishing Steps
Operate the engine until the coolant temperature reaches
70C [160F]. Check for leaks.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat Housing
Coolant Thermostat Housing (008-014)

Preparatory Steps
WARNING
WARNING
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
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.
Remove the EGR cooler coolant return tube, if
Remove the refrigerant compressor. Refer to
Procedure 009-051.
Remove the refrigerant compressor mounting
bracket. Refer to Procedure 009-055.
Coolant Thermostat Housing Signature, ISX, and QSX15 Eng [...]
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.
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.
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.
Install the thermostat into the thermostat housing cover by

pushing on the outer rim.

capscrews.
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.
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.

capscrews on the cylinder head.
Torque Value:
Short capscrews 34 Nm [ 25 ft-lb ]
Long capscrews 56 Nm [ 41 ft-lb ]
Connect the vent line. Refer to the OEM instructions.

Connect the coolant sensor connector.
Install the upper radiator hose.

Tighten the hose clamp.
Industrial engines use a thermostat housing cover with

either a cover plate or a water connection.
Install the thermostat cover if removed.
Automotive has a similar design with connector for
transmission cooler.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat Seal
Finishing Steps
Install the refrigerant compressor mounting bracket.
Install the refrigerant compressor. Refer to
Procedure 009-051.
Install the EGR cooler coolant return tube, if
Install the EGR cooler connection tube, if required.
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.
Operate the engine until the coolant temperature
reaches 70C [158F] and check for leaks.
Coolant Thermostat Seal (008-016)

Remove
Single Seal
Remove the thermostat seal. Do not damage the
thermostat cover.
Coolant Thermostat Seal Signature, ISX, and QSX15 Eng [...]
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

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: When installing a new seal, the flat side of the seal
must be toward the mandrel for correct installation.
Use thermostat seal mandrel, Part Number 3164350, and
a lead hammer to install the seal.
A counterbore in the housing bore locates the seal.
Install the thermostat housing cover. Refer to Procedure
008-014.
Signature, ISX, and QSX15 Eng [...] Cooling System
Coolant Vent Lines (008-017)

Initial Check
The cooling system must be designed to allow air to
escape while filling the coolant system.
During engine operation, coolant will continuously flow

through the engine vent line to remove air from the
coolant.
Engine Vent Line

The cooling system vent line is plumbed from a special
connection located on the top of the thermostat cover. The
line then goes to the radiator fill tank or auxiliary tank
above the coolant level.
Cooling System (008-018)

Drain
Position the equipment on level ground.
Cooling System Signature, ISX, and QSX15 Eng [...]
WARNING
Remove the radiator cap after the engine has cooled down
ad adequately.
WARNING
Do not allow the cooling system to dry out.
If the coolant is to be reused, the holding container must
be free of oil and dirt. Before pouring coolant back into the
engine, it must be tested for SCA (Supplemental Coolant
Additive) concentration.
For automotive applications, use the Signature and ISX
Operation and Maintenance Manual, Bulletin 3666251.
For industrial applications, use the Industrial and Power
Generation QSX15 Engines Operation and Maintenance
Manual, Bulletin 3666423. Refer to Procedure 018-004 in
Section V.
Open the radiator draincocks.
Remove the lower radiator hose(s).
Do not remove the coolant filter.
Flush
CAUTION
Do not use caustic cleaners in the cooling system.
Aluminum components will be damaged.
The cooling system must be clean to work correctly and
to eliminate buildup of harmful chemicals.
Restore is a heavy-duty cooling system cleaner that

removes corrosion, silica gel, and other deposits. The
performance of Restore is dependent on time,
temperature, and concentration levels. An extremely
scaled or flow-restricted system, for example, can require
higher concentrations of cleaners, higher temperatures,
longer cleaning times, or the use of Restore Plus. Up to
twice the recommended concentration levels of Restore
can be used safely. Restore Plus must be used only at
its recommended concentration level. Extremely scaled or
fouled systems can require more than one cleaning.
CAUTION
Fleetguard Restore contains no antifreeze. Do not
allow the cooling system to freeze during the cleaning
operation.
After draining the coolant, immediately add 3.8 liters [1
gal] of Fleetguard Restore, Restore Plus, or
equivalent, for each 38 to 57 liters [10 to 15 gal] of cooling
system capacity, and fill the system with plain water.
Turn the cab heater temperature switch to high to allow
maximum coolant flow through the heater core. The
blower does not have to be on.
WARNING
WARNING
Operate the engine at normal operating temperatures, at
least 85C [185F], for one to one and a half hours.
Shut off the engine and drain the cooling system.
Fill the cooling system with clean water.

WARNING
WARNING
Operate the engine at high idle for 5 minutes with the
coolant temperature above 85C [185F].
Shut off the engine and drain the cooling system.
If the water being drained is still dirty, the system must be
repeatedly flushed until the water is clean.
CAUTION
To reduce the possibility of engine damage, do not
add coolant while the engine is hot.
Fill the cooling system with fully-formulated coolant or a
50/50 mixture of fully-formulated antifreeze and good-
quality water. Use a service filter to bring the coolant to
the correct SCA concentration level.
For automotive applications, use the Signature and ISX
Operation and Maintenance Manual, Bulletin 3666251.
For industrial applications use the Industrial and Power
Section V.
Fill
CM570
Close the radiator draincocks.
Install the lower radiator hose(s).
Tighten the hose clamps.
Cummins Inc. recommends the use of either a 50/50

mixture of good-quality water and fully-formulated
antifreeze, or fully-formulated coolant when filling the
cooling system. The fully-formulated antifreeze or coolant
must meet TMC RP329 or TMC RP330 specifications.
Good-quality water is important for cooling system
performance. Excessive levels of calcium and magnesium
contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Water Quality
Calcium Magnesium Maximum 170 ppm as (CaCO3 +
(Hardness) MgCO3)
Chloride 40 ppm as (CI)
Sulfate 100 ppm as (SO4)
Cummins Inc. recommends the use of Fleetguard ES

COMPLEAT. It is available in glycol forms (ethylene and
propylene) and complies with TMC RP329 and RP330
standards.
Fill the cooling system with heavy-duty coolant and install

the correct service filter.
Identify the correct filter. For automotive applications, use
the Signature and ISX Operation and Maintenance
Manual, Bulletin 3666251.Refer to Procedure 018-004 in
Section V.
Section V.
CAUTION
Opening the manual bleed valve or removing the pipe
plug on applicable installations is critical. Failure to
do so can result in engine damage.
NOTE: Some applications can have a manual bleed valve
or pipe plug that is required to be opened to properly fill
the system. The upper radiator pipe is a common location.
NOTE: Some applications can have a pipe plug installed
in place of the manual bleed valve.
If applicable, open the manual bleed valve or remove the
pipe plug before filling the cooling system.
Once filled, close the manual bleed valve or install the pipe
plug. For the torque specification, refer to the OEM service
manual.
NOTE: Some radiators have two fill locations, both of

which must be filled when the cooling system has been
drained.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.
Install the radiator or expansion tank fill cap.

Operate the engine until it reaches a temperature of 82
C [180F], and check for leaks.
Shut off the engine and allow it to cool.

WARNING
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50C [120F] before adding coolant.
Remove the radiator or fill cap and check the coolant level
according to the operator equipment manual
recommendations. Add coolant if necessary. Do not
overfill.

Close the radiator draincocks.
Install the lower radiator hose(s).
Cummins Inc. recommends the use of either a 50/50

mixture of good-quality water and fully-formulated
antifreeze, or fully-formulated coolant when filling the
cooling system. The fully-formulated antifreeze or coolant
must meet TMC RP329 or TMC RP330 specifications.
Good-quality water is important for cooling system
performance. Excessive levels of calcium and magnesium
contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Water Quality
Calcium Magnesium Maximum 170 ppm as (CaCO3 +
(Hardness) MgCO3)
Chloride 40 ppm as (CI)
Sulfate 100 ppm as (SO4)
Cummins Inc. recommends the use of Fleetguard ES

COMPLEAT. It is available in glycol forms (ethylene and
propylene) and complies with TMC RP329 and RP330
standards.
Fill the cooling system with heavy-duty coolant and install

the correct service filter.
Identify the correct filter. For automotive applications, use
the Signature and ISX Operation and Maintenance
Manual, Bulletin 3666251.Refer to Procedure 018-004 in
Section V.
Section V.
CAUTION
Opening the manual bleed valve or removing the pipe
plug on applicable installations is critical. Failure to
do so can result in engine damage.
NOTE: Some applications can have a manual bleed valve
or pipe plug that is required to be opened to properly fill
the system. The upper radiator pipe is a common location.
NOTE: Some applications can have a pipe plug installed
in place of the manual bleed valve.
If applicable, open the manual bleed valve or remove the
pipe plug before filling the cooling system.
Once filled, close the manual bleed valve or install the pipe
plug. For the torque specification, refer to the OEM service
manual.
NOTE: Some radiators have two fill locations, both of

which must be filled when the cooling system has been
drained.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.
Without installing the coolant pressure cap, operate the

engine until the thermostat opens.
CAUTION
Check the coolant level according to the operator
equipment manual recommendations. Add coolant, if
necessary. Do not overfill.
Pressure Test
Connect the air line in place of a vent line on the surge
tank.
Install an air regulator (2) between the ball valve (1) of the
air line and the surge tank connection.
Attach a hose to the radiator overflow connection (3).
Place the free end of the hose below the water level in a
container of water.
Cooling System - Air or Combustion Gas Test Signature, ISX, and QSX15 Eng [...]
CAUTION
Do not apply more than 140 kPa [20 psi] air pressure
to the cooling system. The water pump seal can be
damaged.
Pressurize the cooling system slowly to the rated radiator
cap pressure until bubbles can be seen in the overflow
bottle.
If the bubbles start at a lower pressure than the minimum

recommended cap pressure (See Cooling System
Specifications), inspect the radiator pressure cap. Refer
to Procedure 008-047 in Section 8. Replace the radiator
pressure cap, if necessary.
Cooling System - Air or Combustion

Gas Test (008-019)
Initial Check
Air in Cooling System
WARNING
Allow the engine to cool and remove the radiator cap.
Check the coolant level according to the operator's

equipment manual recommendations and fill, if
necessary.
Add heavy-duty coolant. Refer to Procedure 018-004
(Coolant Recommendations and Specifications) in
Section V, in the Signature and ISX Operation and
Maintenance Manual, Bulletin 3666251. Refer to Service
Bulletin 3810340 for a description of heavy-duty coolants.
Signature, ISX, and QSX15 Eng [...] Cooling System - Air or Combustion Gas Test
The pressure cap must be tightly sealed in the top of the

radiator fill neck.
Place the radiator cap back on and attach a rubber hose
to the radiator overflow connection.
Place the free end of the hose below the water level in a
container of water.
The engine coolant temperature must be stable to

perform this test. An increasing coolant temperature will
give a false indication of air due to expansion of the
coolant in the system.
Operate the engine at rated rpm until it reaches 82C
[180F].
Check for a continuous flow of air bubbles from the hose
into the water container.
A continuous flow of air bubbles can be caused by one of

the following:
An air compressor cylinder head leak. See the Leak
Test - Air Compressor in this procedure.
Fan, shutter, or heater air control thermostat valve
leaking air. See the Leak Test - Fan, Shutter, or
Heater Air Control Valve in this procedure.
A cracked cylinder head. Refer to Procedure
002-004 (Cylinder Head) in Section 2.
A cylinder head gasket combustion leak. See the
Combustion Gas Leak - Overflow Method in this
procedure.
If no air is found in the cooling system, do the following:

Remove the test equipment.
Operate the engine until it reaches 80C [180F],
and check for coolant leaks.
Leak Test
Fan, Shutter, or Heater Air Control Valve
CAUTION
The engine can overheat with the fan control or the
shutter air control valve disconnected. Monitor the
engine coolant temperature while performing this
test. The coolant temperature must not exceed 100
C [212F] or engine damage can occur.
Disconnect the vehicle air supply hose from the fan, the
shutter, and the heater air control valve.
Install a plug into the air supply hose.
If the vehicle is equipped with more than one air control
valve, check only one valve at a time.
Start the engine and run for five minutes before testing for
air in the coolant. This will allow any trapped air to purge
from the system.
Repeat the test for air in the cooling system, as previously
described.
If no air is found in the cooling system with the air control
valve(s) isolated, install a new control valve.
Air Compressor
CAUTION
The air compressor discharge line must be
disconnected at the compressor to allow the
compressor to discharge air to the atmosphere during
this next test to prevent the compressor from
overheating. Do not run the engine over 5 minutes
with components isolated from the cooling system.
Component damage can occur.
Disconnect the coolant supply and the return tubes from

the air compressor.
Use a short piece of hose to connect the tubes together to
prevent coolant loss during engine operation.
Drain the air tanks completely to reduce the possibility of

air entering the cooling system through the cab heater
control valve.
Repeat the test for air in the cooling system as previously

described in this procedure.
If no air is found in the cooling system with the air
compressor isolated, repair or replace the air compressor.
Combustion Gas Leak

Use combustion gas tester, Part Number 3822985 or its
equivalent, to test for combustion gases in the cooling
system.
A 50 percent antifreeze and 50 percent water mixture
must be used in the cooling system when performing the
combustion gas leak test.
WARNING
NOTE: Coolant that gets into the combustion analyzer will
stop the color change and render the test ineffective.
Drain the coolant level down approximately 75 mm [3 in]
below the radiator cap seal ledge in the radiator fill neck.
Pour the test fluid into the combustion gas leak test
instrument until it is up to the yellow fill line on the
instrument.
Insert the rubber tip of the combustion gas leak test

instrument into the radiator fill neck. Hold the instrument
down firmly and turn back and forth to make sure that an
airtight seal is formed between the tester and the radiator
fill neck.
Start the engine and run at high idle for approximately 30

minutes. Monitor the engine temperature and color of the
test fluid during engine operation. Do not allow the engine
temperature to exceed 100C [212F] during the test.
A flow of bubbles will occur as the engine warms up and
coolant expands.
Bubbles in the combustion analyzer is not a sign of a
combustion leak.
If the color of the test fluid changes from blue to green or

yellow any time during the test, combustion gases are
leaking into the cooling system. Discontinue the test if the
color of test fluid changes from blue to green or yellow.
If the color of the test fluid does not change from blue to
green or yellow during the 30-minute test period, return
the engine to low idle.
Check the test instrument to make sure it is firmly sealed

in the radiator fill neck.
Insert the tip of the rubber ball into the hole in the top of
the test instrument. Squeeze the rubber ball 2 to 3 minutes
to draw air from the radiator through the test fluid.
If the color of the test fluid remains blue, combustion
gases are not entering the cooling system. If the color of
the test fluid changes from blue to green or yellow,
combustion gases are entering the cooling system and
further investigation is required to determine the source of
the combustion leak.
As the cooling system warms up to operating temperature,

air will be expelled through the combustion gas tester in
the form of bubbles in the test fluid. This is due to normal
expansion of the coolant. Do not mistake the presence of
air bubbles in the tester as combustion gases or air leaks
into the cooling system. A change in the color of the test
fluid from blue to green or yellow is the only indication of
combustion gas in the cooling system.
A positive result from the combustion gas leak tester

indicates the following:
Injector sleeve leakage. Be sure that the injector
hold-down torque is correct. Refer to Procedure
006-026 (Injector) in Section 6.
Cylinder liner protrusion not correct. Refer to
Procedure 001-028 (Cylinder Liner) in Section 1.
Cylinder head gasket or cylinder head casting
leakage. Refer to Procedure 002-004 (Cylinder
Head) in Section 2.
Cracked cylinder liner. Refer to Procedure 001-028
(Cylinder Liner) in Section 1.
NOTE: Discard the tester fluid if it has indicated positive.
A negative result from the combustion gas leak tester,

coupled with a continuous flow of air bubbles from the
previous test, indicates the following:
Defective fan, shutter, or heater air control valve.
Air compressor head or head gasket leakage.
Air entrained due to a bad radiator check valve or
incorrect fill.
Overflow Method
WARNING
Allow the engine to cool and remove the radiator cap.
Signature, ISX, and QSX15 Eng [...] Fan Clutch, On-Off
Install a radiator pressure cap that has had the spring and
the pressure relief valve removed to allow free flow from
the overflow tube.
The pressure cap must be tightly sealed in the top of the
radiator fill neck.
Attach a rubber hose to the radiator overflow connection.
Put the free end of the hose below the water level in a
container of water.
The engine coolant temperature must be stable to

perform this test. An increasing coolant temperature will
give a false indication of air due to expansion of the
coolant in the system.
Operate the engine at rated rpm until it reaches a
temperature of 82C [180F].
Check for a continuous flow of air bubbles from the hose
in the water container.
Fan Clutch, On-Off (008-027)

Initial Check
With Low Temperature Fan-On Control
CAUTION
If the fan clutch logic is not set correctly, the ECM will
not be able to engage the fan for engine cooling and
engine protection. The engine can overheat and
damage is possible.
The fan clutches can be controlled by the ECM. The ECM
can be programmed for either 12 volts, fan ON or 12 volts,
fan OFF. Check the ECM program using INSITE.
Restrict the air flow to the radiator.

Operate the engine at rated rpm.
Fan Clutch, On-Off Signature, ISX, and QSX15 Eng [...]
If the vehicle is air conditioned, make sure the air

conditioning is turned off to prevent continuous operation
of the fan. When the coolant temperature reaches 99C
[210F], check for fan engagement.
NOTE: The temperature given for fan engagement is for
fans controlled by the ECM.
NOTE: Fan noise and airflow will increase when the fan
clutch engages.
Return the engine to idle and remove the radiator air flow
restriction.
The fan clutch must disengage when the coolant

temperature drops to 96C [205F].
NOTE: The temperature given for fan disengagement is
for fans controlled by the ECM.
With High Temperature Fan On

On Signature, ISX, and QSX engines, the fan clutches can
be controlled by the ECM. The ECM is programmed to turn
the fan clutch on and off.
Signature, ISX, and QSX15 Eng [...] Fan Clutch, On-Off
Restrict the radiator airflow.

Operate the engine at rated rpm.
If the vehicle is air conditioned, make sure the air

conditioning is turned off to prevent continuous operation
of the fan. When the coolant temperature reaches 110C
[215F], check for fan engagement.
NOTE: The temperature given for fan engagement is for
fans controlled by the ECM.
NOTE: Fan noise and airflow will increase when the fan
clutch engages.
Return the engine to idle and remove the radiator air

restriction.
The fan clutch must disengage before the coolant

temperature drops to 93C [200F]. Cummins Inc.
recommends that the fan disengage at 3C [6F] below
the temperature stamped on the temperature sensor.
NOTE: The temperature given for fan disengagement is
for fans controlled by the ECM.
Fan Drive Idler Pulley Assembly Signature, ISX, and QSX15 Eng [...]
Fan Drive Idler Pulley Assembly

(008-030)
Preparatory Steps
Remove the fan drive belt. Refer to Procedure
Remove
On initial installation, remove the three capscrews
indicated in the illustration from the lower front cover.
Install
Install the bracket on the engine with the three spacers
and three capscrews.
Torque Value:
Fan drive idler 18 Nm [ 159 in-lb ]
pulley bracket
capscrew
M8x60mm
Mount the fan drive idler pulley assembly to the fan drive
idler pulley bracket and tighten the capscrew. Make sure
the washer is centered on the idler pulley.
Torque Value:
Fan drive idler 54 Nm [ 40 ft-lb ]
pulley assembly
capscrew
M10x80mm
Install the dust shield by pressing on the outside diameter
of the shield to prevent damage to the dust shield.
Use an appropriate size driver or other suitable tool.
Signature, ISX, and QSX15 Eng [...] Fan Hub, Belt Driven
Finishing Steps
Install the drive belt. Refer to Procedure 008-002 in
Section 8.
Fan Hub, Belt Driven (008-036)

Preparatory Steps
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).

008-040.
Remove the water pump belt. Refer to Procedure
008-003.
Remove the alternator belt Refer to Procedure
013-005.
Industrial CM570 and Power Generation without

CM570
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
Fan Hub, Belt Driven Signature, ISX, and QSX15 Eng [...]
Remove
WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Remove the mounting capscrews and the fan hub
assembly.
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.

CM570
Remove the fan hub mounting capscrews.
Remove the fan hub from the fan support.

Inspect the fan hub for the following:
Freedom of rotation
Cracks
Grease seal leakage.
Repair or replace the fan hub if the fan hub does not rotate
freely or if there is evidence of cracks or grease seal
leakage.
Refer to the OEM service literature for repair of the fan
hub.
Signature, ISX, and QSX15 Eng [...] Fan Hub, Belt Driven
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
Refer to OEM service manual for additional inspection
steps.

Inspect the fan hub for the following:
Freedom of rotation
Cracks
Grease seal leakage.
Repair or replace the fan hub if the fan hub does not rotate
freely or if there is evidence of cracks or grease seal
leakage.
Measure the fan hub end clearance. The end clearance is

dependent upon the fan hub style.
Replace the fan hub if the end clearance is not within
specifications.
Fan Hub End Clearance

mm in
0.08 MIN 0.003
0.25 MAX 0.009
Install
WARNING
Install the fan hub assembly and the capscrews.
Fan Hub, Belt Driven Signature, ISX, and QSX15 Eng [...]
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.
Install the belt tensioner bracket.

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.
Finishing Steps
Install the automatic belt tensioner (water pump).
Install the cooling fan drive belt. Refer to Procedure
008-002.
Install the cooling fan. Refer to Procedure 008-040.
Signature, ISX, and QSX15 Eng [...] Fan Shroud Assembly

Install the alternator belt. Refer to Procedure
013-005.
Install the water pump belt. Refer to Procedure
008-003.

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.
Fan Shroud Assembly (008-038)

Initial Check
CAUTION
The fan shroud must be installed correctly and be in
good condition. The shroud-to-fan clearance must be
within the manufacturer's specifications to maintain
proper air flow through the radiator to provide
adequate engine cooling, or engine damage can
occur.
Inspect the fan shroud for proper fan clearance, cracks,
air leaks, or damage. Replace if necessary. Refer to the
manufacturer's instructions.
Cummins Inc. recommends fan clearance be 5.08 to 10.16

cm [2 to 4 in] from the radiator core. Refer to the
equipment manufacturer for alternative positions.
Fan, Cooling Signature, ISX, and QSX15 Eng [...]
Fan, Cooling (008-040)

Remove
WARNING
Disconnect the batteries or air supply line to the air
starter to prevent accidental engine starting and
personal injury.
CAUTION
Do not pry or pull on the fan. The fan blades can be
damaged.
Remove the fan.
Inspect for Reuse
WARNING
Do not straighten a bent fan blade or continue to use
a damaged fan. A bent or damaged fan blade can fail
during operation and cause personal injury or
property damage.
Replace the original equipment fan with a fan of the

identical part number. Cummins Inc. must approve any
other fan changes.
An inspection of the cooling fan is required daily.

Check for cracks, loose rivets, bent or loose blades, and
for contact between the fan blade tips and the fan shroud.
Check the fan to make sure it is securely mounted.
Tighten the capscrews, if necessary. Refer to the vehicle
manufacturer's specifications for fan capscrew torque
value.
Replace any fan that is damaged.
Signature, ISX, and QSX15 Eng [...] Radiator
Install
NOTE: Replace the original equipment fan with a fan of
the identical part number. Cummins Inc. must approve
any fan changes.
Install the fan.

Tighten the mounting capscrews. Refer to OEM
specifications.
Connect the batteries or air starter supply line.
Radiator (008-042)
Initial Check
Inspect the radiator for plugged radiator fins.
Use 550-kPa [80-psi] air pressure to blow the dirt and
debris from the fins. Blow the air in the opposite direction
of the fan airflow.
Inspect the CAC and the clearance between the CAC and
the radiator for trapped debris. Remove the CAC if
necessary.
Remove any debris found.
Inspect the radiator for bent or broken fins.

NOTE: The radiator must be replaced due to bent or
broken fins that can cause the engine to overheat. Refer
to the manufacturer's replacement procedures.
Inspect the radiator for core and gasket leaks.
Radiator Pressure Cap Signature, ISX, and QSX15 Eng [...]
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
Remove the radiator pressure cap.
Inspect the rubber inner seal and the brass outer seal of
the pressure cap for damage.
Inspect the radiator or expansion tank fill neck for cracks
or other damage.
Refer to the radiator manufacturer's or vehicle
manufacturer's instructions if the fill neck is damaged.
Make sure the correct pressure cap is used. Refer to the
Cooling System Specifications.
Signature, ISX, and QSX15 Eng [...] Water Pump
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
Be sure the shutters open completely at the desired
temperature setting.
NOTE: If the shutters are closed, refer to the
Water Pump (008-062)

Preparatory Steps
WARNING
WARNING
008-018.
Remove the water pump drive belt and tensioner.
Remove the refrigerant compressor drive belt. Refer
Water Pump Signature, ISX, and QSX15 Eng [...]
WARNING
WARNING
008-018.
Remove the water pump and fan drive belt. Refer to
Procedure 008-003.
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.

CM570
WARNING
WARNING
Coolant is toxic. Keep children and pets away. If the
coolant is not going to be reused, dispose of it in
008-018.
Remove the cooling fan and water pump belt. Refer
013-005.
If required, remove the damper assembly. Refer to
Procedure 001-052.
WARNING
WARNING
008-018.
Remove the water pump cartridge. Refer to
Procedure 008-102.
Remove
Remove two water pump mounting capscrews and install
two guide studs.
Remove the remaining three capscrews, the water pump,

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

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.

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.

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.
WARNING
WARNING
personal injury.
Clean the water pump components with solvent and dry
with compressed air.
Inspect the water pump housing for cracks and damage.

Inspect the water pump inlet tube for out of roundness,
damage, or leaks.
If the water pump housing is damaged, it must be
replaced.
Continuous pitting deeper than 0.635 mm [0.025 in] or
individual pits deeper than 2.54 mm [0.100 inch] are not
acceptable.
Replace the water pump housing if not within
specifications.
Disassemble
WARNING
The retaining clip contains extreme amounts of
potential energy. To reduce the possibility of personal
injury from the clip slipping, place the water pump in
a box prior to removing the retaining clip.
Place the water pump in a box.
Remove the retaining clip securing the impeller cover.
Remove and discard the water pump outlet o-ring.
Use a heel bar to remove the impeller cover from the

pump.
Discard the o-ring.
Support the water pump housing pulley in a press with the

pulley facing up.
Press the pulley off of the water pump and shaft assembly.
Position the water pump with the pulley end facing up.
Remove the bearing bore retaining clip.
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).
WARNING
WARNING
personal injury.
Clean the water pump components with solvent and dry
Inspect the water pump housing for cracks and damage.

If the water pump housing is damaged, it must be
replaced.
Inspect the cast iron impeller for cracks, pitting and other
damage.
Continuous pitting deeper than 0.635 mm [0.025 in] or
individual pits deeper than 2.54 mm [0.100 in] are not
acceptable.
Replace the impeller if damaged or if pits are not within
specifications.
The water pump bearings are sealed bearings.

Spin the bearings to check for roughness.
Inspect the bearings for signs of grease purge.
If the bearing seals show signs of grease purge or the
bearing does not spin smoothly, it must be replaced.
Inspect the impeller cover for cracks and other damage.

Scratching on the inside face is acceptable.
If there is any damage to the outer o-ring area, the impeller
cover must be replaced.
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
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
Measure the outside diameter of the water pump shaft.
Water Pump Shaft Diameter

mm in
Small End 25.015 MIN 0.9848
25.002 MAX 0.9843
Large End 29.015 MIN 1.1423
29.002 MAX 1.1418
Measure the outside diameter of the larger end of the
shaft.
If the shaft is not within specifications, it must be
replaced.
Measure the inside diameter of the pulley bore.
Pulley Bore Inside Diameter

mm in
28.936 MIN 1.139
29.964 MAX 1.140
If the pulley bore is not within specifications, the pulley
must be replaced.
Assemble
CAUTION
The mandrel must make contact on the inner race of
the bearing to prevent damage to the bearing.
Support the shaft in an arbor press.
Use an arbor press with water pump mandrel, Part
Number ST-658 (4), or equivalent to install the bearings.
Install the retaining clip with the beveled side of the clip
facing away from the bearing.
Support the water pump housing on a table with the pulley

end facing up.
Install the shaft and bearing assembly into the bearing
bore with the smaller bearing end of the assembly entering
first.
If the shaft does not drop into position from its weight, the
assembly can be pressed into place.
Install the retaining clip with the beveled side of the clip
facing away from the bearing.
CAUTION
To reduce the possibility of damage to the water pump
housing, make sure the impeller end of the shaft is
supported before pressing on the pulley.
Support the impeller end of the shaft in a press.
Press on the pulley until it is flush with the end of the shaft.
Make sure the pulley rotates freely.
Press the water pump seal onto the shaft.

Measure the water pump seal installed height.
Water Pump Seal Installed Height

mm in
10.919 MIN 0.430
11.679 MAX 0.460
If the water pump seal installed height is not within
specifications, the seal must be removed and installed
again.
Support the water pump in a press with the pulley down.

Press the impeller, vane side up, onto the shaft until it is
flush with the end of the shaft.
CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.
CAUTION
Make sure the o-ring is seated properly. If the o-ring
is not seated properly it can be damaged during
impeller cover installation.
Lubricate the impeller cover o-ring with soapy water.
Install the cover o-ring into the water pump housing.
CAUTION
Do not use petroleum lubricant on the impeller cover,
o-ring damage can result from the use of petroleum
lubricant.
Lubricate the outside diameter of the impeller cover and
the o-ring bore with soapy water.
Support the water pump in a press.
Press the impeller cover into the bore until seated.
WARNING
The retaining clip contains extreme amounts of
potential energy. To reduce the possibility of personal
injury from the clip slipping, place the water pump in
a box prior to installing the retaining clip.
Place the water pump in a box.
Install the retaining clip.
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
CAUTION
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.

Install a new o-ring seal in the water inlet.
CAUTION
Install a new o-ring seal in the water pump outlet groove.
Apply a thin layer of non-petroleum-based lubricant, such
as vegetable oil, to both o-ring seals.
Use clean engine oil to lubricate the threads and bottom

of the capscrew heads of all the water pump capscrews.
Install the water pump and two lower capscrews.
Tighten the capscrews to hold the pump in place.
NOTE: Some configurations do not use the middle

aluminum belt tensioner bracket shown. Refer to
Procedure 008-088 for the appropriate tensioner bracket
installation.
Install the belt tensioner bracket, if equipped, and
capscrews in the location shown.
Finger tighten all capscrews.
Tighten the water pump mounting capscrews in the

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

CM570
Install a new o-ring seal in the water inlet.
CAUTION
Install a new o-ring seal in the water pump outlet groove.
Apply a thin layer of non-petroleum-based lubricant, such
as vegetable oil, to both o-ring seals.
Use clean engine oil to lubricate the threads and bottom

of the capscrew heads of all the water pump capscrews.
Position the water pump on the engine.
Install the bottom two capscrews finger tight.
NOTE: Some configurations do not use the middle

aluminum belt tensioner bracket. Refer to Procedure
008-088 for the appropriate tensioner bracket installation.
NOTE: Early engines that did not have a slotted hole on
the middle aluminum belt tensioner idler bracket required
the vibration dampers to be removed to remove and install
the water pump.
Install the belt tensioner bracket, if equipped, and the
capscrews in the locations shown.
Finger tighten all capscrews.
Tighten the water pump mounting capscrews in the

sequence and values shown.
Torque Value:
Capscrews 1, 2, 58 Nm [ 43 ft-lb ]
and 3
Capscrews 4 and 72 Nm [ 53 ft-lb ]
5
All Capscrews, 72 Nm [ 53 ft-lb ]
Engines Without
Belt Tensioner
Bracket
Align the idler pulley (1) and the shaft of the pilot adapter
(2) with the belt tensioner bracket (3) using the guide pin
on the pilot adapter (4), if equipped.
Install the belt idler pulley and shaft on the belt idler
bracket using one washer and capscrew.
Install the dust seal.
CAUTION
Do not use petroleum based lubricants, petroleum
based lubricants cause the o-ring to crack or swell,
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.
Install the two bracket capscrews.
Install the EGR tube outlet capscrew.
Finishing Steps
Install the water pump drive belt and tensioner. Refer
Install the refrigerant compressor drive belt. Refer to
Procedure 009-052.

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.
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.

CM570
Install the damper assembly, if removed. Refer to
Procedure 001-052.
013-005.
Install the fan and water pump drive belt. Refer to
procedure 008-003.
Procedure 008-018.

Install the water pump cartridge. Refer to Procedure
008-102.
Procedure 009-052.
Belt Tensioner, Automatic (Water Pump) Signature, ISX, and QSX15 Eng [...]
Belt Tensioner, Automatic (Water

Pump) (008-080)
Initial Check
All Applications
With the engine turned off and with the water pump/fan
belt installed, check that neither the top nor bottom
tensioner arm stop is touching the cast boss on the
tensioner body. If either of the stops is touching a boss,
the water pump/fan belt must be replaced. Check to make
sure the correct belt part number is being used if either
condition exists.
Check the tensioner pulley and body for cracks. If any

cracks are noticed, the tensioner must be replaced.
Using a inch square drive, lift belt tensioner to relieve

tension on the belt.
Remove the water pump/fan belt.
The belt tensioner is spring-loaded and must be pivoted
away from the drive belt. Pivoting in the wrong direction
can result in damage to the belt tensioner.
If the tensioner pulley touches the accessory drive pulley
after the tensioner has been fully relaxed, the bottom
tensioner arm stop boss has broken and the tensioner
must be replaced.
Make sure the bottom tensioner arm stop is in contact with

the bottom tensioner arm stop boss on the tensioner body.
If these two are not contacting, the tensioner must be
replaced.
Signature, ISX, and QSX15 Eng [...] Belt Tensioner, Automatic (Water Pump)
Preparatory Steps
Drives Alternator
CAUTION
tensioner or personal injury.
Remove the cooling fan belt. Refer to Procedure
008-002.
Remove
Drives Alternator
Remove the mounting capscrew and the belt tensioner
from the bracket.
Automotive Applications
NOTE: Different engine configurations utilize different belt
tensioner bracket and belt tensioner arrangements.
For the low-mount belt tensioner:
Remove the belt tensioner mounting capscrew and belt
tensioner from the bracket.
Remove the belt tensioner bracket from the water pump.
For the mid-mount belt tensioner:

Remove the belt tensioner mounting capscrew and the
belt tensioner from the bracket.
The mid-mount aluminum belt tensioner/idler bracket is
part of the water pump removal and installation because
of common capscrew usage. Refer to Procedure 008-062.
Industrial and Power Generation

For the low-mount (small version) belt tensioner:
Remove the belt tensioner bracket from the front engine

support.
For the low-mount (large version) belt tensioner:

Remove the belt tensioner bracket from the front engine

support.

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
Check the tensioner for dirt buildup. If the tensioner has
dirt buildup, remove and clean with safety solvent.
Pivot the tensioner through the full range of motion.

Tensioner must move with resistance while pivoting the
tensioner down. If not, replace the tensioner.
Check and make sure the correct belt part number is being
used.
Check the belt tensioner pulley and body for cracks or

damage. If any are found, replace the tensioner.
Inspect the tensioner arm stop bosses, for cracks or
damage. If cracks or damage is found, replace the
tensioner.
Spin the tensioner pulley. If pulley does not spin freely,

replace the tensioner.
CM570
WARNING
Check the tensioner for dirt buildup. If this condition
exists, the tensioner must be removed and steam-
cleaned.
Inspect the tensioner for evidence of the pivoting

tensioner arm contacting the stationary circular base. If
there is evidence of these two areas contacting, the pivot
tube bushing has failed and the tensioner must be
replaced.
Install
Drives Alternator
Install the belt tensioner and mounting capscrew.
For the low-mount belt tensioner:
Install the belt tensioner bracket to the water pump.
Tighten capscrew.
Install the belt tensioner and capscrew.
For the mid-mount belt tensioner:

Install the belt tensioner mounting capscrew and the belt
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.

For the low-mount (small tensioner):
Install the belt tensioner bracket to the front engine
support with three mounting capscrews.
Install the belt tensioner.

For the low-mount (large tensioner):

Install the belt tensioner bracket to the front engine
support with three mounting capscrews.
Water Inlet Connection Signature, ISX, and QSX15 Eng [...]
Install the belt tensioner.

Finishing Steps
Drives Alternator
CAUTION
tensioner or personal injury.
Install the drive belt. Refer to Procedure 008-002.
Water Inlet Connection (008-082)

Preparatory Steps
WARNING
WARNING
008-018.
Remove the coolant filter. Refer to Procedure
008-006.
Remove the water pump. Refer to Procedure
008-062.
Signature, ISX, and QSX15 Eng [...] Fan Support
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.
Install the coolant hoses.
Finishing Steps
Install the water pump. Refer to Procedure 008-062.
Install the coolant filter. Refer to Procedure 008-006.
Procedure 008-018.
Fan Support (008-088)

Preparatory Steps
Remove the fan and water pump drive belt. Refer to
Procedure 008-003.
013-005.
Remove the alternator belt tensioner bracket. Refer
Remove the fan pulley. Refer to Procedure 008-089.
Fan Support Signature, ISX, and QSX15 Eng [...]
Remove
Remove the belt tensioner support bracket from the fan
support.
Remove two capscrews and install two guide studs.

Remove the remaining six capscrews.
Remove the fan support and guide studs.
Install
Install two guide studs into the upper gear cover.
Signature, ISX, and QSX15 Eng [...] Fan Support
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.
Install the belt tensioner support bracket to the engine and

fan support.
Tighten all eight capscrews finger tight.
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.

Fan Pulley Signature, ISX, and QSX15 Eng [...]
Tighten capscrew numbers 1, 2, 7, and 8.

Finishing Steps
Install the fan pulley. Refer to Procedure 008-089.
Install the alternator belt tensioner bracket. Refer to
Procedure 013-040.
013-005.
Procedure 008-003.
Fan Pulley (008-089)

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

013-005.
Signature, ISX, and QSX15 Eng [...] Fan Pulley
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.
Install
Install the fan pulley using six capscrews.
Tighten the capscrews in a star pattern.

013-005.
Water Pump Cartridge Signature, ISX, and QSX15 Eng [...]

Procedure 008-003.
Water Pump Cartridge (008-102)

Preparatory Steps
WARNING
WARNING
008-018.
Remove
Remove the four water pump cartridge mounting
capscrews.
Remove the water pump cartridge and o-ring.
Discard the o-ring.
Signature, ISX, and QSX15 Eng [...] Water Pump Cartridge

Clean the water pump cartridge.
Inspect the water pump cartridge for cracks.
Inspect the water pump weep hole for indication of leaks.
Stains around the weep hole are normal and will be
expected and is not considered a warrantable failure. A
warrantable water pump failure is defined as stains
around the weep hole which form a drip or accumulation
of liquid.
Inspect the cast iron impeller for cracks, pitting and other
damage.
If the indication of a steady flow of coolant is observed,
replace the water pump cartridge with a new or rebuilt unit.
Install
CAUTION
Do not use petroleum based lubricant. Petroleum
based lubricants will cause the o-ring to crack or
swell, leading to a coolant leak.
Install the new o-ring seal on the cartridge.
Install the cartridge in the water pump housing.
Install the four water pump cartridge capscrews
Finishing Steps
Procedure 009-052.
Water Pump Cartridge Signature, ISX, and QSX15 Eng [...]
Notes
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
Install..............................................................................................................................................................9-15
Remove.......................................................................................................................................................... 9-13
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
Install................................................................................................................................................................9-6
Remove............................................................................................................................................................9-6
Drive Belt, Refrigerant Compressor .................................................................................................................9-3
Finishing Steps.................................................................................................................................................9-4
Install................................................................................................................................................................9-4
Remove............................................................................................................................................................9-3
Idler Pulley, Refrigerant Compressor ...............................................................................................................9-7
Finishing Steps.................................................................................................................................................9-8
Install................................................................................................................................................................9-7
Remove............................................................................................................................................................9-7
Refrigerant Compressor ....................................................................................................................................9-1
Climate Control Incorporated..........................................................................................................................9-2
Finishing Steps.................................................................................................................................................9-3
Install................................................................................................................................................................9-2
Sanden..........................................................................................................................................................9-2
Page 9-b Section 9 - Drive Units - Group 09

Remove............................................................................................................................................................9-1
Sanden..........................................................................................................................................................9-1
Refrigerant Compressor Mounting Bracket ......................................................................................................9-8
Finishing Steps...............................................................................................................................................9-12
Install..............................................................................................................................................................9-11
Sanden........................................................................................................................................................9-11
Climate Control Incorporated........................................................................................................................9-11
Remove............................................................................................................................................................9-9
Sanden..........................................................................................................................................................9-9
Signature, ISX, and QSX15 Eng [...] 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.
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 Eng [...]
Page 9-2 Section 9 - Drive Units - Group 09

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.

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.

Install the four mounting capscrews through the
refrigerant compressor to the alternator/refrigerant
compressor mounting bracket. Make sure the roll pins
align properly.
Signature, ISX, and QSX15 Eng [...] Drive Belt, Refrigerant Compressor
Finishing Steps
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
Routing
Procedure 008-002.
Remove
Routing
CAUTION
Pivot the automatic tensioner counterclockwise to
relieve tension on the belt.
Remove the belt.

Routing
Inspect the refrigerant compressor pulley for cracks or
broken grooves. Replace compressor if damaged.
Drive Belt, Refrigerant Compressor Signature, ISX, and QSX15 Eng [...]
Inspect belt for cracks, glazing, tears or cuts, and

excessive wear. Replace belt, if necessary.
Install
Routing
CAUTION
Pivot counterclockwise and hold the belt tensioner.
Install the drive belt and relieve the tensioner.
Finishing Steps
Routing
008-002.
Signature, ISX, and QSX15 Eng [...] Belt Tensioner, Refrigerant Compressor, Automatic
Belt Tensioner, Refrigerant

Compressor, Automatic (009-053)
Initial Check
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 Eng [...]
Preparatory Steps
Routing
Remove the fan drive belt. Refer to Procedure
008-002.
Remove the refrigerant compressor belt. Refer to
Procedure 009-052.
Remove
Routing
Remove the mounting capscrew and the refrigerant
compressor belt tensioner from the bracket.
Install
Routing
Install the refrigerant compressor belt tensioner.
Install and tighten capscrew.
Finishing Steps
Routing
Procedure 009-052.
Signature, ISX, and QSX15 Eng [...] Idler Pulley, Refrigerant Compressor
Idler Pulley, Refrigerant Compressor

(009-054)
Preparatory Steps
Routing
Procedure 008-002.
Procedure 009-051.
Remove
Routing
Remove the pulley mounting capscrew.
Remove the refrigerant compressor idler pulley.
Inspect for Reuse

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
Routing
Install the refrigerant compressor idler pulley and the
mounting capscrew.
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 Eng [...]
Finishing Steps
Routing
Procedure 009-051.
008-002.
Refrigerant Compressor Mounting

Bracket (009-055)
Preparatory Steps
WARNING
Procedure 008-002.
Procedure 009-052.
Procedure 009-051.

WARNING
Remove the refrigerant compressor and alternator
belt. Refer to Procedure 013-005.
Procedure 009-051.
Signature, ISX, and QSX15 Eng [...] Refrigerant Compressor Mounting Bracket
Remove
Sanden
Remove the mounting capscrew from each refrigerant
compressor bracket.
Remove the refrigerant compressor brackets.

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

Remove the two bracket mounting capscrews and the
bracket.
Remove the support links from the bracket.

WARNING
for use. Wear goggles and protect clothing to reduce
the possibility of personal injury.
WARNING
personal injury.
Clean the refrigerant compressor mounting brackets with
solvents.
Inspect the refrigerant compressor mounting brackets.
Replace the refrigerant compressor mounting brackets if
cracked or damaged.
have any damage. Replace the refrigerant compressor
mounting brackets, if the roll pins are loose or damaged.

WARNING
WARNING
personal injury.
Clean the bracket, links, and mounting capscrews with
solvent.
Dry the parts with compressed air.
Signature, ISX, and QSX15 Eng [...] Refrigerant Compressor Mounting Bracket
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.

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.

Before installation, inspect the refrigerant compressor
bracket to make sure the mounting spacers are installed
properly.
Install the refrigerant compressor bracket on the gear

housing with two long capscrews.
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
Procedure 009-051.
Procedure 009-052.

Procedure 009-051.
Install the refrigerant compressor and alternator belt.
Signature, ISX, and QSX15 Eng [...] Alternator/Refrigerant Compressor Mounting Bracket
Alternator/Refrigerant Compressor
Mounting Bracket (009-056)
Preparatory Steps
Remove the turbocharger control valve. Refer to
013-005.
Remove the alternator spacers. Refer to Procedure
013-036.
Procedure 009-051.
Remove the refrigerant compressor mounting
bracket. Refer to Procedure 009-055.
Remove the refrigerant compressor belt tensioner.
Remove the refrigerant idler pulley. Refer to
Procedure 009-054.
Remove the water pump belt tensioner. Refer to
Procedure 008-080.

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
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/
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/
Alternator/Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Eng [...]

Remove the six mounting capscrews from the alternator/
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

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.

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 Eng [...] Alternator/Refrigerant Compressor Mounting Bracket
Install
Install the wire harness jumper to the alternator/refrigerant
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 Nm [ 27 ft-lb ]
(5) 56 Nm [ 41 ft-lb ]

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.
Tighten the short capscrew (1).

Tighten the remaining capscrews (2, 3, 4, and 5).
Torque Value:
(1, 2, 3, 4, and 5) 34 Nm [ 25 ft-lb ]
Alternator/Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Eng [...]
Finishing Steps
Install the water pump belt tensioner. Refer to
Procedure 008-080.
Install the refrigerant compressor idler pulley. Refer
Install the refrigerant compressor belt tensioner
Install the refrigerant compressor mounting bracket.
Procedure 009-051.
Procedure 009-052.
Install the alternator spacers. Refer to Procedure
013-036.
013-005.
Install the turbocharger control valve. Refer to

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.
Section 10 - Air Intake System - Group 10 Page 10-a
Section 10 - Air Intake System - Group 10

Section Contents
Page
Air Intake Connection ....................................................................................................................................10-59
Clean and Inspect for Reuse......................................................................................................................... 10-61
All Applications...........................................................................................................................................10-61
Finishing Steps............................................................................................................................................. 10-62
Automotive, Industrial with CM570 and Power Generation without CM570.................................................. 10-62
Automotive with CM870..............................................................................................................................10-63
Automotive With CM871.............................................................................................................................10-63
Install............................................................................................................................................................10-61
Preparatory Steps......................................................................................................................................... 10-59
Remove.........................................................................................................................................................10-60
Air Intake Restriction .................................................................................................................................... 10-14
Measure........................................................................................................................................................10-14
Air Leaks, Air Intake and Exhaust Systems ...................................................................................................10-3
Initial Check....................................................................................................................................................10-3
Charge-Air Cooler ............................................................................................................................................10-9
Clean..............................................................................................................................................................10-9
Leak Test......................................................................................................................................................10-10
Pressure Differential Test..............................................................................................................................10-12
Temperature Differential Test........................................................................................................................10-11
Intake Manifold Pressure .............................................................................................................................. 10-58
Measure........................................................................................................................................................10-58
Service Tools ...................................................................................................................................................10-1
.......................................................................................................................................................................10-1
Turbocharger .................................................................................................................................................10-15
Assemble......................................................................................................................................................10-33
Clean............................................................................................................................................................10-26
Disassemble..................................................................................................................................................10-25
Finishing Steps............................................................................................................................................. 10-40
Initial Check..................................................................................................................................................10-15
Inspect for Reuse..........................................................................................................................................10-27
Install............................................................................................................................................................10-34
Leak Test......................................................................................................................................................10-18
Remove.........................................................................................................................................................10-21
Test...............................................................................................................................................................10-17
Turbocharger Air Shutoff Valve Filter ..........................................................................................................10-69
Variable Geometry......................................................................................................................................10-70
Finishing Steps............................................................................................................................................. 10-70
Install............................................................................................................................................................10-70
Remove.........................................................................................................................................................10-69
Page 10-b Section 10 - Air Intake System - Group 10
Turbocharger Control Shutoff Valve Filter Head ..........................................................................................10-71

Finishing Steps............................................................................................................................................. 10-73
Install............................................................................................................................................................10-72
Remove.........................................................................................................................................................10-71
Turbocharger Coolant Hoses ........................................................................................................................10-43
Finishing Steps............................................................................................................................................. 10-48
Install............................................................................................................................................................10-46
Remove.........................................................................................................................................................10-44
Turbocharger Wastegate Actuator ............................................................................................................... 10-49
Adjust............................................................................................................................................................10-54
Finishing Steps............................................................................................................................................. 10-57
Initial Check..................................................................................................................................................10-49
Inspect..........................................................................................................................................................10-52
Install............................................................................................................................................................10-55
Remove.........................................................................................................................................................10-52
Turbocharger Wastegate Controller .............................................................................................................10-63
Install............................................................................................................................................................10-64
Remove.........................................................................................................................................................10-63
Turbocharger Wastegate Valve Body ...........................................................................................................10-57
Turbocharger, Variable Geometry Actuator .................................................................................................10-65
Finishing Steps............................................................................................................................................. 10-69
General Information.......................................................................................................................................10-65
Install............................................................................................................................................................10-68
Remove.........................................................................................................................................................10-66
Test...............................................................................................................................................................10-68
Turbocharger, Variable Geometry Actuator Air Supply Line .......................................................................10-73
Install............................................................................................................................................................10-74
Remove.........................................................................................................................................................10-73
Turbocharger, Variable Geometry Control Valve Air Supply Line ...............................................................10-75
Install............................................................................................................................................................10-76
Remove.........................................................................................................................................................10-75
Section 10 - Air Intake System - Group 10 Page 10-c
Variable Geometry Turbocharger Actuator, Electric ....................................................................................10-77

Calibrate.......................................................................................................................................................10-84
Clean and Inspect for Reuse.........................................................................................................................10-78
Finishing Steps.............................................................................................................................................10-84
Install............................................................................................................................................................10-80
Preparatory Steps.........................................................................................................................................10-77
Remove.........................................................................................................................................................10-78
Variable Geometry Turbocharger Cross Shaft .............................................................................................10-85
Assemble......................................................................................................................................................10-92
Disassemble..................................................................................................................................................10-86
Finishing Steps.............................................................................................................................................10-99
Initial Check..................................................................................................................................................10-85
Steam Cleaning.............................................................................................................................................10-86
Page 10-d Section 10 - Air Intake System - Group 10

Section 10 - Air Intake System - Group 10 Page 10-1
Service Tools
Repair Location.

Slack Tube Manometer
Used to measure pressure differential.
ST-1111-3
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
Fluorescent Tracer
Added to oil and used with black light to find oil leaks.
3376891
Fluke Digital Thermometer

Used to measure intake air temperature.
3822666
Thermocouple Wire Kit

Used with fluke digital thermometer.
3822988
Page 10-2 Section 10 - Air Intake System - Group 10

Charge-Air Cooler Tester
Used to pressure-test charge air coolers.
3824556
Bushing Replacer
Used to remove and install the turbocharger actuator cross shaft
4919166 bushing and oil seal on variable geometry turbochargers.
Turbocharger Actuator Inspection Gauge Kit

Used to determine if the variable geometry turbocharger has full
4919281 travel of the sector gear.
Air Handling Clean Care Kit for ISX Engine Components

Contains a variety of caps to prevent contamination of engine air
4919403 handling plumbing during service procedures.
Air Handling Clean Care Kit for Vehicle Plumbing

Contains a variety of caps to prevent contamination of vehicle air
Signature, ISX, and QSX15 Eng [...] Air Leaks, Air Intake and Exhaust Systems
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
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.
Air Leaks, Air Intake and Exhaust Systems Signature, ISX, and QSX15 Eng [...]
Any charge-air cooler piping or connecting hose.

Inspect the hose and piping for damage.
Turbocharger-to-exhaust-manifold mounting gasket.

Replace the gasket.
Refer to Procedure 010-033 for turbocharger removal and
installation.
CAUTION
to not be able to be used.
Turbine housing sealing surface air leak.
Tighten the v-band clamp.
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.
Check for an air leak.
If an air leak is still present, remove and replace the
turbocharger.
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.

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.
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.
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
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.
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.

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
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.
If a leak is still present, remove and replace the gasket
with a new gasket and v-band clamp.
Check the aftertreatment diesel particulate filter to outlet

connection.
Check the aftertreatment outlet connection.

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.
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.
Procedure 014-013.
Signature, ISX, and QSX15 Eng [...] Charge-Air Cooler
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.
Use protective caps from the Air Handling Clean Care Kit
to cover open points on the plumbing and engine.
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: Make 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.
to cover open points on the charge air cooler after
cleaning.
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 Eng [...]
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.
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, the charge-air cooler does not need
to be replaced.
After the test is complete, cover open points on the

charge-air cooler with protective caps from the Air
Handling Clean Care Kit.
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.
Charge-Air Cooler Signature, ISX, and QSX15 Eng [...]
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.
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 = Differenti
Temperat Air al
ure Temperat Temperat
ure ure
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 0C [32F]
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.
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 oil, excessive fuel, or excessive
black smoke entering the exhaust system, the
Air Intake Restriction Signature, ISX, and QSX15 Eng [...]
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.
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.
Signature, ISX, and QSX15 Eng [...] Turbocharger
Remove the test equipment.

Procedure 014-013.
Turbocharger (010-033)
Initial Check
Flourescent Tracer Dye Test
Automotive with CM870 or 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.
NOTE: Brush away any loose dirt from around the area of
air handling connections to avoid contamination of the
interior of the engine.
Allow the turbocharger to cool.
Remove the intake piping and compressor discharge
piping. Cover the openings in the pipes with caps from the
Air Handling and Vehicle Air Plumbing Clean Care Kits,
Part Numbers 4919403, and 4919425 respectively.
Inspect the turbocharger compressor impeller blades for

damage.
Replace the turbocharger if damage is found.
Turbocharger Signature, ISX, and QSX15 Eng [...]
Use a high-intensity black light, Part Number 3163337

(100 watt), or equivalent, or Part Number 3163338 (50
watt), or equivalent, to 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.
If the compressor impeller is damaged, inspect the intake

air piping and the filter element for damage.
Repair any damage before operating the engine further.
Inspect the turbine wheel for damage.

Replace the turbocharger if damage is found.
Install the intake piping and compressor discharge piping.
Disconnect the exhaust pipe from the turbocharger.
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.
Check the engine breather or the crankcase vent tube for

restrictions.
Clear any restrictions and/or replace damaged
components. Refer to Procedure 003-001 in Section 3.
If equipped, check the engine crankcase ventilation filter
assembly for excessive restriction or blockage. Refer to
Inspect the bearing housing for external oil or coolant
leaks.
Remove the oil supply and oil drain tubes from the
turbocharger.
Discard the oil drain tube gasket.
Check for evidence of coolant in the oil supply and oil drain
fittings.
Test
Flourescent Tracer Dye Test
WARNING
WARNING
Variable Geometry
Drain the cooling system. Refer to Procedure 008-018
in Section 8.
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.
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 in Section 10.
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.
Operate the engine at full throttle and maximum load, and
check for air leaks.

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.
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 excessively, and the hose
connections are not leaking, replace the turbocharger.
Preparatory Steps
ISX Automotive with CM570, QSX15 with CM570, and
Power Generation with CM570
Remove the wastegate actuator hose. Refer to
WARNING
WARNING
Drain the coolant. Refer to Procedure 008-018 in
Section 8.
Disconnect the turbocharger speed sensor. For
Signature and ISX engines, see the following
procedure in the Troubleshooting and Repair Manual,
CM870 Electronic Control System Signature and ISX
Disconnect the turbocharger compressor air inlet
temperature sensor. For ISX engines, see the following
Engines, Bulletin 4021334.Refer to Procedure 019-395
in Section 19.
Disconnect the variable geometry actuator air supply
line. Refer to Procedure 010-113 in Section 10.
Remove the turbocharger coolant hoses. Refer to
WARNING
WARNING
the air handling connections to avoid contamination of the
Drain the coolant. Refer to Procedure 008-018 in
Section 8.
Disconnect the turbocharger speed sensor. For ISX
and ISM engines, see the following procedure in the
ISX CM871 and ISM CM876 Electronic Control
System, Troubleshooting and Repair Manual, Bulletin
4021560. Refer to Procedure 019-390 in Section 19.
Disconnect the turbocharger compressor air inlet
temperature sensor. For ISX and ISM engines, see the
following procedure in the ISX CM871 and ISM CM876
Electronic Control System, Troubleshooting and
Remove the turbocharger coolant hoses. Refer to
Remove the charge-air piping. Use protective caps
from the Air Handling Clean Care Kit, Paart Number
4919403. to cover open points.
Remove the turbocharger air inlet piping. Use
protective caps from the Air Handling and Vehicle Air
Plumbing Clean Care Kits, Part Numbers 4919403,
and 4919425 respectively to cover open points.
Disconnect the aftertreatment adapter pipe. Use
protective cap from the Air Handling Clean Care Kit,
Part Numbers 4919403 and 4919425 respectively, to
cover the turbocharger exhaust outlet.Refer to
Remove
WARNING
Automotive, Industrial, and Power Generation with
CM570
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.
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 for the removal and installation
of the exhaust manifold. Refer to Procedure 011-007 in
Section 11.
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.
WARNING
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.
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 turbocharger and discard the gasket.
WARNING
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.
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.
Cover the turbocharger exhaust inlet port with heavy tape

or a protective cap from the Air Handling and the Vehicle
Air Plumbing Clean Care Kit, Part Numbers 4919403 and
4919425 respectively. Cover the opening on the exhaust
manifold with heavy tape.
If the turbocharger is being replaced with a new
turbocharger, remove the variable geometry turbocharger
actuator.
Disassemble
Turbine Housing Replacement for ISX Automotive
with CM570, QSX15 with CM570, and Power
Generation with CM570
Place the 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.
NOTE: This procedure applies ONLY to Automotive with
CM570, QSX15 with CM570, and Power Generation with
CM570. Do NOT disassemble variable geometry
turbochargers (VGT).
Loosen the turbine side V-band locknut. Remove and

discard the V-band clamp.
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
Turbine Housing Cleaning for ISX Automotive with
CM570, QSX15 with CM570, and Power Generation
with CM570
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.
NOTE: This procedure applies ONLY to Automotive with
CM570, QSX15 with CM570, and Power Generation with
CM570. Do NOT disassemble variable geometry
turbochargers (VGT).
CAUTION
non-corrosive metal cleaner.
Soak the turbocharger turbine housing in a non-corrosive,
low flash point metal cleaner to loosen deposits.
CAUTION
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.
CAUTION
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, and lead 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
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

Inspect the turbocharger casings.
Replace the housing if through cracks are found in the
outer walls.
Cracking in 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 the turbine housing inlet flange flatness. It must be
within 0.1 mm [0.004 in] to be acceptable 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.
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
If the engine experiences a turbocharger malfunction 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 in
Section 10.

Inspect for cracks in the turbocharger and compressor
casings.
Replace the turbocharger if through cracks in the outer
walls are found.
Inspect for cracks on the turbine inlet and exhaust
mounting flanges. Replace the turbocharger if any cracks
are found.
Clean the retaining nut mating surfaces of the

turbocharger and the exhaust manifold.
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.

fretting.
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.
Section 10.
Check the axial movement of the turbocharger wheels and

shaft.

mm in
0.025 MIN 0.001
0.127 MAX 0.005
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.

Inspect the variable geometry actuator and mechanism for
proper operation. Refer to Procedure 010-134 in Section
10.
Inspect for cracks in the turbocharger and compressor

casings.
Replace the turbocharger if through cracks in the outer
walls are found.
Inspect for cracks on the turbine inlet and exhaust
mounting flanges. Replace the turbocharger if any cracks
are found.
NOTE: All openings on the turbocharger, including the

turbine inlet connection, must be plugged with caps from
the Air Handling and Vehicle Air Plumbing Clean Care
Kits, Part Numbers 4919403, and 4919425 respectively,
during flange cleaning.
Clean the turbocharger and exhaust manifold where the
retaining nut contacts the turbocharger and exhaust
manifold.
abrasive pad.
After abrasive cleaning, wipe debris from both surfaces
with a clean shop towel.
The surface under the mounting nuts must be free of dirt,
rust, or any other debris, before applying anti-seize
compound, Part Number 3823097.
Replace turbocharger if any leaks are found.

Check for evidence of coolant in the oil supply and oil drain
fittings.

fretting.
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.
Section 10.
Check the axial movement of the turbocharger wheels and

shaft.

mm in
0.051 MIN 0.002
0.152 MAX 0.006
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.
Assemble
ISX Automotive with CM570, QSX15 with CM570 and
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 for Holset-branded turbochargers.
Loosen the locknut 180 degrees, and torque the locknut.
Torque value for Cummins-branded turbochargers.
Torque value for Holset-branded turbochargers.
Make certain the rotor assembly rotates freely and neither
compressor wheel or turbine wheel is rubbing against the
housing.
Install
Apply a film of high-temperature anti-seize compound,
Part Number 3823097, or equivalent, to the
turbocharger mounting studs.
WARNING
NOTE: If the exhaust manifold and turbocharger were
removed together in order for the turbocharger to clear the
lubricating oil cooler assembly, see the following
procedure for installation of the exhaust manifold. Refer
Install a new mounting gasket, the turbocharger, and the
four mounting nuts.
Tighten the mounting nuts.
Torque value for the standard nut:
Torque value for the Spiralock nut (identified by "SPL"
on the nut flange):
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.
If a new turbocharger is being installed, the variable

geometry turbocharger actuator from the original
turbocharger must be reused.
Install a new o-ring, the clamp, and the discharge elbow
to the turbocharger.
Tighten the clamp.
Install a new gasket, oil drain tube, and capscrews.

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.
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.
If installing a new turbocharger, install the male union
elbow.
Install the turbocharger oil supply tube on the elbow.
Install the intake and exhaust pipes to the turbocharger.

Tighten the clamp.

Variable Geometry
Part Number 3823097, to the turbocharger mounting
studs.
WARNING
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.
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.

Install the intake and exhaust pipes to the turbocharger,

and tighten the clamps.

Part Number 3823097, or equivalent, 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.
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.
Install the turbocharger actuator coolant supply and return
fittings into the electronic actuator. Refer to Procedure
WARNING
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.
Install a new o-ring seal, the clamp, and the discharge

elbow to the turbocharger.
Tighten the clamps.

Connect the oil supply hose to the oil supply fitting located
on the lubricating oil filter head.
Tighten the oil supply hose.
Finishing Steps
Install the wastegate actuator hose. Refer to
Start and operate the engine until the coolant
temperature reaches 82C [180F] and check for air,
coolant, and oil leaks.
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
Connect the variable geometry actuator air supply line.
Connect the electrical connectors on the turbocharger
speed sensor and the turbocharger compressor air
inlet temperature sensor. For ISX engines, see the
Manual, CM870 Electronic Control System Signature
and ISX Engines, Bulletin 4021334.Refer to Procedure
019-395 in Section 19. Also, see the following
in Section 19.
Fill the cooling system with coolant. Refer to Procedure
Start and operate the engine until the coolant
temperature reaches 82C [180F] and check for air,
coolant, and oil leaks.

Install the charge-air piping. Refer to Procedure
Install the aftertreatment adapter pipe. Refer to
Install the turbocharger coolant hoses. Refer to
Connect the turbocharger compressor air inlet
temperature sensor. For the ISX and ISM engines, see
the following procedure in the ISX CM871 and ISM
CM876 Electronic Control System, Troubleshooting
and Repair Manual, Bulletin 4021560.Refer to
Connect the electrical connector on the turbocharger
speed sensor, turbocharger electric actuator and the
turbocharger compressor air inlet temperature sensor.
For the ISX and ISM engines, see the following
procedure in Section 19 in the ISX CM871 and ISM
CM876 Electronic Control System, Troubleshooting
and Repair Manual, Bulletin 4021560.Refer to
Connect the aftertreatment adapter pipe. Refer to
Section 8.
If a malfunction resulted in coolant, oil, excessive fuel, or
Signature, ISX, and QSX15 Eng [...] Turbocharger Coolant Hoses
Turbocharger Coolant Hoses (010-041)

Preparatory Steps
WARNING
cable last.
WARNING
WARNING
Disconnect the batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
Drain the coolant. Refer to Procedure 008-018
Remove the turbocharger oil supply and oil drain
lines from the turbocharger. Refer to Procedure
010-033 (Turbocharger) in Section 10.
WARNING
cable last.
WARNING
WARNING
Disconnect the batteries. Refer to Procedure
013-009 (Battery and Cable Connections) in Section
13.
Drain the coolant. Refer to Procedure 008-018
Remove the turbocharger oil drain line from the
turbocharger. Refer to Procedure 010-033
Turbocharger) in Section 10.
Turbocharger Coolant Hoses Signature, ISX, and QSX15 Eng [...]
Remove
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.

Remove the turbocharger coolant return line from the top
of the turbocharger and the thermostat housing.

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).

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).
WARNING
WARNING
WARNING
personal injury.
Clean the turbocharger coolant hoses with solvent.
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
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.
while tightening the line.
CAUTION
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.
while tightening the line.
Install the tube brace onto the turbocharger coolant return

hose and the air tube.
CAUTION
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).
turbocharger actuator (2).
lubricating oil filter head (1).
NOTE: Use a second wrench to hold the coolant hose
coupling while tightening the hose.
Tighten the fittings.
CAUTION
can damage the lines.
CAUTION
Do not use petroleum products on the turbocharger
coolant line o-rings. The o-rings will swell and cause
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.
Install the turbocharger coolant return hose in the
thermostat housing. Tighten the banjo fitting.
Install the turbocharger actuator coolant hose to the
thermostat housing. Tighten the fitting.
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.
Finishing Steps
WARNING
cable last.
Install the turbocharger oil supply and oil drain hoses
from the turbocharger. Refer to Procedure 010-033
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.
Signature, ISX, and QSX15 Eng [...] Turbocharger Wastegate Actuator
WARNING
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.
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.
Turbocharger Wastegate Actuator Signature, ISX, and QSX15 Eng [...]
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).
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 [14.5 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 [14.5
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 [14.5

psi]
mm in
0.356 MIN 0.014
3.810 MAX 0.150
Preparatory Steps
Remove the turbocharger. Refer to Procedure
010-033 (Turbocharger) in Section 10.
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.
Use a micrometer depth gauge. To made 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
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.
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 the
assembly from the mounting bracket.
Inspect for Reuse

A new hose clamp is required to install 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 [14.5 psi] to make sure the wastegate is
functioning properly.
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 [14.5

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
(Turbocharger Wastegate Valve Body) in Section 10.
Adjust
CAUTION
If there is a turnbuckle with an adjusting link, do NOT
adjust the piston guided actuator by turning the rod
of the actuator. This will damage the rubber
diaphragm inside the actuator. The knurled
turnbuckle on the new end adjusting link must be
used.
Leave the setting pressure air supply connected to the
wastegate capsule.
Loosen the actuator end-link locknut.
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.
Remove the actuator end-link retaining clip.
Remove the actuator end link from the wastegate lever.
CAUTION
If there is a turnbuckle with an adjusting link, do NOT
adjust the piston guided actuator by turning the rod
of the actuator. This will damage the rubber
diaphragm inside the actuator. The knurled
turnbuckle on the new end adjusting link must be
used.
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
After adjusting is completed, tighten the end-link locknut

against the end link.
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.
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.
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.

Signature, ISX, and QSX15 Eng [...] Turbocharger Wastegate Valve Body
Remove the actuator clamp.
Finishing Steps
Operate the engine and check for proper operation.
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.
Intake Manifold Pressure Signature, ISX, and QSX15 Eng [...]
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 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.
Signature, ISX, and QSX15 Eng [...] Air Intake Connection
Air Intake Connection (010-080)

Preparatory Steps
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.

Remove the charge air cooler piping. Refer to
Remove the EGR mixer. Refer to Procedure 011-021
in Section 11.
Disconnect the engine wiring harness from the
intake manifold pressure sensor and intake manifold
air temperature sensor.

Remove the charge air piping. Use protective caps
from the Air Handling Clean Care Kit to cover the
connection points.
Intake manifold pressure temperature sensor. For
ISX and ISM engines, see the following procedure in
the CM871 and CM876 Troubleshooting and Repair
Manual Electronic Control System ISX and ISM
Remove the air compressor supply line. Refer to
Front EGR Connection tube and EGR venturi. Refer
EGR differential pressure sensor. For ISX and ISM
engines, see the following procedure in the
Electronic Control System CM871 and CM876
Signature, ISX and QSX15 Engines, Bulletin
4021560. Refer to Procedure 019-370 in Section 19.
EGR differential pressure sensing tubes. Refer to
Air Intake Connection Signature, ISX, and QSX15 Eng [...]
Remove
Remove the four capscrews holding the air intake
connection to the cylinder head.

Remove the four capscrews that hold the air intake
connection to the cylinder head.
Cover all open points on the air intake connection and

cylinder head with caps and heavy tape from the Air
Handling Clean Care Kit or heavy tape.

Remove the four mounting capscrews, air inlet
connection, and gasket.
Signature, ISX, and QSX15 Eng [...] Air Intake Connection

All Applications
WARNING
Inspect the air intake connection for the amount of carbon
on the inside of the air intake connection.
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
Install the four mounting capscrews, air inlet connection,
and new gasket.
Air Intake Connection Signature, ISX, and QSX15 Eng [...]
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.

Install a new gasket between the cylinder head and the air
intake connection.
Install and tighten the four capscrews.

Install a new gasket between the cylinder head and the air
intake connection.
Install and tighten the four capscrews.
Finishing Steps
Connect the air pipe from the charge air cooler to the
air inlet connection.
Install the four-step wastegate controller wires, hose,
mounting capscrews, and controller.
Signature, ISX, and QSX15 Eng [...] Turbocharger Wastegate Controller

Install the four-step wastegate controller, mounting
capscrews, hose, and controller wires.
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 in
Section 11.
Start and operate the engine. Check for air leaks.

Install the front EGR connection tube and EGR
venturi. Refer to Procedure 011-025 in Section 11.
Install the air compressor supply line. Refer to
Install the intake manifold pressure/temperature
sensor. For ISX and ISM engines, see the following
procedure in the CM871 and CM875
Troubleshooting and Repair Electronic Control
System ISX and ISM Engines, Bulletin 4021560.
Operate the engine and check for air leaks.
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.
Turbocharger Wastegate Controller Signature, ISX, and QSX15 Eng [...]
Remove the four capscrews.

Remove the coil and the fuel shield.
Remove the spring washer, valve disc, and actuator
spacer from the valve housing.
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.
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.
Signature, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Actuator
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.
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.
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.
Turbocharger, Variable Geometry Actuator Signature, ISX, and QSX15 Eng [...]
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.
Signature, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Actuator
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.
Turbocharger, Variable Geometry Actuator Signature, ISX, and QSX15 Eng [...]
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.
Install the actuator rod to the turbocharger cross-shaft.

Install the snap ring.
Install and tighten the capscrew.
Signature, ISX, and QSX15 Eng [...] Turbocharger Air Shutoff Valve Filter
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
Procedure 014-013.
Turbocharger Air Shutoff Valve Filter

(010-114)
Preparatory Steps
Variable Geometry
WARNING
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.
Turbocharger Air Shutoff Valve Filter Signature, ISX, and QSX15 Eng [...]

Variable Geometry
WARNING
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 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.
Signature, ISX, and QSX15 Eng [...] Turbocharger Control Shutoff Valve Filter Head
Turbocharger Control Shutoff Valve

Filter Head (010-115)
Preparatory Steps
Variable Geometry
WARNING
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.
Remove the air line from the turbocharger control
valve. Refer to Procedure 019-388 in the
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
Remove
Variable Geometry
Remove the two mounting capscrews.
Remove the turbocharger control shutoff valve filter head.
Turbocharger Control Shutoff Valve Filter Head Signature, ISX, and QSX15 Eng [...]

Variable Geometry
WARNING
personal injury.
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
personal injury.
WARNING
mounting surfaces with solvent.
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.
Signature, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Actuator Air Supply Lin [...]
Finishing Steps
Variable Geometry
Install the air shutoff valve. Refer to Procedure
019-386 in the Troubleshooting and Repair Manual
Connect the air line from the air tank.
Install the air line from the turbocharger control
valve. Refer to Procedure 019-388 in the
Install the turbocharger control shutoff valve filter.
Connect the electrical harness to the turbocharger
control shutoff valve.

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.
Turbocharger, Variable Geometry Actuator Air Supply Lin [...] Signature, ISX, and QSX15 Eng [...]
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
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.
Connect the p-clip to the thermostat housings.
Connect the air supply line to the turbocharger actuator.
Start and run the engine.
Verify proper operation.
Check for air leaks.
Signature, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Control Valve Air Suppl [...]

Control Valve Air Supply Line
(010-121)
Remove
CAUTION
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.
Turbocharger, Variable Geometry Control Valve Air Suppl [...] Signature, ISX, and QSX15 Eng [...]
Install
CAUTION
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.
Connect the p-clips holding air line to engine.
Connect the air supply line to the turbocharger control
shutoff valve.
Start and run the engine.
Verify proper operation.
Check for air leaks.
Signature, ISX, and QSX15 Eng [...] Variable Geometry Turbocharger Actuator, Electric
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.
Use the following procedure for further information
regarding variable geometry turbocharger and
aftertreatment system interactions. Refer to Procedure
011-999 in Section F.
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.
The starting motor wiring can electrically interfere with the
VGT pigtail and wiring harness. The starting motor wiring
must be at least 152 mm [6 in] away from the actuator and
harness.
Preparatory Steps
WARNING
personal injury.
WARNING
WARNING
Clean the area around the turbocharger actuator and
dry with compressed air.
Drain the engine coolant. Refer to Procedure
Disconnect the turbocharger actuator coolant supply
and return lines from the turbocharger actuator.
Remove the turbocharger actuator wiring harness
zip ties.
Variable Geometry Turbocharger Actuator, Electric Signature, ISX, and QSX15 Eng [...]
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.
CAUTION
Make sure the coolant has been drained before the
actuator is removed. Failure to do so can result in
damage to the actuator.
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.

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.
If the sealing surface of the turbocharger is damaged and

causing a leak, the turbocharger must be replaced.
Discontinue work with this procedure. Refer to Procedure
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.
Confirm the actuator is disconnected from the engine
harness. Rotate the output pinion gear by hand. Do not
use any tools to turn the gear.
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
entire 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.
The sector gear travel gages are designed for specific

turbocharger models. To determine the correct gage,
verify the turbocharger model number from the
turbocharger data plate. Select the gage that matches the
first three letters of the turbocharger model number.
Example: HE5xx, HE4xx, and so on.
An alternate method of determining the turbocharger

model number, if the turbocharger data tag is missing or
covered with paint, is to measure the distance between
the top of the cup plug hole to the bearing housing edge.
If the distance is greater than 19 mm [0.748 in], the
turbocharger model is HE4xx. If the distance is less than
19 mm [0.748 in], the model is a HE5xx.
To install the sector gear travel gage, carefully bend the

gage and slide the thin section under the sector gear. If
necessary, pull the sector gear out by hand to allow more
clearance for the gage.
Verify that the three alignment bosses are fully engaged
in the bearing housing.
Rotate the sector gear counterclockwise, toward the

turbocharger turbine housing, until it stops. The edge of
the sector gear must be in the green acceptance zone of
the gage.
Rotate the sector gear clockwise, toward the

turbocharger compressor housing, until it stops. The edge
of the sector gear must be in the green acceptance zone
of the gage.
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.
Install
CAUTION
During the turbocharger actuator install procedure,
the pinion gear on the actuator will move. Keep hands
and tools away from the pinion gear during the
procedure.
Following these instructions in order is very important.
Continue through the entire turbocharger actuator

installation procedure 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 INSITE electronic
service tool and wait 60 seconds.
Connect the turbocharger actuator electrical
connector to the engine wiring harness.
If Fault Code 2634 becomes active, disconnect the
turbocharger actuator connector from the engine wiring
harness with the keyswitch ON. Connect the turbocharger
actuator electrical connector. Fault Code 2634 will go
inactive.
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.
Use INSITE electronic service tool and go to the ECM

Diagnostic Tests screen.
From the list, select VGT Electronic Actuator Installation
and Calibration and click on the next button.
NOTE: The VGT Electronic Actuator Installation and
Calibration is not a diagnostic test. It is the procedure to
properly install and calibrate the turbocharger actuator.
Running this procedure improperly can result in additional
fault codes and/or damage to the turbocharger or
actuator.
INSITE electronic service tool INSTALL ACTUATOR
command must only be run with the actuator not
mounted to the turbocharger.
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.
Fault Code 2449 will be active at this point in the
procedure. Continue through the turbocharger actuator
procedure before troubleshooting fault codes.
If at any point, INSITE electronic service tool status
message indicates the procedure was stopped or failed,
leave the keyswitch ON and cycle the power to the
actuator by unplugging it from the harness, and then
reconnecting it.
If cycling the power to the actuator does not work, unplug
the actuator, turn the keyswitch OFF for 30 seconds, and
then restart INSITE electronic service tool. Then start
over, beginning with the INSTALL ACTUATOR step.
Grasp the sector gear by hand and rotate the sector gear
toward the turbocharger compressor housing. Make sure
the edge of the sector gear is rotated all the way towards
the Install Position arrow.
Coat the teeth on the sector gear with the grease 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
grease.
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.
It could be necessary to twist the actuator housing to align
it with the mounting holes.
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 Nm [ 27 in-lb ]
Step2 11 Nm [ 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.
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.
INSITE electronic service tool CALIBRATE
ACTUATOR command must only be run with the
actuator mounted to the turbocharger.
Follow the instruction on the screen in order to calibrate
the 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 procedure was stopped or failed, turn the
keyswitch OFF for 30 seconds and key back ON. Then
start over, beginning with the INSTALL ACTUATOR
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 should be inactive. Use
INSITE electronic service tool to clear all fault codes.
NOTE: Make sure all fault codes are inactive and cleared
before adding coolant to the engine.
Finishing Steps
WARNING
Install the turbocharger actuator coolant supply and
return lines. Refer to Procedure 010-041 in Section
10.
in Section 8.
Operate the engine to make sure the turbocharger
actuator operates properly and all turbocharger
actuator fault codes are inactive.
Check the engine for leaks.
Signature, ISX, and QSX15 Eng [...] Variable Geometry Turbocharger Cross Shaft
The starting motor wiring can electrically interfere with the

VGT pigtail and wiring harness. The starting motor wiring
must be at least 152 mm [6 in] away from the actuator and
harness.
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).
Variable Geometry Turbocharger

Cross Shaft (010-137)
Initial Check
Before beginning this repair, check the turbocharger serial
number on the turbocharger data plate.
This repair procedure applies to ISX CM870 variable
geometry turbochargers with serial numbers less than
C060306601. Do NOT perform this repair if the
turbocharger serial number is C060306601 or greater.
This repair is recommended only for ISX CM870 variable

geometry turbochargers built with aluminum compressor
impellers.
ISX CM870 CPL 8283 or 8284 (530 to 565 horsepower)
engines built between 01-November-2002 and 31-
December-2003 were built with variable geometry
turbochargers that have a titanium impeller. Before
beginning this repair, check the engine manufacture date
(1) and CPL (2) on the engine data plate. Do NOT perform
the repair if the CPL is 8283 or 8284 and the engine
manufacture date is between 01-November-2002 and 31-
December-2003.
Variable Geometry Turbocharger Cross Shaft Signature, ISX, and QSX15 Eng [...]
Inspect the turbocharger at the variable geometry actuator

cross shaft lever arm for an oil leak.
If oil is leaking from under the cross shaft lever arm where
the cross shaft enters the bearing housing, the oil seal,
cross shaft bushing, and cross shaft must be replaced.
Start with the Steam Cleaning section to begin the seal,
bushing, and cross shaft replacement.
Steam Cleaning
WARNING
WARNING
bodily injury.
Steam clean the area around the turbocharger.
Preparatory Steps
Remove the discharge elbow, intake pipes, and
exhaust pipes from the turbocharger. Refer to
Disconnect the turbocharger compressor inlet air
temperature sensor connector from the
turbocharger.
Disassemble
Create an alignment mark on the turbocharger
compressor housing, bearing housing, and v-band clamp.
This mark will make certain the components are oriented
correctly during assembly.
Loosen the turbocharger compressor housing v-band

clamp.
NOTE: Use care when removing the turbocharger

compressor housing so the housing does not contact the
impeller blades. Turbocharger compressor impeller
blades can easily be damaged, which can lead to
performance complaints.
Use a soft hammer to tap the turbocharger compressor
housing away from the bearing housing. Tap the
turbocharger compressor housing around the outside
diameter. Turn the turbine impeller while tapping to be
sure the housing is not binding the turbocharger
compressor impeller and shaft.
NOTE: A wedge type tool may be required to separate the

compressor housing from the bearing housing, but be
sure the wedge tool does not damage the compressor or
bearing housing joint.
Once the turbocharger compressor housing is removed,
visually inspect the impeller blades for damage. If the
blades are damaged, the turbocharger must be replaced.
Remove the turbocharger compressor housing v-band
clamp.
CAUTION
This mark is required during the installation of the
compressor impeller, so the turbocharger shaft and
impeller retains its balance after assembly. Failure to
mark the turbocharger shaft and impeller for
alignment can cause turbocharger imbalance, which
can result in a performance complaint by the operator.
Before loosening the compressor impeller nut, create an
alignment mark on the compressor impeller and the end
of the compressor shaft.
CAUTION
To avoid damaging the turbocharger shaft, do not
apply too much side load on the turbocharger shaft
while loosening the impeller nut. The turbocharger
compressor impeller shaft and nut have LEFT HAND
threads. The impeller nut must be removed correctly
to prevent damage to the turbocharger shaft.
Use a 12-point socket on the turbine side of the
turbocharger to hold the shaft stationary.
Loosen the turbocharger compressor impeller nut by
turning the nut clockwise. Then remove the nut from the
turbocharger shaft.
WARNING
When using a heat gun, wear protective gloves to
prevent personal injury from hot components.
Remove the compressor impeller from the shaft.
NOTE: If the compressor impeller hangs on the shaft, heat
the impeller for 2 minutes with a heat gun, while rotating
the impeller from the turbine side of the turbocharger. If
the impeller can not be removed, the turbocharger must
be replaced to repair the oil leak from under the cross shaft
lever arm.
Create an alignment mark on the diffuser plate and the

bearing housing. This will aid in the correct orientation of
the diffuser plate during assembly.
Remove and discard the three Allen head capscrews

from the diffuser plate. Replacement capscrews and
washers must be used during the assembly.
NOTE: Use care not to damage the diffuser plate or

bearing housing during the removal.
Carefully pry the diffuser plate away from the bearing
housing and remove it from the turbocharger shaft.
Remove and discard the o-ring from the diffuser plate.
If the oil slinger does not come off with the diffuser plate,
grasp the oil slinger tightly and slide it off the impeller
shaft.
If the oil slinger is difficult to remove, carefully pry the oil
slinger to remove it.
NOTE: Use care when prying the oil slinger in order not
to damage the oil deflector located behind the oil slinger.
Remove and discard the capscrew and anode washer or

dust shield from the variable geometry actuator rod.
NOTE: The anode washer assembled on some variable
geometry turbochargers has been obsoleted and replaced
with a dust shield.
Remove and discard the variable geometry actuator snap

ring.
Remove the air supply line to the variable geometry

turbocharger actuator.
Remove and discard the two capscrews from the actuator.
Apply regulated air pressure to the actuator air inlet, to

reduce the spring load at the linkage.
Remove the actuator from the turbocharger.
Rotate the cross shaft clockwise, by hand, to the end of

the cross shaft travel.
Create clearly visible marks onto the bearing housing
along both sides of the cross shaft lever arm. These marks
are required to correctly align the replacement cross shaft
during assembly.
Plug the turbocharger lubricating oil drain hole in the

bearing housing with a clean lint free cloth to prevent
items from falling into the turbocharger oil drain line.
Loosen the Allen head capscrew in the variable

geometry actuator cross shaft yoke.
Slide the actuator cross shaft out of the turbocharger

bearing housing and discard. Do not reuse the cross
shaft.
Carefully remove the yoke from the bearing housing.

Remove the Allen head capscrew from the yoke.
Make sure the pivot blocks on the sides of the yoke do
not fall off.
Remove and discard the variable geometry actuator oil

seal from the bearing housing.
CAUTION
Use care not to damage the bearing housing bore
when removing the bushing.
Use the bushing replacer tool to remove the variable
geometry actuator cross shaft bushing from the bearing
housing. Gently tap the bushing all the way through the
bore and remove it from the inside of the bearing housing.

NOTE: If using solvents to clean the parts, use care not to
remove any alignment marks.
Use a lint free cloth to clean the diffuser plate, bushing
bore, seal bore, and yoke before starting the assembly.
Use a Scotch-Brite pad to clean up the inside of the
compressor housing flange.
Inspect all parts for nicks, burrs, and other damage.
Assemble
Read and understand the assembly process before
beginning the assembly.
Use clean engine lubricating oil to lubricate the outside
diameter of the new bushing.
CAUTION
To avoid damage to the bushing during installation,
do not tap the end of the bushing at an angle.
Excessive side load will result if the bushing is tapped
at an angle.
Orient the replacement bushing to install the chamfered
end into the bore.
Next, gently tap the bushing with a soft hammer to start
the bushing squarely into the bore.
Tap the bushing squarely on the end to install the bushing
as far as possible, without contacting the face of the
bearing housing with the soft hammer.
CAUTION
To avoid damage to the bushing during installation,
do not tap the end of the bushing replacer at an angle.
Excessive side load will result if the bushing replacer
is tapped at an angle.
Use the bushing replacer and the small installer plate.
Tap the bushing replacer squarely on the end to install the
replacement bushing until the installer plate contacts the
bottom of the counterbore in the bearing housing.
CAUTION
An oil leak will result if the new seal is not oriented
correctly and installed properly.
Install the stepped installer plate onto the bushing
replacer.
Install the seal onto the end of the bushing replacer. Orient
the replacement seal so the rubber coated face of the seal
contacts the step on the installer plate and the steel carrier
outer diameter is pointed toward the seal bore in the
bearing housing.
Align the seal with the bore in the bearing housing. Gently
tap the bushing replacer until the stepped installer plate
bottoms out on the face of the bearing housing.
Install the pivot blocks on each side of the yoke.

Orientation of the pivot blocks is not required.
NOTE: Be sure the turbocharger oil drain hole in the
bearing housing is plugged with a clean lint free cloth to
prevent items from falling into the turbocharger oil drain
line.
Install a replacement mounting Allen head capscrew
through the clearance hole into the threads at the bottom
of the yoke. Do not torque at this time.
Install the yoke with the mounting capscrew oriented

upward.
Make sure the pivot blocks are seated in the nozzle ring
push rod slots.
Lubricate the outside of the replacement cross shaft with

clean engine lubricating oil.
Install the replacement cross shaft from the outside
through the replacement seal and bushing.
Apply additional clean engine lubricating oil to the cross

shaft.
Slide the cross shaft into the yoke, with one hand, while
holding the yoke in place with the opposite hand. Slide the
shaft all the way through the yoke and into the rear
bushing.
Be sure the cross shaft rotates freely in the bushings.

Use a screwdriver to apply pressure to the yoke to pull it

to the end of its travel.
Maintain the pressure to hold the yoke in position.
Align the outside edges of the replacement cross shaft
lever arm with the marks on the bearing housing made
during disassembly.
Insert a 0.76 mm [0.030 in] shim between the bearing

housing and the cross shaft lever arm while maintaining
pressure on the yoke.
CAUTION
Do not over tighten the yoke mounting capscrew.
Damage to the yoke will result.
With the yoke position fixed and the cross shaft lever arm
aligned with the alignment marks, torque the yoke
capscrew.
Remove the 0.76 mm [0.030 in] shim.
Check the cross shaft orientation to verify the lever arm is
still aligned with the alignment marks. Proper cross shaft
lever arm alignment is required for proper turbocharger
operation.
Install a new o-ring onto the outside diameter of the

diffuser plate.
CAUTION
Use care during assembly to prevent damage to the
sealing ring or the oil slinger bore.
If the oil slinger was removed separately, install the oil
slinger into the diffuser plate. Be sure the slinger is
oriented with the sealing ring gap (1) facing upward.
A small amount of clean engine lubricating oil can be used
on the oil slinger.
Lubricate the diffuser plate o-ring with clean engine

lubricating oil.
Remove the lint free cloth that was used to plug the
turbocharger oil drain hole in the bearing housing.
Install the diffuser plate onto the impeller shaft and align
the marks made during disassembly.
Install three replacement Allen head capscrews and

washers finger tight. Tighten all capscrews to the initial
torque specification before tightening to the final torque
specification.
Torque Value: Step1 4 Nm [ 35 in-lb ]
Step2 8 Nm [ 71 in-lb ]
Install the compressor impeller onto the impeller shaft.

Align the mark on the impeller with the mark on the end
of the impeller shaft.
CAUTION
To avoid damaging the turbocharger shaft, do not
apply too much side load on the turbocharger shaft
while tightening the nut. The turbocharger
compressor impeller shaft and nut have LEFT HAND
threads. The nut must be installed correctly to prevent
damage to the turbocharger shaft.
Install the nut and tighten. Use a 12-point socket on the
turbine side of the turbocharger to hold the shaft from
rotating.
Turn the nut counterclockwise to tighten. The nut and
shaft have left hand threads.
Visually check to make sure the alignment marks on the

impeller wheel and shaft are aligned after the nut has been
tightened.
Install the variable geometry actuator. Refer to Procedure

010-113 (Turbocharger, Variable Geometry Actuator) in
Section 10.
Install the compressor housing v-band clamp over the

bearing housing.
NOTE: Use care when installing the turbocharger

compressor housing, so the housing does not contact the
impeller blades. Turbocharger compressor impeller
blades can easily be damaged, which can lead to
performance complaints.
Lubricate the inside mounting flange of the compressor
housing with clean engine lubricating oil prior to
installation.
Install the compressor housing squarely onto the bearing
housing. Use a soft hammer to tap around the outside
diameter of the compressor housing.
Expand the v-band clamp over the compressor housing

and bearing housing flange.
Align the compressor housing and v-band clamp marks to
the mark on the bearing housing.
Tighten the v-band clamp.

Tap the circumference of the v-band clamp at 90-degree
increments and check the torque.
Finishing Steps
Connect the turbocharger compressor inlet air
temperature sensor connector to the turbocharger.
Install the discharge elbow, intake pipes, and
exhaust pipes to the turbocharger. Refer to

Notes
Section 11 - Exhaust System - Group 11 Page 11-a
Section 11 - Exhaust System - Group 11

Section Contents
Page
Aftertreatment Adapter Pipe .........................................................................................................................11-93
Finishing Steps............................................................................................................................................. 11-96
Install............................................................................................................................................................11-96
Remove.........................................................................................................................................................11-94
Aftertreatment Diesel Oxidation Catalyst ...................................................................................................11-113
Clean and Inspect for Reuse........................................................................................................................11-115
Finishing Steps............................................................................................................................................11-119
General Information.....................................................................................................................................11-113
Install..........................................................................................................................................................11-118
Preparatory Steps........................................................................................................................................11-113
Remove.......................................................................................................................................................11-114
Aftertreatment Diesel Particulate Filter ........................................................................................................11-82
Adjust............................................................................................................................................................11-87
Finishing Steps............................................................................................................................................. 11-88
Install............................................................................................................................................................11-87
Maintenance Check.......................................................................................................................................11-86
Remove.........................................................................................................................................................11-83
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting Bracket ...........................11-99
Finishing Steps............................................................................................................................................11-102
Install..........................................................................................................................................................11-102
Remove.......................................................................................................................................................11-100
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes ............................................11-103
Install..........................................................................................................................................................11-106
Remove.......................................................................................................................................................11-104
Aftertreatment Fuel Injector ..........................................................................................................................11-89
Finishing Steps............................................................................................................................................. 11-93
Install............................................................................................................................................................11-92
Remove.........................................................................................................................................................11-89
Aftertreatment Fuel Injector Coolant Test ..................................................................................................11-152
Finishing Steps............................................................................................................................................11-154
Setup..........................................................................................................................................................11-153
Test.............................................................................................................................................................11-153
Aftertreatment Fuel Injector Flow ...............................................................................................................11-140
Finishing Steps............................................................................................................................................11-145
Flow Test....................................................................................................................................................11-143
Initial Check................................................................................................................................................11-140
Leak Test....................................................................................................................................................11-144
Setup..........................................................................................................................................................11-140
Aftertreatment Fuel Shutoff Manifold .........................................................................................................11-134
Finishing Steps............................................................................................................................................11-139
Install..........................................................................................................................................................11-138
Remove.......................................................................................................................................................11-134
Page 11-b Section 11 - Exhaust System - Group 11
Aftertreatment Injector Lines ......................................................................................................................11-123

Finishing Steps............................................................................................................................................11-133
Install..........................................................................................................................................................11-130
Remove.......................................................................................................................................................11-124
Aftertreatment Inlet and Outlet ...................................................................................................................11-107
Assemble....................................................................................................................................................11-110
Disassemble................................................................................................................................................11-109
Finishing Steps............................................................................................................................................11-112
Install..........................................................................................................................................................11-111
Remove.......................................................................................................................................................11-109
Aftertreatment System ................................................................................................................................11-119
Assemble....................................................................................................................................................11-122
Disassemble................................................................................................................................................11-121
Finishing Steps............................................................................................................................................11-123
Install..........................................................................................................................................................11-122
Remove.......................................................................................................................................................11-120
EGR Connection Tubes .................................................................................................................................11-51
Finishing Steps............................................................................................................................................. 11-60
Install............................................................................................................................................................11-57
Remove.........................................................................................................................................................11-52
EGR Cooler ....................................................................................................................................................11-19
Finishing Steps............................................................................................................................................. 11-36
Install............................................................................................................................................................11-33
Pressure Test................................................................................................................................................11-29
Remove.........................................................................................................................................................11-21
EGR Cooler Connection ................................................................................................................................11-48
Finishing Steps............................................................................................................................................. 11-50
Install............................................................................................................................................................11-50
Remove.........................................................................................................................................................11-48
EGR Cooler Coolant Lines ............................................................................................................................ 11-70
Finishing Steps............................................................................................................................................. 11-77
Install............................................................................................................................................................11-75
Remove.........................................................................................................................................................11-71
EGR Differential Pressure Sensor Adapter ...................................................................................................11-67
Finishing Steps............................................................................................................................................. 11-68
Install............................................................................................................................................................11-68
Remove.........................................................................................................................................................11-67
EGR Differential Pressure Sensor Tubes ..................................................................................................... 11-61
Finishing Steps............................................................................................................................................. 11-65
Install............................................................................................................................................................11-64
Section 11 - Exhaust System - Group 11 Page 11-c

Remove.........................................................................................................................................................11-61
EGR Mixer ......................................................................................................................................................11-37
Finishing Steps.............................................................................................................................................11-39
Install............................................................................................................................................................11-39
Remove.........................................................................................................................................................11-38
EGR Valve ......................................................................................................................................................11-40
Assemble......................................................................................................................................................11-45
Disassemble..................................................................................................................................................11-42
Finishing Steps.............................................................................................................................................11-47
Install............................................................................................................................................................11-45
Remove.........................................................................................................................................................11-41
EGR Valve Coolant Lines ..............................................................................................................................11-68
Finishing Steps.............................................................................................................................................11-70
Install............................................................................................................................................................11-69
Remove.........................................................................................................................................................11-69
EGR Valve Mounting Bracket ........................................................................................................................11-96
Finishing Steps.............................................................................................................................................11-98
Install............................................................................................................................................................11-98
Remove.........................................................................................................................................................11-97
Exhaust Gas Pressure Sensor Adapter ........................................................................................................11-80
Finishing Steps.............................................................................................................................................11-81
Install............................................................................................................................................................11-81
Remove.........................................................................................................................................................11-80
Exhaust Gas Pressure Sensor Tube .............................................................................................................11-65
Finishing Steps.............................................................................................................................................11-66
Install............................................................................................................................................................11-66
Remove.........................................................................................................................................................11-65
Exhaust Manifold, Dry .....................................................................................................................................11-4
Assemble......................................................................................................................................................11-12
Automotive, Industrial with CM570 and Power Generation without CM570..................................................11-12
Automotive with CM870 and CM871.............................................................................................................11-9
Disassemble...................................................................................................................................................11-7
Page 11-d Section 11 - Exhaust System - Group 11
Finishing Steps.............................................................................................................................................11-16
Initial Check....................................................................................................................................................11-4
Install............................................................................................................................................................11-13
Automotive with CM870 and CM871...........................................................................................................11-13
Remove..........................................................................................................................................................11-7
Repair.............................................................................................................................................................11-4
Exhaust Restriction .......................................................................................................................................11-17
Initial Check..................................................................................................................................................11-17
Exhaust System Diagnostics .......................................................................................................................11-145
Heat Shield ....................................................................................................................................................11-78
Finishing Steps.............................................................................................................................................11-80
Install............................................................................................................................................................11-79
Remove.........................................................................................................................................................11-78
Service Tools ...................................................................................................................................................11-1
.......................................................................................................................................................................11-1
Section 11 - Exhaust System - Group 11 Page 11-1
Service Tools
Repair Location.

Manometer
Used to measure exhaust restriction.
ST-1111-3
Pressure Gauge
Used to measure inches of mercury (in Hg) pressure.
ST-1273
EGR Cooler Leak Check Kit

Used to identify leaks and clean the EGR cooler on ISX with CM870
3164225 engines.
Infrared Thermometer
Used to measure the surface temperature of the exhaust
3824941 components.
EGR Cooler Leak Check Kit

Used to pressure test and clean the EGR cooler on ISX with CM871
4918655 engines.
Exhaust Seal Installer

Use to install the exhaust manifold seal on the ISX with CM871
4918709 engines.
Page 11-2 Section 11 - Exhaust System - Group 11

Pressure Adapter Fitting
This fitting is inserted into the thermistor ports of the aftertreatment
4918756 system in order to measure the pressure and pressure differences at
various points in the aftertreatment system.
Diesel Particulate Filter Cleaner HEPA Filter

Used to replace the HEPA filter on diesel particulate filter cleaner,
4918839 Part Number 4918840.
Diesel Particulate Filter Cleaner

This machine is used with diesel particulate filter cleaner adapter kit,
4918840 Part Number 4918893 or 4919182, to clean the diesel particulate filter
once it is removed from the vehicle. (U.S.A. only. Not intended for
use in Canada.)
Diesel Particulate Filter Cleaner Vacuum Filter

Used to replace the vacuum filter on diesel particulate filter cleaner,
4918841 Part Number 4918840.
Diesel Particulate Filter Cleaner Canister Filter

Used to replace the canister filters on diesel particulate filter cleaner,
4918842 Part Number 4918840. Two are required per machine.
Diesel Particulate Filter Cleaner Water Separator

Used to replace the water separator on diesel particulate filter
4918851 cleaner, Part Number 4918840.
Diesel Particulate Filter Cleaner Adapter Kit

Used with Part Number 4918840 to adapt the diesel particulate filter
4918893 to the cleaner.
Diesel Particulate Filter Cleaner Oil Separator Filter

Used to replace the oil separator filter on diesel particulate filter
4918896 cleaner, Part Number 4918840.

Diesel Particulate Filter Cleaner
This machine is used with diesel particulate filter cleaner adapter kit,
4919052 Part Number 4919172 or 4919182, to clean the diesel particulate filter
once it is removed from the vehicle. (For use in the U.S.A. and
Canada.)
Diesel Particulate Filter Cleaner Canister Filter

Used to replace the canister filters on diesel particulate filter cleaner,
4919053 Part Number 4919052. Two are required per machine.
Diesel Particulate Filter Cleaner HEPA Filter

Used to replace the HEPA filter on diesel particulate filter cleaner,
4919054 Part Number 4919052.
Diesel Particulate Filter Cleaner Mounting Adapter Kit

Used with Diesel Particulate Filter Cleaner, Part Number 4919052, to
4919172 adapt the diesel particulate filter to the cleaner. Software unlock card,
Part Number 4919055, is included in this adapter kit to upload the
required cleaning parameters.
Diesel Particulate Filter Cleaner Mounting Adapter Kit

Used with Diesel Particulate Filter Cleaner, Part Number 4919052 or
4919182 4918840, to adapt the diesel particulate filter to the cleaner.
Air Handling Clean Care Kit for Vehicle Plumbing

Air Handling Clean Care Kit for ISX Engine Components

Exhaust Manifold, Dry Signature, ISX, and QSX15 Eng [...]
Exhaust Manifold, Dry (011-007)

Initial Check
NOTE: Some ISX CM870 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.

NOTE: Some ISX 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
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

service manual.
Twist the graphite seal in order to open it, allowing it to be
placed onto the exhaust manifold.
Signature, ISX, and QSX15 Eng [...] Exhaust Manifold, Dry
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
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.

illustration in order to show the seal kit installation. The
return tube.
Place the bottom cover over the slip joint and graphite seal
with the notch in the cover towards the center of the
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.
illustration, in order to show the seal kit installation. The
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.
Or until the ends of the cover make contact.
Preparatory Steps
WARNING
WARNING
Remove the charge air cooler piping. Refer to the
OEM service manual.
Remove the variable geometry turbocharger. Refer
Remove the heat shield. Refer to Procedure 011-032
in Section 11.
Remove the EGR valve. Refer to Procedure 011-022
in Section 11.

Remove the turbocharger. Refer to Procedure
WARNING
WARNING
Remove the charge air cooler piping. Refer to the
OEM service manual. Use protective caps from the
Air Handling Clean Care Kit to cover the connection
points.
Remove the air intake pipe to the turbocharger.
Refer to the OEM service manual. Use protective
caps from the Cummins Vehicle Air Plumbing Clean
Care Kit to cover the connection points.
Remove the variable geometry turbocharger (VGT).
Remove the exhaust gas pressure sensor tube.
Remove
WARNING
Remove two mounting capscrews and install two guide
studs.
Remove the remaining mounting capscrews, the spacers,
the exhaust manifold assembly and the gaskets.
Cover open points on the exhaust manifold and cylinder
head using heavy tape.
Disassemble
Disassemble the exhaust manifold end sections.
Discard the exhaust seal ring on the slip-joint, if equipped.

Remove the exhaust manifold end sections.

Disassemble the exhaust manifold end sections.

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
personal injury.
Use a 240-grit emery cloth to remove carbon deposits from
the sealing surfaces.
Steam-clean and dry with compressed air.
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
Inspect for cracks or other damage.
Inspect the manifold seal bore for wear.
Inspect the exhaust manifold turbocharger mounting
flange for warping.
WARNING
personal injury when using a steam cleaner or high
pressure water.
WARNING
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].
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
Inspect for cracks or other damage.
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.
A wear width larger than 1 mm [0.04 in] indicates

excessive wear and the exhaust seal must be replaced.
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 the seal
in two locations about 25.4 mm [1 in] apart.
NOTE: Take care not to damage the seal carrier surface.

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.
Discard the exhaust seal rings.
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.
Cover the open points on the exhaust manifold with heavy

tape to prevent engine contamination.
Assemble
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.

The exhaust manifold sections must be assembled on a
flat surface for proper alignment.
section.

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.
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.

section.
The end section bolt holes must be 152.4 mm [6 in] center
to center before installing onto the cylinder head.
Install
Remove the tape from the open exhaust ports and cylinder
head.
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.
WARNING
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.


Install two guide studs into center section mounting
location.
Install the center mounting gasket over the guide studs.
WARNING
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.

Torque values given have been established using anti-
seize compound as a lubricant.
Step2 55 Nm [ 41 ft-lb ]
Finishing Steps
Install the EGR valve. Refer to Procedure 011-022 in
Section 11.
Install the heat shield. Refer to Procedure 011-032 in
Section 11.
Install the variable geometry turbocharger (VGT).
Install the charge air cooler piping. Refer to the OEM
service manual.
Fill the cooing system. Refer to Procedure 008-018
in Section 8.
Operate the engine and check for air leaks and
exhaust gas leaks.

in Section 10.
exhaust gas leaks.
Signature, ISX, and QSX15 Eng [...] Exhaust Restriction

Install the exhaust gas pressure sensor tube. Refer
Install the variable geometry tubes. Refer to
Remove the protective caps and heavy tape.
Install the charge air cooler piping. Refer to the OEM
service manual.
in Section 8.
exhaust gas leaks.
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
Exhaust Restriction Signature, ISX, and QSX15 Eng [...]
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.
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.
Signature, ISX, and QSX15 Eng [...] EGR Cooler
EGR Cooler (011-019)

Preparatory Steps
WARNING
WARNING
NOTE: If the EGR cooler is being replaced due to an
internal coolant leak, the EGR differential pressure tubes
must be replaced.
NOTE: Brush away all loose dirt from around the area of
NOTE: If the Exhaust Gas Recirculation (EGR) cooler is
being replaced due to an internal coolant leak, the EGR
differential pressure tubes must be replaced.
the air-handling connections to avoid contamination of the
Drain the engine coolant. Refer to Procedure 008-018
in Section 8.
Remove the air intake pipe to turbocharger. Refer to
the OEM service manual. Use protective caps from the
Cummins Vehicle Air Pumping Clean Care Kit, Part
Number 4912425, to cover the connection points.
Remove the charge-air cooler pipe between the
turbocharger and charge-air cooler. Refer to the OEM
service manual. Use protective caps from the
Cummins Vehicle Plumbing Clean Care Kit, Part
Remove the turbocharger. Refer to Procedure 010-033
in Section 10.
Remove the exhaust gas pressure sensor tube. Refer
Remove the EGR cooler coolant lines. Refer to
EGR Cooler Signature, ISX, and QSX15 Eng [...]
WARNING
WARNING
NOTE: If the EGR cooler is being replaced due to a
malfunction that caused an internal coolant leak, the
crankcase breather element must be replaced.
malfunction that caused an internal coolant leak, the EGR
differential pressure sensor tubes should be inspected for
deposits. If deposits are found, replace the EGR
differential pressure tubes.
NOTE: If pressure testing the EGR cooler on ISX CM871
engines, do not remove the aftertreatment injector or
turbocharger before pressure testing the EGR cooler.
in Section 8.
Remove the air intake pipe to turbocharger. Refer to
the OEM service manual. Use protective caps from the
Cummins Vehicle Air Plumbing Clean Care Kit, Part
Remove the charge-air cooler pipe between the
turbocharger and charge-air cooler. Refer to the OEM
service manual. Use protectve caps from the
Cummins Vehicle Plumbing Clean Care Kit, Part
Remove the aftertreatment adapter pipe and
aftertreatment injector lines. Refer to Procedure
011-051 in Section 11. Refer to Procedure 011-043 in
Section 11.
Remove the turbocharger. Refer to Procedure 010-033
in Section 10.
Remove the EGR cooler coolant lines. Refer to
Remove
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.
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.

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.
Use protective caps from the Air Handling Clean Care Kit,
Part Number 4919403, to cover the open points on both
the EGR cooler and EGR plumbing.
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.
to cover the open ports on the EGR cooler and exhaust
manifold.

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
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.
WARNING
WARNING
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
Clean the EGR cooler connection with safety solvent and
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
Replace the EGR cooler if cracks or other damage is found
on the EGR cooler.
WARNING
WARNING
personal injury.
With the EGR connection tube attached, clean the cooler
end of the EGR connection tube with safety solvent.
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
WARNING
WARNING
personal injury.
Clean the EGR cooler connection with safety solvent and
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 in
Section 11.
WARNING
Clean the mounting surfaces with safety solvent to remove
any coolant deposits or debris.
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
WARNING
personal injury.
WARNING
Inspect the v-band clamp threads for damage. Replace
the clamp if damage is found.
Inspect the EGR cooler and the EGR cooler clamping

plates for cracks or other damage. Replace the EGR
cooler or EGR cooler clamping plates if cracks or other
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. Dispose of the liquid properly.
WARNING
personal injury.
WARNING
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.
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.
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
Replace the EGR cooler if cracks or other damage is
found.
WARNING
compressed air. Flying debris or dirt can cause
personal injury.
Clean the EGR cooler exhaust gas outlet with safety
solvent.
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
WARNING
personal injury.
WARNING
Clean the EGR cooler bellows with safety solvent and dry
Inspect the EGR cooler bellows for cracks or other
damage.
Replace the EGR cooler bellows if cracks or other damage
is found.
WARNING
Clean the mounting surfaces with safety solvent to remove
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.
Pressure Test
Automotive with CM870 - Off Engine Repair
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 damaged 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.
WARNING
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 - On Engine Repair

Install the plug with the o-ring supplied in Service Kit, Part
Number 4918655, into the coolant inlet side of the EGR
cooler, use a M8 x 1.25 capscrew.
Install the two 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.
NOTE: This step is necessary to prevent debris or

moisture from entering the EGR piping or EGR valve.
Loosen the rear EGR connection tube retaining
capscrews at the EGR cooler gas outlet.
WARNING
personal injury.
NOTE: Air pressure regulator kit, Part Number 3164231,
or equivalent, is suitable for use during this step.
Install air pressure regulator and hose assembly onto the
test fitting on the coolant inlet of the EGR cooler.
Install a ball type shutoff valve onto the inlet side of the air
pressure regulator to allow the air supply to be shutoff
during testing.
WARNING
personal injury.
Make sure the air pressure regulator and ball-type valve
are closed and connect compressed air supply to the
pressure regulator.
Apply 620 kPa [90 psi] of air pressure to the EGR cooler.
Inspect for air escaping the EGR cooler assembly as a
result of loose fittings by spraying the exterior of the EGR
cooler and all lines and fittings with a mixture of mild soap
and water.
WARNING
personal injury.
Shut off the air supply to the regulator by using the ball-
valve and disconnect the compressed air supply.
Record the time at which the air supply was shutoff and
the air pressure shown on the air pressure regulator
gauge.
Measure and record the air pressure after 15 minutes.
If the measured pressure loss in the EGR cooler is more
than 35 kPa [5 psi] in 15 minutes, the EGR cooler is not
reusable.
NOTE: If the EGR cooler is not reusable, inspect the air
pressure regulator, air lines, ball-valve, o-rings and other
components carefully for leaks. A mixture of mild soap
and water may be sprayed onto the assembly to aid in leak
detection.
If the EGR cooler is not reusable, inspect the turbocharger

turbine housing and rear EGR connection tube for any
signs of coolant deposits.
coating the inside of the turbine housing.
If coolant deposits are found in the turbocharger turbine
housing, inspect the turbocharger for progressive
damage.
Coolant can cause the turbocharger to stick. Inspect the
turboscharger for reuse. Refer to Procedure 010-033 in
Section 10.
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
coolant to collect.
coating the inside of the EGR valve passages.
If coolant deposits are found, remove the EGR valve and
inspect for reuse. Refer to Procedure 011-022 in Section
11.
Install the parts supplied in the EGR cooler leak test kit:
EGR Cooler Coolant Lines. Refer to Procedure
EGR Connection Tubes. Refer to Procedure 011-025
in Section 11.
Properly fill the cooling system. Refer to Procedure
Install
Install a new hose onto the rear EGR connection tube and
install the hose clamps.
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.
the inside of the v-band clamp, to make sure of proper
loading on the clamp.
Install a v-band clamp.
Install and hand tighten the four mounting nuts and

capscrews. Tighten the capscrews and nuts in the
sequence shown.
Torque Value:
Capscrews 47 Nm [ 35 ft-lb ]
Torque Value:
Nuts 23 Nm [ 204 in-lb ]
Connect the EGR cooler to the new hose on the rear EGR
connection tube.

Torque Value:
Breeze Clamp (1) 7 Nm [ 62 in-lb ]
Torque Value:
Normal Clamp (2) 5 Nm [ 44 in-lb ]
Tighten the v-band clamp between the EGR cooler

connection and the EGR cooler.
CAUTION
Keep all protective caps on the EGR cooler in place
while grinding clearance in the upper mounting
bracket. Failure to do so could cause progressive
damage to the engine once the EGR cooler is
installed. It's important to prevent any debris from
entering the cooler.
Inspect for an interference fit between the upper EGR
cooler mounting bracket and the lower portion of the
exhaust manifold flange. If this interference is present,
grind a clearance on the upper EGR cooler mounting
bracket in the area shown in the illustration.

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.
Install the four EGR cooler mounting capscrews at the top

of the EGR cooler mounting bracket.
Install and hand tighten the four mounting nuts. Tighten
the capscrews and nuts in the sequence shown.
Torque Value:
Capscrews 47 Nm [ 35 ft-lb ]
Torque Value:
Nuts 23 Nm [ 204 in-lb ]
CAUTION
to not be able to be reused.
Position the v-band clamp onto the EGR cooler inlet
connection.
Tighten the two retaining capscrews on the rear EGR

connection tube.
Finishing Steps
NOTE: If the EGR cooler is being replaced due to an
internal coolant leak, the EGR differential pressure tubes
must be replaced.
Install the EGR cooler coolant lines. Refer to
Install the exhaust gas pressure sensor tube. Refer to
Install the turbocharger. Refer to Procedure 010-033 in
Section 10.
Remove the protective caps used to cover the charge-
air cooler pipe connection points.
Install the charge-air cooler pipe. Refer to the OEM
service manual.
Remove the protective caps used to cover the air
intake pipe to the turbocharger
Install the air intake pipe to the turbocharger. Refer to
OEM service manual.
Fill the engine cooling system. Refer to Procedure
Start the engine, check for leaks, and verify proper
operation.
Signature, ISX, and QSX15 Eng [...] EGR Mixer

malfunction that caused an internal coolant leak, the
crankcase breather element must be replaced.
malfunction that caused an internal coolant leak, the EGR
differential pressure sensor tubes should be inspected for
deposits. If deposits are found, replace the EGR
differential pressure tubes.
NOTE: If a malfunction resulted in oil, excessive fuel, or
aftertreatment system must be inspected. Refer to the
Aftertreatment Diesel Oxidation Catalyst and
Aftertreatment Diesel Particulate Filter Reuse Guidelines,
Bulletin 4021600.
NOTE: If a malfunction resulted in coolant entering the
exhaust system, the aftertreatment system can be
recovered. Refer to Procedure 014-013 in Section 14.
Install the EGR cooler coolant lines. Refer to
Install the turbocharger. Refer to Procedure 010-033 in
Section 10.
Install the aftertreatment adapter pipe and
aftertreatment injector lines. Refer to Procedure
011-043 and Refer to Procedure 011-051 in Section 11.
Remove the protective caps used to cover the charge-
air cooler pipe connection points.
Install the charge-air cooler pipe. Refer to the OEM
service manual.
Remove the protective caps used to cover the air
intake pipe connection points.
Start the engine, check for leaks, and verify proper
operation.
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.
EGR Mixer Signature, ISX, and QSX15 Eng [...]
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.
WARNING
personal injury.
WARNING
Use compressed air to blow out any debris or soot buildup
inside the EGR mixer.
Clean all mounting surfaces with solvent.
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.
Signature, ISX, and QSX15 Eng [...] EGR Mixer
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.
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.
Procedure 014-013.
EGR Valve Signature, ISX, and QSX15 Eng [...]
EGR Valve (011-022)

Preparatory Steps
WARNING
environmental regulators.
WARNING
in Section 8.
Remove the water pump drive belt. Refer to Procedure
On some applications, removal of the alternator is
required. Refer to Procedure 013-001 in Section 13.
Remove the air intake pipe to the turbocharger. Refer
to the OEM service manual.
Remove the heat shield. Refer to Procedure 011-032
in Section 11.
Disconnect the EGR valve motor and position sensor
connectors from the harness.
Remove the EGR valve coolant lines. Refer to

Disconnect EGR temperature sensor. See the
Manual CM871 and CM876 Electronic Control System,
ISX and ISM Engines, Bulletin 4021560.Refer to
Remove the front EGR connection tube from the EGR
valve. Refer to Procedure 011-025 in Section 11.
Disconnect the OEM fuel return hose from the
integrated fuel system module. Refer to the OEM
service 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
Disconnect the OEM air compressor discharge line.
Refer to the OEM service manual.
Signature, ISX, and QSX15 Eng [...] EGR Valve
Remove
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.

Disconnect the EGR valve electrical connector.
Make 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.
Use protective caps from the Air Handling Clear Care Kit
to cover open points on the EGR valve and bracket.
Disassemble
NOTE: Be careful not to nick the EGR valve housing when
removing the seal.
Remove the pipe seal from the EGR valve inlet port.
Pry the lip of the pipe seal up from the EGR valve with a
small flat headed screwdriver.
Discard the pipe seal.

WARNING
personal injury.
WARNING
reduce the possibility of injury.
Check to make sure the EGR poppet head is present. If
the poppet head is missing, run a stiff wire through every
port of the exhaust manifold to locate the missing poppet
head.
Do not assemble the engine without finding the missing
poppet head.
Clean the mounting surfaces with a shop towel wetted with
a safety solvent to remove any deposits or debris.
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 clamp threads for damage.
WARNING
WARNING
personal injury.
Clean the EGR valve mounting and sealing surfaces with
a shop towel wetted with safety solvent to remove any
deposits or debris.
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.
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.
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
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; use 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.
Install
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.

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.
NOTE: The longest capscrew passes through the EGR
valve and EGR valve mounting bracket and threads into
the engine block.
Connect the EGR valve connector.

Finishing Steps
Install the EGR valve coolant lines. Refer to Procedure
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 in
Section 11.
Install the alternator, if removed. Refer to Procedure
Install the water pump drive belt. Refer to Procedure
Operate the engine and check for exhaust and coolant
leaks.

Install the EGR heat shield. Refer to Procedure
Connect the OEM air compressor discharge line. Refer
to the OEM troubleshooting and repair manual.
Install the front EGR connection tube. Refer to
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. See the
Manual CM871 and CM876 Electronic Control System
ISX and ISM Engines, Bulletin 4021560. Refer to
Operate the engine and 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 in Section
14.
EGR Cooler Connection Signature, ISX, and QSX15 Eng [...]
EGR Cooler Connection (011-024)

Preparatory Steps
WARNING
environmental regulators.
WARNING
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.
WARNING
WARNING
personal injury.
Clean the EGR cooler connection with safety solvent.
Inspect the EGR cooler connection for cracks or other
damage.
Signature, ISX, and QSX15 Eng [...] EGR Cooler Connection
Clean the EGR cooler mounting flange with safety solvent.

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.

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

Inspect the V-band clamp threads for damage.
Replace the V-band clamp if damage is found.
EGR Cooler Connection Signature, ISX, and QSX15 Eng [...]
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.
Finishing Steps
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.
008-018.
Start engine and verify proper operation.
Signature, ISX, and QSX15 Eng [...] EGR Connection Tubes
EGR Connection Tubes (011-025)

Preparatory Steps
WARNING
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.
Section 6.
Remove the engine wiring harness from the exhaust
temperature sensor. See the following procedure in the
Troubleshooting and Repair Manual, CM870
Remove the dipstick tube. Refer to Procedure 007-011
in Section 7.
Remove the differential pressure sensor tubes from
the connection tube and the sensor adapter. Refer to
Remove the oil pressure sensor. See the following
CM870 Electronic Control System, Signature and ISX
EGR Connection Tubes Signature, ISX, and QSX15 Eng [...]
WARNING
pressure water.
WARNING
the air handling connections to prevent contamination of
the interior of the engine.
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. See the following procedure in the
Troubleshooting and Repair Manual, CM871 and
CM876 Electronic Control System, ISX and ISM
Remove the EGR differential pressure sensing tubes
from the EGR venturi. Refer to Procedure 011-026 in
Section 11.
Remove
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.
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.
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.
Part Number 4919403 and Part Number 4919425, to cover
the open points on all components.
Remove the three EGR venturi mounting capscrews.

Remove the EGR venturi.
Cover the irregular openings on the venturi and air intake

connections with protective caps from the Air Handling
Clean Care Kit, Part Number 4919403 and Part Number
4919425.
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.
Part Number 4919403 and Part Number 4919425, to cover
the open points on all components.

WARNING
WARNING
personal injury.
Clean the connection tubes with solvent.
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.
Inspect the band section of the clamp(s) for cracks or other

damage.
Inspect the threaded section of the clamps for cracks or
other damage.
Replace clamp(s) if cracks or other damage is present.
WARNING
WARNING
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.
Inspect the EGR measurement venturi for soot plugging

at the EGR differential pressure sensing tube ports. The
port labeled R has a hook inside that 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 band section of the clamp(s) for cracks or other

damage.
Inspect the threaded section of the clamps for cracks or
other damage.
Replace the clamp(s) if cracks or other damage is present.
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
Part Number 4919403 and Part Number 4919425, at 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.
Hand-tighten the capscrew and nuts.
Remove the protective caps from the component.

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 capscrews, nuts, and hose
clamps.
Torque Value:
M10 P-clip nut 46 Nm [ 34 ft-lb ]
Torque Value:
M8 P-clip nut 23 Nm [ 204 in-lb ]
Torque Value:
P-clip capscrew and nut 45 Nm [ 33 ft-lb ]
Torque Value:
Breeze Clamp (1) 7 Nm [ 62 in-lb ]
Torque Value:
Norma Clamp (2) 5 Nm [ 44 in-lb ]

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 Nm [ 34 ft-lb ]
Torque Value:
Hose clamps 5 Nm [ 44 in-lb ]
Torque Value:
P-clip capscrew and nut 45 Nm [ 33 ft-lb ]
between the front EGR connection tube and the EGR
mixer.
Tighten the p-clip mounting capscrews, nuts, and clamps.
Torque Value:
P-clip capscrews and nut 45 Nm [ 33 ft-lb ]
Torque Value:
Hose clamps 5 Nm [ 44 in-lb ]

Remove the protective caps from the component.
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.
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.
NOTE: Install the protective sleeve onto the exposed
threads of a T-bolt style clamp.
NOTE: Two different types of hose clamps can be used in
this location. The torque value for each clamp is the same,
regardless of which clamp is used.
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. Hand-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.
Tighten the rear EGR venturi mounting capscrews.
Tighten the two rear tail support mounting capscrews.
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:
Capscrew 1, Capscrew2, Capscrew 1.
Make sure to tighten Capscrew 1 twice.
Center the EGR connection hose evenly between the tube
and the EGR venturi and tighten both retaining clamps.
NOTE: Two different types of hose clamps can be used in
this location. The torque value for each clamp is the same,
regardless of which clamp is used.
Finishing Steps
WARNING
pressure water.
WARNING
Install the oil pressure sensor. Use the following
CM870 Electronic Control System, Signature and ISX
in Section 19.
Install the differential pressure sensor tubes to the
front connection tube and the sensor adapter. Refer to
Install the lubricating oil dipstick tube. Refer to
Install the engine wiring harness to the exhaust
temperature sensor. Use the following procedure in
the Troubleshooting and Repair Manual, CM870
Electronic System, Signature and ISX Engines,
Bulletin 4021334. Refer to Procedure 019-043 in
Section 19.
Section 6.
WARNING
pressure water.
WARNING
Install the EGR differential pressure sensing tubes to
the EGR venturi. Refer to Procedure 011-026 in
Section 11.
Install the engine wiring harness to the exhaust
temperature sensor. Use the following procedure in
the Troubleshooting and Repair Manual CM871 and
CM876 Electronic Control System ISX and ISM
Signature, ISX, and QSX15 Eng [...] EGR Differential Pressure Sensor Tubes
EGR Differential Pressure Sensor

Tubes (011-026)
Preparatory Steps
If necessary, remove the EGR differential pressure
sensor. Refer to Procedure 019-370 in Section 19.
Remove
For engines beginning with ESN 14040552, the pressure
sensor does not have to be removed to allow the removal
of the EGR differential pressure sensor tubes.
Pressure sensor removal is necessary only if the sensor
adapter is being replaced. Refer to Procedure 011-028 in
Section 11.
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.

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.
Loosen the hose clamps at the sensor adapter.
Remove the tubes.

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 delta pressure fault
code.
EGR Differential Pressure Sensor Tubes Signature, ISX, and QSX15 Eng [...]
Check the inside of the tubes.

If a tube is clogged or partially clogged, replace the tube.
WARNING
WARNING
personal injury.
Inspect the mating orifices for 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 tube, making
sure not to damage the orifice.

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.
Signature, ISX, and QSX15 Eng [...] EGR Differential Pressure Sensor Tubes
WARNING
WARNING
personal injury.
NOTE: If coolant is found in the EGR differential pressure
sensor tubes, they must be replaced.
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.
Make 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.
Check the tubes, hose, and hose clamps for cracks or
other damage.
Replace the tubes if the tubes or hose is damaged.
Replace the hose clamps if damaged.
WARNING
WARNING
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 the debris from the mouth of the orifice,
make sure not to damage the orifice.
EGR Differential Pressure Sensor Tubes Signature, ISX, and QSX15 Eng [...]
Install
For engines beginning with ESN 14040552, the tubes
must be installed so they do not cross over each other.
Apply a light lubricant (CRC 3-36, WD-40, or equivalent)
to the tube threads and install the tubes. The lubricant is
to be applied inside the tube nut, directing the spray on
the threads and around the sleeve and flange area.
Position the insulation on the differential pressure sensor
tubes so the tube nuts at the venturi connections are
covered.
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.

The tubes must be installed so they do not cross each
other.
Apply a light lubricant (CRC 3-36, WD-40, or equivalent)
to the tube threads and install the tubes. The lubricant is
to be applied inside the tube nut, directing the spray on
the threads and around the sleeve and flange area.
Tighten the tube nuts at the EGR venturi connection.
Tighten the hose clamps at the differential pressure

sensor adapter.
Position the insulation on the differential pressure sensor
tubes so the tube nuts at the venturi connection are
covered.
The insulation on the pressure tubes is designed to only
cover the bottom portion of the tube which threads into the
EGR transfer tube. This is the most effective location and
also reduces the possibility of heat soaking of the EGR
differential pressure sensor.
Signature, ISX, and QSX15 Eng [...] Exhaust Gas Pressure Sensor Tube
Finishing Steps
If removed, install the EGR differential pressure
Check for fault codes.

If removed, install the EGR differential pressure
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
Remove
Loosen the tube nuts at the exhaust manifold and at the
sensor adapter.
Remove the tube.
Exhaust Gas Pressure Sensor Tube Signature, ISX, and QSX15 Eng [...]
WARNING
WARNING
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.
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.
Finishing Steps
Connect the electrical connectors to the exhaust gas
pressure sensor. Refer to Procedure 019-376 in the
Procedure 014-013.
Signature, ISX, and QSX15 Eng [...] EGR Differential Pressure Sensor Adapter
EGR Differential Pressure Sensor

Adapter (011-028)
Preparatory Steps
Remove or disconnect the following:
EGR differential pressure sensor connector from the
engine wiring harness.
Procedure 011-026.
Remove
Remove the mounting capscrews.
Remove the EGR pressure sensor adapter.
WARNING
personal injury.
WARNING
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.
Inspect the EGR pressure sensor adapter for cracks or
fretting. Replace the EGR pressure sensor adapter if
cracks are found.
EGR Valve Coolant Lines Signature, ISX, and QSX15 Eng [...]
Install
Install the EGR pressure sensor adapter and capscrews.
Finishing Steps
Procedure 011-026.
EGR differential pressure sensor connector to the
engine wiring harness.
EGR Valve Coolant Lines (011-030)

Preparatory Steps
WARNING
WARNING
008-018.
Remove the air intake piping. Refer to the OEM
service manual.
Remove the heat shield. Refer to Procedure
011-032.
Signature, ISX, and QSX15 Eng [...] EGR Valve Coolant Lines
Remove
Disconnect the EGR valve coolant supply (bottom) and
return (top) lines.
WARNING
WARNING
personal injury.
Clean the EGR valve coolant lines with solvent.
Inspect the EGR valve coolant lines and rubber grommets
for cracks or damage.
Replace the lines, if cracks or damage is found.
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.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Eng [...]
Finishing Steps
Install the heat shield. Refer to Procedure 011-032.
manual.
008-018.
Start and operate the engine. Check for leaks.
EGR Cooler Coolant Lines (011-031)

Preparatory Steps
WARNING
WARNING
in Section 8.
Remove the air intake piping. Refer to the OEM service
manual. Use protective caps from the Air Handling
Clean Care Kit, Part Number 4919425, to cover the
connection points.
Remove the exhaust gas pressure sensor tube. Refer
WARNING
WARNING
in Section 8.
Remove the air intake piping. Refer to the OEM service
manual. Use protective caps from the Air Handling
Clean Care Kit, Part Number 4919425, to cover the
connection points.
Signature, ISX, and QSX15 Eng [...] EGR Cooler Coolant Lines
Remove
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.
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.
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.
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.

WARNING
WARNING
personal injury.
Clean the EGR cooler coolant vent and the EGR cooler
coolant return line with solvent.
Inspect the EGR cooler coolant vent and the EGR cooler
coolant return line for cracks or other damage. Replace
the lines if cracked or otherwise damaged.
Inspect the EGR cooler vent line grommets for damage.

Replace the grommets if they are damaged.
WARNING
WARNING
personal injury.
Clean the EGR cooler coolant vent line and the EGR
cooler coolant supply and return tubes with solvent.
Inspect the EGR cooler vent line grommets for damage.

Replace the grommets if they are damaged.
Inspect the EGR cooler for cracks or other damage.

Replace the lines if cracked or otherwise damaged.
Install
CAUTION
Do not use petroleum products on the EGR cooler
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.
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.
CAUTION
Do not use petroleum products on the EGR cooler
Install the new o-rings on the EGR cooler coolant supply
tubes and jumper connection.
water, or vegetable oil to aid in installation.
Install the EGR cooler coolant supply tube mounting

bracket and nuts.
Tighten the nuts.
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 tighten at this time.
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 tighten at this time.
Tighten in the following sequence.

Install the EGR cooler coolant supply tube mounting
capscrew and tighten.
Tighten the EGR cooler coolant supply jumper tube
retaining clamp capscrew.
Tighten the EGR cooler coolant supply tube retaining
clamp capscrew.
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.

water, or vegetable oil, for easier installation.
Install the jumper tube into the EGR cooler.
Install the press in place seal and the coolant return tube.
Finishing Steps
Install the exhaust gas pressure sensor tube. Refer to
Remove the protective caps from the intake piping.
manual.
Section 8.
Operate the engine and check for leaks. Check for
leaks.
Heat Shield Signature, ISX, and QSX15 Eng [...]

Remove the protective caps from the intake piping.
Install the intake piping. Refer to the OEM service
manual.
Section 8.
Heat Shield (011-032)

Preparatory Steps
Remove the air intake piping from the turbocharger.
Refer to the OEM troubleshooting and repair
manual.
Remove
Remove the three mounting capscrews from the EGR
valve.
Remove the heat shield.

Remove the four EGR valve heat shield mounting
capscrews from the EGR valve.
Remove the heat shield.
Signature, ISX, and QSX15 Eng [...] Heat Shield
WARNING
WARNING
personal injury.
Clean the heat shield with solvent.
Inspect the heat shield for cracks or any other damage.
Replace the heat shield, if cracks or any other damage is
found.
Install
Apply high temperature anti-seize compound onto the
mounting capscrews.
Install the three mounting capscrews and the heat shield.

Apply high temperature anti-seize compound onto the
mounting capscrews.
Install the four capscrews and the heat shield.
Exhaust Gas Pressure Sensor Adapter Signature, ISX, and QSX15 Eng [...]
Finishing Steps
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
Remove the exhaust gas pressure sensor. Refer to
Remove the exhaust pressure sensor tube. Refer to
Procedure 011-027.
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.
Inspect the p-clamp for cracks.
Signature, ISX, and QSX15 Eng [...] Exhaust Gas Pressure Sensor Adapter
Install
All Applications
Install the sensor adapter and the p-clamp mounting
capscrew.
Finishing Steps
Install the exhaust pressure sensor tube. Refer to
Procedure 011-027.
Install the exhaust gas pressure sensor. Refer to
Aftertreatment Diesel Particulate Filter Signature, ISX, and QSX15 Eng [...]
Aftertreatment Diesel Particulate Filter

(011-041)
General Information
WARNING
During regeneration, exhaust gas temperature could
reach 800C [1500F], and exhaust system surface
temperature could exceed 700C [1300F], which is
hot enough to ignite or melt common materials, and
to burn the skin. The exhaust and exhaust
components can remain hot after the vehicle has
stopped moving. To avoid the risk of fire, property
damage, burns or 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 being serviced.
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 system.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Diesel Particulate Filter
Preparatory Steps
WARNING
cable last.
Disconnect the vehicle batteries. Refer to the OEM
service manual.
Disconnect the exhaust gas pressure sensor tubes, if
necessary.
- For ISX engines, use this procedure in the Signature,
ISX and QSX Service Manual, Bulletin 3666239.Refer
- For ISM engines, use this procedure in the ISM, ISMe,
and QSM11 Service Manual, Bulletin 3666322. Refer
Disconnect the aftertreatment particulate filter
differential pressure sensor tubes, if necessary. Refer
Disconnect the exhaust gas temperature sensor
electrical connector(s) from wiring harness.
Use this procedure in the Troubleshooting and Repair
Manual, CM871 and CM876 Electronic Control
System, ISX and ISM Engines, Bulletin 4021560. Refer
Remove
Mark the direction of the exhaust flow on the outside of
the aftertreatment system to aid in assembly.
WARNING
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 any 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.
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. Do not use
an open flame to burn off soot accumulation from the
face of the aftertreatment diesel particulate filter. Do
not scrape off soot accumulation from the face of the
aftertreatment diesel particulate filter.
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
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 reusable
according to the Catalyst and Aftertreatment Particulate
Filter Reuse Guidelines, Bulletin 4021600, the filter can be
cleaned using diesel particulate filter cleaner, Part
Number 4918840, with adapter kit, Part Number 4918893,
or diesel particulate filter cleaner, Part Number 4919052,
with adapter kit, Part Number 4919172, or other Cummins
Inc. approved cleaning machine if cleaning an aftermarket
or retro-fit filter, either the Part Number 4918840 or
4919052 diesel particulate filter cleaner can be used with
adapter kit, Part Number 4919182. Refer to the
manufacturer's service manual for appropriate cleaning
procedures.
NOTE: If the aftertreatment diesel particulate filter was
removed due to an active Fault Code 1981 or Fault Code
1922 and is contaminated with coolant, it must be
replaced with a new aftertreatment diesel particulate filter.
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.
Maintenance Check
If the aftertreatment diesel particulate filter is being
removed for an ash cleaning or soot cleaning
maintenance interval, the aftertreatment diesel particulate
filter will need to be removed and cleaned using a cleaning
tool approved by Cummins Inc. Consult the Service Tool
Instruction, Bulletins 3400284 and 3400253, for
information regarding parts and operation of Cummins
Inc. approved cleaning tools. Conventional cleaning can
not be used to clean aftertreatment diesel particulate
filters.
Because it can be difficult to determine if an aftertreatment
diesel particulate filter is plugged with ash or soot, it will
be necessary to clean the aftertreatment diesel particulate
filter before performing a stationary regeneration to
prevent any system damage from occurring. For
information on how to perform a stationary regeneration
use the following procedre. Refer to Procedure 014-013 in
Section 14.
Performing the ash and/or soot cleaning procedure will:
Remove excess soot to allow a stationary regeneration
without damaging the aftertreatment diesel particulate
filter
Allow the aftertreatment diesel particulate filter to be
reused after a 1981 and/or 1922 fault code occurs
Remove excess ash and improve regeneration
frequency.
Performing a stationary regeneration after cleaning the
aftertreatment diesel particulate filter for ash and/or soot
will:
Remove any residual soot from the system that was
not removed during the cleaning procedure
Test the diesel oxidation catalyst efficiency
Test the aftertreatment system functionality.
NOTE: Soot will plug the cleaning machine filter quicker
than ash. Cleaning soot from a DPF using Cummins Inc.
approved machines can result in the need for increased
maintenance intervals of the cleaning machine filter.
Install
WARNING
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, an
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
final alignment of the differential pressure sensor tubes.
NOTE: Some accumulation of exhaust residue/soot is

normal and does not indicate a malfunctioning
A heavy buildup of exhaust residue/soot can indicate a
malfunction of the aftertreatment diesel particulate filter.
If the aftertreatment diesel particulate filter is being
replaced due to black smoke, and the exhaust stack is
found to have heavy black soot accumulation, clean the
last 152 to 254 mm [6 to 10 in] of the exhaust system
outlet.
Adjust
If the aftertreatment diesel particulate filter was replaced
or cleaned due to Fault Code 1922, it will be necessary to
reset the stored soot load in the engine's ECM.
Advanced ECM Data
Use INSITE electronic service tool to perform the
Aftertreatment Maintenance Reset Procedure.
Use INSITE electronic service tool or the in cab
switch, if equipped, to perform a stationary
regeneration.Refer to Procedure 014-013 in Section 14
In situations where Fault Code 1981 is active and Fault
Codes 2639, 1921, and 1922 are not active, it is not
necessary to perform a stationary regeneration after
replacing the aftertreatment diesel particulate filter
In situations where Fault Code 1981 and/or 1922 are
active and the aftertreatment diesel particulate filter
was cleaned,a stationary regeneration must be
performed after installing the filter on the vehicle.
Finishing Steps
WARNING
cable last.
Connect the exhaust gas temperature sensor electrical
connector(s) to the wiring harness, if necessary.
Use this procedure in the Troubleshooting and Repair
Manual, CM871 and CM876 Electronic Control
System, ISX and ISM Engines, Bulletin 4021560. Refer
Connect the aftertreatment particulate filter differential
pressure sensor tubes, if necessary.
Connect the exhaust gas pressure sensor tubes, if
necessary.
- For ISX engines, use this procedure in the Signature,
ISX and QSX Service Manual, Bulletin 3666239.Refer
- For ISM engines, use this procedure in the ISM, ISMe,
Tighten the V-band clamps.
Connect the vehicle batteries. Refer to the OEM
service manual.
Operate the vehicle on an engine dynamometer or
perform a road test with the engine at rated load for a
minimum of 5 minutes to make sure the aftertreatment
system is performing properly. Refer to Procedure
Check for exhaust leaks.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector
Aftertreatment Fuel Injector (011-042)

Preparatory Steps
WARNING
WARNING
Drain the coolant.
- For Signature, ISX, and QSX15 engines, use the
following procedure in the Signature, ISX, and
QSX15 Service Manual, Bulletin 3666239. Refer to
- For ISM, ISMe, and QSM11 engines, use the following
procedure in the ISM, ISMe, and QSM11 Service
Manual, Bulletin 3666322.Refer to Procedure
Disconnect the fuel lines and coolant lines. Refer to
Disconnect the wiring harness from the aftertreatment
injector.
Remove the adapter tube and injector as an assembly.
Remove
Remove the adaptor tube gasket.
Remove the capscrews holding the injector.

Remove the injector assembly.
Cut the EZ tie holding the injector harness to the heat
shield.
Discard the metal gasket.
Discard the fibrous insulator.
Remove the capscrew spacers.
Aftertreatment Fuel Injector Signature, ISX, and QSX15 Eng [...]
WARNING
WARNING
personal injury.
Inspect the injector tip.
Some carboning can occur on the tip of the injector.
Spray the tip of the aftertreatment fuel injector with

carburetor cleaner. When spraying, focus the spray on the
tip of the injector. Use enough carburetor cleaner to fill the
cavity surrounding the tip and to cover the tip.
Allow the carburetor cleaner to sit for 15 seconds so that
it can break down and penetrate the debris that has
collected in the tip area.
NOTE: Carburetor cleaner is the most effective solvent for
this procedure. Do not substitute any other cleaning
solvent.
CAUTION
Use only a stiff brass brush with undamaged bristles
to clean the tip of the aftertreatment fuel injector.
CAUTION
The use of a brush with damaged bristles will not be
as effective.
CAUTION
The use of a steel wire brush or a steel wire wheel will
cause permanent damage to the aftertreatment fuel
injector.
Use a brass brush to agitate the carburetor cleaner,
focusing on the tip of the injector.
Repeat spraying and brushing for 1 minute. Often the
carbon will be removed from the tip in a short period, but
cleaning for a full minute will remove the carbon built up
in the nozzle.
NOTE: The carbon this procedure is attempting to remove
can often not be seen with the unaided eye. This carbon
builds up in the nozzle tip area of the injector.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector
Inspect the injector tip for cracks or other damage.

Clean the adapter tube injector mounting surface.Refer to
Use safety solvent to clean the capscrews.

Clean the capscrews thoroughly with a wire brush, a soft
wire wheel, or use a non-abrasive bead blast to remove
deposits from the shaft and the threads.
Inspect the capscrews for damaged threads, corroded

surfaces, or a reduced diameter (due to capscrew
stretching).
Inspect the harness and connector pins for the following:
Loose connector
Corroded pins
Bent or broken pins
Pushed back or expanded pins
Moisture in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
Connector shell broken
Wire insulation damage
Damaged connector locking tab.
For general inspection techniques, reference the following
procedure in the CM871 and CM876 Electronic Control
Systems, ISX and ISM Engines Troubleshooting and
Aftertreatment Fuel Injector Signature, ISX, and QSX15 Eng [...]
Inspect the heat shield for the following:

Cracks
Dents
Install
Attach the heat shield to the injector.
Install a new high temperature EZ tie to hold the injector
harness to the heat shield.
Install a new fibrous insulator.
Install a new metal gasket.
NOTE: The fibrous insulator will be against the injector.
Install the aftertreatment injector onto the adapter pipe.
Apply a coat of high temperature anti-seize compound to
the capscrews.
Install the capscrews and spacers.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Adapter Pipe
Finishing Steps
WARNING
Connect the fuel line and coolant lines. Refer to
Connect the adapter pipe to the turbocharger. Refer to
Connect the wiring harness to the aftertreatment
injector.
Fill the cooling system.
- For Signature, ISX, and QSX15 engines, use the
- For ISM, ISMe, and QSM11 engines, use the following
Manual, Bulletin 3666322.Refer to Procedure 008-018
in Section 8.
aftertreatment system must be inspected. In the ISM,
ISMe, and QSM11 Service Manual, Bulletin 3666322,
reference the following procedure. Refer to Procedure
Aftertreatment Adapter Pipe (011-043)

Preparatory Steps
WARNING
WARNING
environment regulations.
Drain the coolant.
For Signature, ISX, and QSX15 engines, use the
For ISM, ISMe, and QSM11 engines, use the following
Manual, Bulletin 3666322. Refer to Procedure 008-018
in Section 8.
Disconnect the aftertreatment injector and coolant
lines. Refer to Procedure 011-051 in Section 11.
Disconnect the electrical connection.
Aftertreatment Adapter Pipe Signature, ISX, and QSX15 Eng [...]
WARNING
WARNING
environment regulations.
NOTE: Determine the appropriate radiator or coolant
expansion tank cap adapter for the vehicle being serviced.
A list of available caps and applications can be found in
Section 14 of the Service Products Catalog, Bulletin
3377710.
Use a vacuum pump type device on the cooling system.
Install the adapter on the radiator or coolant expansion
tank. Connect an automotive hand held vacuum pump and
apply 3 in Hg [40 in H2O] of vacuum.
NOTE: Depending on the cooling system configuration,
more vacuum may be required to keep the cooling system
in balance.
Place a container under the aftertreatment fuel injector.
There may be a small quantity of coolant that drains from
the coolant lines when disconnected.
Disconnect the aftertreatment injector and coolant
lines. Refer to Procedure 011-051 in Section 11.
Disconnect the electrical connection.
Remove the aftertreatment injector from the adapter
pipe. Refer to Procedure 011-042 in Section 11.
Remove the NOx sensor module from the adapter
pipe.
Remove
Remove the V-band clamp between the exhaust adapter
pipe and the turbocharger.
Remove the V-band clamp between the exhaust adapter
pipe and the OEM exhaust down-pipe.
Remove the adapter pipe assembly from engine.
Remove the gasket from each end and discard. Do not use
a screwdriver or other sharp tool to remove the gaskets.
This will damage the gasket seating area.
Remove the aftertreatment injector from the adapter pipe.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Adapter Pipe
WARNING
WARNING
personal injury.
Saturate the inside of the adapter pipe with safety solvent.
Mineral based solvents can be used if results from safety
solvent are not acceptable.
Clean the inside of the adapter pipe with a non-abrasive
brush.
Saturate the injector mounting pad with safety solvent.
Clean the mounting surface with a non-abrasive brush.
Make sure the locator pin is in the adapter pipe. Replace

the adapter if necessary.
Inspect all mating surfaces for cracks or any other
damage. Replace the adapter if necessary.

EGR Valve Mounting Bracket Signature, ISX, and QSX15 Eng [...]
Install
Install the aftertreatment injector assembly onto the
adapter pipe. Refer to Procedure 011-042 in Section 11.
Install new gaskets on each end of the adapter pipe.
Place the exhaust adapter pipe in position with the pin in
the correct location in the turbocharger.
Tighten the v-band clamps on each end.
Finishing Steps
Connect the electrical connection.
Connect the aftertreatment injector coolant lines.
Fill the cooling system.
For Signature, ISX, and QSX15 engines, use the
For ISM, ISMe, and QSM11 engines, use the following
Manual, Bulletin 3666322. Refer to Procedure 008-018
in Section 8.
EGR Valve Mounting Bracket (011-044)

Preparatory Steps
Remove the EGR valve heat shield. Refer to
Remove the front and rear EGR connection tubes.
Remove the EGR valve and remove the EGR valve
seal from the EGR valve outlet port. Refer to
Disconnect the aftertreatment fuel injector lines and
bulkhead support bracket from the EGR valve
mounting bracket. Refer to Procedure 011-051 in
Section 11.
Signature, ISX, and QSX15 Eng [...] EGR Valve Mounting Bracket
Remove
Remove one of the EGR valve bracket rear support
mounting capscrews (2) from the EGR valve mounting
bracket and cylinder head.
Remove the remaining two EGR valve mounting bracket
capscrews (1).
to cover open points.

Inspect the ends and mating joints of the bracket for signs
of fretting or material transfer, cracks, or other damage.
Replace the EGR valve support bracket if fretting or
material transfer, cracks, or other damage is found.
Corrosion is normal and will be found at the EGR valve to

bracket joint. Clean the corrosion off the sealing surface
using safety solvent, or a Scotch Brite 7448 abrasive
pad.
The new seal will not function properly if the bracket
sealing surface have been cleaned with a power tool
combined with abrasive pads.
Inspect the sealing surface for signs of excessive pitting
at the EGR connection jumper seals. If the pitting is large
enough to catch a fingernail, replace the EGR valve
support bracket.
EGR Valve Mounting Bracket Signature, ISX, and QSX15 Eng [...]
Install
Install the EGR valve mounting bracket onto the engine
block and the EGR valve mounting bracket rear support.
Install three capscrews into the engine block and the rear
support.
Tighten the two EGR valve mounting bracket capscrews
first (1).
Tighten the rear support bracket capscrew into the back
of the engine block (2).
Finishing Steps
Connect the aftertreatment fuel injector lines and
bulkhead support bracket to the EGR valve mounting
bracket. Refer to Procedure 011-051 in Section 11.
Install the EGR valve and a new EGR seal. Refer to
Install the front and rear EGR connection tubes.
Refer to Procedure011-025 in Section 11.
Install the EGR valve heat shield. Refer to Procedure
Signature, ISX, and QSX15 Eng [...] Aftertreatment Diesel Particulate Filter Differential P [...]

Differential Pressure Sensor Mounting
Bracket (011-046)
General Information
CAUTION
The 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 catalyst element can result.
Due to the number of exhaust aftertreatment applications,
this procedure is generic. Not all illustrations within the
procedure will represent all applications.
The exhaust aftertreatment system is composed for four
sections. These sections are:
1 Inlet
2 Aftertreatment Diesel Oxidation Catalyst
3 Aftertreatment Diesel Particulate Filter
4 Outlet
NOTE: In some applications, the catalyst can be
integrated into the inlet of the exhaust aftertreatment.
NOTE: On some vertically oriented aftertreatment
systems, the differential pressure sensor mounting
bracket may be welded to the outlet section of the
aftertreatment system. The outlet section of this type of
aftertreatment system must be replaced if the differential
pressure sensor mounting bracket is damaged.
Aftertreatment Diesel Particulate Filter Differential P [...] Signature, ISX, and QSX15 Eng [...]
Preparatory Steps
WARNING
cable last.
CAUTION
The aftertreatment diesel particulate filter and
catalyst can remain hot for long periods of time after
the engine has stopped.
Disconnect the batteries. Refer to the OEM service
manual.
Disconnect the aftertreatment wiring harness from the
aftertreatment diesel particulate filter differential
pressure sensor. Refer to Procedure 019-443 in
Section 19. This procedure can be located in the
Troubleshooting and Repair CM871 and CM876
Electronic Control System ISX and ISM Engines,
Bulletin 4021560.
Remove the aftertreatment diesel particulate filter
differential pressure sensor tubes. Refer to Procedure
Remove the aftertreatment diesel particulate filter
differential pressure sensor. Refer to Procedure
019-376 in Section 19. This procedure can be located
in the Troubleshooting and Repair CM871 and CM876
Bulletin 4021560.
Mark the orientation and location of the bracket before
it is removed, to aid installation if there is not a locating
tab present.
Remove
Remove the nut on the aftertreatment diesel particulate
filter differential pressure sensor mounting bracket strap.
NOTE: A cylindrical locating tab may be welded to the
outside of the catalyst canister to position the differential
pressure sensor mounting bracket. Note the orientation of
the mounting bracket prior to removal.
NOTE: Remove the differential pressure sensor mounting
bracket and strap.

Inspect the differential pressure sensor mounting bracket
for cracks, damaged threads, or broken studs.
Replace the differential pressure sensor mounting bracket
if it is damaged.
Inspect the differential pressure sensor mounting bracket

strap for cracks, damaged threads, or bends.
Replace the differential pressure sensor mounting bracket
strap if it is damaged.
Install
CAUTION
The aftertreatment system must be installed so the
pressure sensor tubes slope downward to drain
condensation away from the differential pressure
sensor.
NOTE: A cylindrical locating tab may be welded to the
outside of the catalyst canister to position the differential
pressure sensor mounting bracket.
NOTE: Make sure the aftertreatment system is oriented
so the aftertreatment diesel particulate filter differential
pressure sensor is installed in the same orientation noted
during disassembly.
Install the differential pressure sensor mounting bracket
and strap. Be sure to align the cylindrical locating tab, if
present, with the mounting bracket, as noted during
removal.
If there is not a locating tab, use the reference mark that
was made during removal.
Apply a coating of anti-seize compound to the threads of
the aftertreatment diesel particulate filter differential
pressure sensor mounting bracket strap.
Install the nut on the aftertreatment diesel particulate filter
differential pressure sensor mounting bracket strap.
Tighten the differential pressure sensor mounting bracket
strap.
Finishing Steps
WARNING
cable last.
Install the aftertreatment diesel particulate filter
differential pressure sensor. Refer to Procedure
in the Troubleshooting and Repair CM871 and CM876
Bulletin 4021560.
differential pressure sensor tubes. Refer to Procedure
Connect the aftertreatment wiring harness from the
pressure sensor. Refer to Procedure 019-443 in
Section 19. This procedure can be located in the
Troubleshooting and Repair CM871 and CM876
Bulletin 4021560.
Connect the batteries. Refer to the OEM service
manual.
Operate the engine and check for proper operation.

Differential Pressure Sensor Tubes
(011-047)
General Information
The aftertreatment diesel particulate filter differential
pressure sensor tubes connect the differential pressure
sensor to the ports on the aftertreatment system. There
are two aftertreatment diesel particulate filter differential
pressure sensor tubes. One tube connects to the
aftertreatment system upstream of the aftertreatment
diesel particulate filter and the other connects
downstream of the aftertreatment diesel particulate filter.
Due to the number of exhaust gas aftertreatment
configurations, this procedure is generic. Not all
illustrations within this procedure will represent all
applications.
CHECK ENGINE light.
Remove
CAUTION
pressure sensor will not operate properly if the
differential pressure sensor tubes are not connected
to the correct port. Mark the differential pressure
sensor tube connection port locations before
disconnecting.
CAUTION
If the flexible hose section between the differential
pressure sensor tube and the differential pressure
sensor are difficult to remove, cut and replace the
hose. Twisting or bending the hose can damage the
pressure sensor.
NOTE: The mounting location of the aftertreatment diesel
particulate filter differential pressure sensor varies with
exhaust aftertreatment orientation and OEM mounting
location.
Remove the spring clamps from the stainless steel tube
end of the flexible hose sections attached to the exhaust
gas filter pressure sensor.
Loosen the aftertreatment diesel particulate filter
differential pressure sensor tube nuts.
If p-clips or tube clamps are used to hold the exhaust gas
filter pressure sensor tubes on the exhaust aftertreatment
system, mark their location prior to removal.
Remove the p-clips or tube clamp mounting capscrews, if
necessary.
WARNING
WARNING
personal injury.
Inspect the inside of the tube.
If the 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 tubes, make
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.
Check the tube for cracks and thread damage. Replace
the tube, if damage is found.
Inspect the inside of the threaded bosses on the

aftertreatment canister.
Clean debris from the inside of the threaded bosses, while
being careful to not damage the threads.
Install
CAUTION
to the correct port. Install the differential pressure
sensor tubes as noted during disassembly.
CAUTION
The aftertreatment system must be installed so the
condensation away from the differential pressure
sensor.
pressure sensor port closest to the sensor mounting
bracket connects upstream of the aftertreatment diesel
particulate filter.
NOTE: In vertical aftertreatment orientations, an
aftertreatment diesel particulate filter differential pressure
sensor tube support can be present. Be sure the
differential pressure tubes are seated in the support clip.
Apply a coating of Locite 80209, 51002, 76732, copper
or silver grade, or equivalent to the threads on the
differential pressure sensor tubes prior to assembly. Do
not allow Loctite to enter inside of the differential
pressure sensor tubes. This can cause a blockage.
Minimum Loctite Anti-Seize Temperature Range

C F
870 MIN 1600
Install the differential pressure sensor tubes on the
aftertreatment system.
Attach the flexible hose sections of the differential
pressure sensor tubes to the differential pressure sensor
using two spring clamps.
NOTE: Make sure the differential pressure sensor tubes
are not making contact with each other or any other
vehicle components prior to tightening the differential
pressure sensor tube nuts.
NOTE: Tighten the aftertreatment diesel particulate filter
differential pressure sensor tube nuts.
Install the p-clips or the tube clamps that hold the exhaust
gas filter pressure sensor tubes on the exhaust
aftertreatment system.
Tighten the p-clips or the tube clamp bolts, if necessary.
Operate the vehicle on a dynamometer or perform a road
test with the engine at rated load for a minimum of 5
minutes to make sure the aftertreatment system is
performing properly.
Check for fault codes and exhaust leaks.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Inlet and Outlet
Aftertreatment Inlet and Outlet

(011-048)
General Information
WARNING
During regeneration, exhaust gas temperature could
reach 800C [1500F], and exhaust system surface
temperature could exceed 700C [1300F], 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
strike the side of the aftertreatment system as damage
to the catalyst element can result.
Due to the number of various exhaust aftertreatment
applications, this procedure has been written to be
generic. Illustrations within this procedure will not
represent all applications.
These sections are:
1 Inlet
2 Aftertreatment diesel oxidation catalyst
3 Aftertreatment diesel particulate filter
4 Outlet.
integrated into the inlet of the exhaust aftertreatment
system.
Aftertreatment Inlet and Outlet Signature, ISX, and QSX15 Eng [...]
Preparatory Steps
WARNING
cable last.
CAUTION
to the correct port. Mark the differential pressure
sensor tube connection locations before
disconnecting.
Disconnect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
Mark the direction of exhaust flow to aid in assembly.
Draw an orientation reference line across each of the
v-band clamps, aftertreatment canister sections, and
connection points to the tailpipe. This will aid in
returning the sections and the v-band clamps to their
original orientation during installation.
Mark the number of each exhaust gas temperature
sensor connector prior to disconnecting the exhaust
temperature sensor from the wiring harness.
Disconnect the aftertreatment gas temperature sensor
wiring harness connectors. Refer to Procedure
019-449 (Aftertreatment Gas Temperature Sensor) in
Section 19 of the Troubleshooting and Repair Manual,
CM871 and CM876 Electronic Control Systems, ISX
and ISM Engines, Bulletin 4021560.
Remove the mounting straps or bolts from the inlet, if
necessary. Refer to the OEM troubleshooting and
repair manual.
Remove the mounting straps or bolts from the outlet,
if necessary. Refer to the OEM troubleshooting and
repair manual.
Disconnect the aftertreatment diesel particulate filter
differential pressure sensor tube from the outlet, if
necessary. Refer to Procedure 011-047
(Aftertreatment Diesel Particulate Filter Differential
Pressure Sensor Tubes) in Section 11.
Remove
WARNING
CAUTION
In some applications, the catalyst is integrated into the
aftertreatment inlet.Refer to Procedure 011-046
Pressure Sensor Mounting Bracket) in Section 11 for
removal of the differential pressure sensor mounting
bracket.
Support the catalyst and aftertreatment diesel particulate
filter to avoid applying a cantilevered load on the v-band
joints.
Remove the Torca or v-band clamp used to connect the
aftertreatment system to the exhaust pipe, if necessary.
Remove the v-band clamp connecting the inlet to the
catalyst, if necessary.
Remove the v-band clamp connecting the outlet to the
aftertreatment diesel particulate filter, if necessary.
Disassemble
Remove the aftertreatment gas temperature sensor from
the boss in the inlet and/or outlet, if necessary. Refer to
Procedure 019-449 (Aftertreatment Gas Temperature
Sensor) in Section 19 of the Troubleshooting and Repair
Manual, CM871 and CM876 Electronic Control Systems,
ISX and ISM Engines, Bulletin 4021560.

Inspect the aftertreatment inlet and outlet canisters for
cracks or other damage.
Inspect the aftertreatment gas temperature sensor boss
threads for damage, if the sensor was removed.
Inspect the aftertreatment diesel particulate filter
differential pressure sensor tube boss threads for
damage, if the tube was removed.
If thread damage is found on the aftertreatment gas
temperature sensor boss threads or differential pressure
sensor tube boss threads, a helicoil must be used for
repair.
Flange Preparation - Use a putty knife to remove any

residual gasket material from the flanges on the
Do not use compressed air to remove fragments of gasket
material that have fallen into the filter during gasket
removal.
Do not grind on the flange surface, as this can damage
the flange and cause the connection to leak.
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 clamp and mounting strap threads for
damage.
Replace the v-band clamp or mounting strap if damage is
found.
Assemble
Install the aftertreatment gas temperature sensor in the
boss on the inlet and/or outlet. Refer to Procedure 019-449
(Aftertreatment Gas Temperature Sensor) in Section 19 of
the Troubleshooting and Repair Manual, CM871 and
CM876 Electronic Control Systems, ISX and ISM Engines,
Bulletin 4021560.
Install
Apply a coat of anti-seize compound on the treads of the
v-band clamps and Torca clamps.
The aftertreatment outlet section contains a differential
pressure sensor tube boss. Align the differential pressure
sensor tube boss with the differential pressure sensor tube
nut prior to tightening the v-band clamp or the Torca
clamp.
NOTE: If the Torca clamp is replaced during service, be
sure to replace it with another Torca clamp. Do not use
a u-bolt as a replacement clamp. U-bolt clamps can crush
the tailpipe and make it difficult to remove the
aftertreatment system for future service.
Tighten the Torca clamps or v-band clamps used to

secure the inlet and outlet of the aftertreatment to the
exhaust pipe.
Torque Value:
Torca Clamp
Step 1 55 Nm [ 41 ft-lb ]
Torque Value:
V-Band Clamp
Step 1 14 Nm [ 124 in-lb ]
Install a new gasket between the v-band clamp joints that
have been disconnected.
Install the v-band clamp used to connect the outlet to the
aftertreatment diesel particulate filter, if necessary.
Install the v-band clamp use to connect the inlet to the
catalyst, if necessary.
Tighten the v-band clamps.
Finishing Steps
WARNING
cable last.
CAUTION
If the temperature sensor wire connectors are not
connected to the proper locations after installation,
aftertreatment system damage can result.
CAUTION
to the correct port. Install the differential pressure
sensor tubes as noted during disassembly.
Install the mounting straps or bolts to the inlet, if
repair manual.
Install the mounting straps or bolts from the outlet, if
repair manual.
Connect the aftertreatment gas temperature sensor
wiring harness connectors, if necessary. Refer to
Procedure 019-449 (Aftertreatment Gas Temperature
Sensor) in Section 19 of the Troubleshooting and
Repair Manual, CM871 and CM876 Electronic Control
Systems, ISX and ISM Engines, Bulletin 4021560.
Connect the aftertreatment diesel particulate filter
differential pressure sensor tube to the outlet, if
necessary. Refer to Procedure 011-047
Pressure Sensor Tubes) in Section 11.
Connect the vehicle batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
Operate the vehicle on a dynamometer or perform a
road test with the engine at rated load for a minimum
of 5 minutes to make sure the aftertreatment system is
performing properly. Refer to Procedure For ISX
engines, 010-024 (Air Leaks, Air Intake and Exhaust
Systems) in Section 10 in the Signature, ISX, and
Procedure For ISM engines, 010-024 (Air Leaks, Air
Intake and Exhaust Systems) in Section 10 in the ISM,
ISMe, and QSM11 Engines Service Manual, Bulletin
3666322.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Diesel Oxidation Catalyst
Aftertreatment Diesel Oxidation

Catalyst (011-049)
General Information
CAUTION
Due to number of exhaust aftertreatment applications, this
procedure is generic. Illustrations within this procedure
will not represent all applications.
The exhaust aftertreatment is composed of four sections.
These sections are:
1 Inlet
2 Aftertreatment diesel oxidation catalyst
4 Outlet.
NOTE: In some applications the catalyst can be integrated
into the inlet of the exhaust aftertreatment.
Preparatory Steps
WARNING
reduce the possibility of arching, remove the negative
(-) battery cable first and attach the negative (-) batter
cable last.
CAUTION
The catalyst can remain hot for a long time after the
engine has stopped.
Disconnect the batteries. Refer to the OEM service
manual.
Disconnect the aftertreatment exhaust gas
temperature sensor electrical connector(s) from the
wiring harness, if necessary. Refer to Procedure
in the Troubleshooting and Repair Manual, ISX and
ISM Engines, Bulletin 4021560.
differential pressure sensor mounting bracket, and
strap if applicable. Refer to Procedure 011-046 in
Section 11.
Aftertreatment Diesel Oxidation Catalyst Signature, ISX, and QSX15 Eng [...]
Remove
Draw an orientation reference line across each of the v-
band clamps, aftertreatment canister sections, and
connection points to the tailpipe. This will aid in returning
the sections and v-band clamps to their original orientation
during installation.
Mark the direction of exhaust flow on both the catalyst
section and the aftertreatment diesel particulate filter
section to aid in assembly.
WARNING
The component weighs 23 kg [50 lbs] or more. To
or get assistance to lift the component.
CAUTION
CAUTION
damage the threads or the bolt and cause the camp to
not be reusable.
NOTE: If necessary, remove additional mounting
hardware to remove the catalyst from the vehicle.
Remove the v-band clamps from the inlet and outlet of the
catalyst.
Separate the component sections by approximately one-
half inch to allow removal over the gasket retainer rings.

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
CAUTION
Do not scrape off soot accumulation from the face of
the aftertreatment diesel particulate filter.
Remove any residual gasket material from the flanges on
the aftertreatment diesel particulate filter with a putty
knife.
NOTE: If the aftertreatment diesel particulate filter is being
inspected due to progressive damage that introduced
engine oil or excessive fuel into the exhaust, inspect the
tailpipe from the turbocharger outlet to the aftertreatment
diesel oxidation catalyst.
If a trail of liquid engine oil or fuel can be seen from the
turbocharger outlet to the aftertreatment diesel oxidation
catalyst, the aftertreatment diesel oxidation catalyst
must be replaced.
If a trail of engine oil or fuel can be seen exiting the
turbocharger outlet, the tailpipe between the turbocharger
outlet and aftertreatment diesel oxidation catalyst must be
cleaned. Refer to Procedure 011-048 in Section 11.
WARNING
The material captured in a diesel particulate filter may
contain elevated concentrations of metals, primarily
zinc and molybdenum, and possibly polynuclear
aromatic hydrocarbons that may be regulated. These
materials must be characterized, handled, and
disposed of according to applicable local regulations.
In addition, due to the presence of the above-listed
chemicals and other potentially toxic components
such as oxides of calcium, zinc, phosphorous,
silicone, sulfur, and iron, exhaust filter maintenance
must be completed only by appropriately trained
personnel.
WARNING
personal injury.
Inspect the outlet of the aftertreatment diesel oxidation
catalyst for loose debris and soot. Use a rag to wipe off
any soot. Use a HEPA vacuum to remove any remaining
loose debris.
NOTE: Use a vacuum bag, such as a drywall dust bag, to
capture the soot that is removed.
Attach the Cummins aftertreatment diesel particulate

filter cleaning machine cone, Part Number 4918850, to the
inlet and outlet sides of the aftertreatment diesel oxidation
catalyst with the adapter rings, Part Number 4918847 and
4918848. Evenly space 4 to 5 spring clamps or C-clamps
around the circumference of the aftertreatment diesel
oxidation catalyst to seal the cone and adapter ring to the
aftertreatment diesel oxidation catalyst.
Service tool kit, Part Number 4918877 contains the cones
and rings needed for this procedure.
If the aftertreatment diesel oxidation catalyst is integrated
into the aftertreatment inlet, use one cone only, and attach
it to the outlet side of the unit.
Use tape to seal any open ports.
Obtain a 76 mm to 51 mm [3 in to 2 in] rubber pipe reducer

from a local supplier. If the aftertreatment diesel oxidation
catalyst is integrated into the aftertreatment inlet, obtain a
102 mm to 51 mm [4 in to 2 in] rubber pipe reducer.
Attach the vacuum hose to the 51 mm [2 in] end of the

pipe reducer. Attach the larger end of the reducer to the
aftertreatment diesel particulate filter cleaning machine
cone attached to the inlet side of the diesel oxidation
catalyst. If the aftertreatment diesel oxidation catalyst is
integrated into the inlet, install the larger end of the
reducer onto the aftertreatment inlet.
CAUTION
Use only a rubber-tipped air gun near the catalyst
material. Damage will result if a metal air gun strikes
the catalyst material.
Adjust the air supply for a rubber-tipped air gun to 621 kPa
[90 psi].
Switch on the vacuum. The vacuum and service tool kit is
properly installed if the air flow through the aftertreatment
diesel oxidation catalyst is opposite to exhaust flow.
Exhaust flow is indicated by an arrow on the canister of
the diesel oxidation catalyst.
Blow compressed air across the outlet face of the
aftertreatment diesel oxidation catalyst for approximately
5 minutes.
After 5 minutes, remove the aftertreatment diesel

particulate filter cleaning machine cone and continue
blowing compressed air into the outlet of the diesel
oxidation catalyst for an additional 10 to 15 minutes.
Maintain a 13 mm to 25 mm [1/2 in to 1 in] distance
between the air gun and diesel oxidation catalyst face.
Use a sweeping motion across the entire face of the diesel
oxidation catalyst and attempt to blow air through every
cell.
Allow the vacuum to operate for 1 minute after blowing out
the aftertreatment diesel oxidation catalyst. After the
vacuum is switched off, disconnect the cleaning machine
cone and inspect the cells of the diesel oxidation catalyst.
Inspect the cells of the diesel oxidation catalyst by looking

through each cell. Shine a light on the opposite side of the
diesel oxidation catalyst to aid inspection. If the cell is
clear of soot, it is possible to see straight through the
diesel oxidation catalyst.
Upon inspection, if less than 50 percent of the cells are

blocked (1) the aftertreatment diesel oxidation catalyst can
be reused. If more than 50 percent of the cells remain
blocked (2), repeat the cleaning procedure.
NOTE: It should not take more than two attempts to clean
the face of the DOC.
If the catalyst section has shifted, moved, or is loose inside

the canister, replace the catalyst section.
Inspect the inlet and outlet faces of the aftertreatment
diesel oxidation catalyst for signs of damage. Refer to
Additional Aftertreatment Diesel Oxidation Catalyst and
Aftertreatment Diesel Particulate Filter Reuse Guidelines,
Bulletin 4021600.
Inspect the v-band clamps and catalyst mounting straps

for signs of over-extension. The v-band must not be bent
or damaged.
Replace the v-band clamps or catalyst mounting straps if
damage is found.
Install
Install the exhaust gas temperature sensor into the
catalyst section, if necessary. Refer to Procedure 019-449
in Section 19. This procedure can be located in the
Troubleshooting and Repair Manual, ISX and ISM
NOTE: If the engine had turbocharger damage or any
other damage that introduced foreign objects into the
exhaust system, the aftertreatment exhaust gas
temperature 1 sensor must be inspected for damage. If
the sensor is broken or damaged it must be replaced.
WARNING
The component weighs 23 kg [50 lbs] or more. To
Install new gaskets on the inlet and outlet of the exhaust
gas catalyst.
Install the catalyst.
Tighten the v-band clamps
differential pressure sensor tubes into the catalyst section.
Signature, ISX, and QSX15 Eng [...] Aftertreatment System
Finishing Steps
WARNING
(-) battery cable first and attach the negative (-) batter
cable last.
Connect the aftertreatment gas temperature sensor
electrical connector(s) to the wiring harness, if
necessary. Refer to Procedure 019-449 in Section 19.
differential pressure sensor mounting bracket and
strap if necessary. Refer to Procedure 011-046 in
Section 11.
Connect the batteries. Refer to Procedure 013-009 in
Section 13.
Operate the engine. Check for fault codes and exhaust
leaks.
Aftertreatment System (011-050)

General Information
CAUTION
Due to the number of exhaust aftertreatment applications,
this procedure has been written to be generic. Illustrations
within this procedure will not represent all applications.
These sections are:
1 Inlet
2 Catalyst
4 Outlet.
integrated into the inlet of the exhaust aftertreatment.
Aftertreatment System Signature, ISX, and QSX15 Eng [...]
Preparatory Steps
WARNING
cable first.
Refer to the OEM service manual for aftertreatment
system removal instructions. The OEM will designate
whether aftertreatment system components are to be
removed as individual components or as a complete
system for service.
Mark the direction of exhaust flow on the outside of the
aftertreatment system to aid in installation.
Mark the orientation of the exhaust gas particulate trap
differential pressure sensor to aid in installation.
Disconnect the vehicle batteries. Refer to Procedure
Remove
System - Remove the straps or bolts securing the
aftertreatment system to the vehicle chassis. Refer to the
OEM service manual.
Remove the v-band from the inlet, and the Torca clamp
from the outlet of the aftertreatment system. Refer to
differential pressure sensor wiring harness connector.
This procedure is found in the Troubleshooting and Repair
Manual, CM871 and CM876 Electronic Control System,
Component - To remove the aftertreatment inlet or outlet

sections: Refer to Procedure 011-048 in Section 11.
To remove the aftertreatment diesel particulate filter and
the joined catalyst - aftertreatment diesel particulate filter:
Remove the catalyst: Refer to Procedure 011-049 in
Section 11.
Signature, ISX, and QSX15 Eng [...] Aftertreatment System
Disassemble
Us this procedure to remove the aftertreatment inlet or
outlet sections. Refer to Procedure 011-048 in Section 11.
Use this procedure to remove the catalyst. Refer to
Use this procedure to remove the aftertreatment diesel
particulate filter. Refer to Procedure 011-041 in Section
11.
Use this procedure for aftertreatment diesel particulate
filter cleaning instructions. Refer to Procedure 011-041 in
Section 11.

Inspect inlet or outlet canister. Refer to Procedure 011-048
in Section 11.
Inspect the aftertreatment diesel particulate filter canister.
Inspect the catalyst canister. Refer to Procedure 011-049
in Section 11.
Inspect the exhaust gas temperature sensors. Refer to
Procedure 019-449 in Section 19
Inspect the differential pressure sensor. Refer to
Inspect the differential pressure sensor tubes. Refer to
Inspect the aftertreatment system wire harness.
Inspect the Torca clamps and/or v-band clamps for
leaks. Refer to Procedure 010-024 in Section 10.
This procedure is found in the Signature, ISX, and
QSX15 Service Manual, Bulletin 3666239.
This procedure is found in the ISM, ISMe, and QSM11
Service Manual, Bulletin 3666322.
Aftertreatment System Signature, ISX, and QSX15 Eng [...]
Assemble
Install the aftertreatment inlet or outlet sections. Refer to
Install the aftertreatment diesel particulate filter. Refer to
Install the catalyst. Refer to Procedure 011-049 in Section
11.
Install
NOTE: Make sure that the aftertreatment system is
oriented so that the aftertreatment diesel particulate filter
differential pressure sensor is installed in the same
orientation noted during disassembly.
NOTE: The aftertreatment system must be installed so
that the aftertreatment diesel particulate filter differential
condensation away from the differential pressure sensor.
NOTE: Make sure that the differential pressure sensor
tubes are not making contact with each other or any other
vehicle components prior to tightening the Torca clamps
or v-band clamps.
System - Install the straps or bolts that secure the
aftertreatment system to the vehicle chassis. Refer to the
OEM service manual.
Install the inlet and outlet of the aftertreatment on to the
exhaust pipe. Refer to Procedure 011-048 in Section 11.
NOTE: If a Torca clamp is replaced during service, be
sure to replace it with another Torca clamp. Do not use
a u-bolt as a replacement clamp. U-bolt clamps can crush
the tailpipe and make it difficult to remove the
aftertreatment system for future service.
Tighten the Torca clamps used to secure the inlet and
outlet of the aftertreatment to the exhaust pipe. Refer to
Connect the exhaust temperature sensor to the wiring
harness connectors. Refer to Procedure 011-048 in
Section 11.
differential pressure sensor wiring harness connector.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Injector Lines
Component - To install the aftertreatment inlet or outlet

sections: Refer to Procedure 011-048 in Section 11.
To install the catalyst: Refer to Procedure 011-049 in
Section 11.
To install the aftertreatment diesel particulate filter or
joined catalyst-aftertreatment diesel particulate filter:
Finishing Steps
WARNING
cable first.
Connect the battery. Refer to Procedure 013-009 in
Section 13.
If the aftertreatment system was being serviced for an
aftertreatment diesel particulate filter cleaning, use
INSITE electronic service tool to clear related fault
codes.
Aftertreatment Injector Lines

(011-051)
Preparatory Steps
WARNING
WARNING
in Section 8.
Aftertreatment Injector Lines Signature, ISX, and QSX15 Eng [...]
Remove
Disconnect the aftertreatment injector coolant supply line
at the inlet to the aftertreatment injector.
at the EGR cooler.
Remove the aftertreatment injector coolant supply line.
Disconnect the aftertreatment injector coolant return line

at the aftertreatment injector.
at the oil cooler.
Remove the aftertreatment injector coolant return line.
WARNING
Depending on the circumstance, diesel fuel is
flammable. When inspecting or performing service or
repairs in the fuel system, to reduce the impossibility
of fire and resulting severe personal injury, death or
property damage, never smoke or allow sparks or
flames (such as pilot lights, electrical switches, or
welding equipment) in the work area.
3375249.
Disconnect the wiring harness from the shut off valve, fuel
drain valve, and pressure sensor.
Disconnect the aftertreatment injector fuel supply line

from the supply outlet of the fuel rifle.
Disconnect the aftertreatment injector fuel supply line at
the inlet to the fuel shutoff manifold.
Remove the aftertreatment injector fuel supply line.
For access lower the fuel shutoff manifold by removing the

two mounting capscrews.
Disconnect the fuel return line from the fuel shutoff

manifold and the fuel control module.

the outlet of the fuel shutoff manifold.
Disconnect the fuel lines from the union fitting, located just
above the EGR valve.
the inlet to the aftertreatment injector, use a 9/16 inch
wrench. In some applications, access to the
aftertreatment injector is difficult and requires removal of
the exhaust adapter pipe. Refer to Procedure 011-043 in
Section 11.

at the inlet to the aftertreatment injector.
at the coolant heater housing.
Remove the aftertreatment injector coolant supply line.

at the aftertreatment injector.
at the coolant return manifold.
Remove the aftertreatment injector coolant return line.
Disconnect the aftertreatment injector fuel supply line

from the supply outlet of the fuel rifle.
the inlet to the fuel shutoff manifold.
Remove the aftertreatment injector fuel supply line.
Disconnect the fuel return line from the fuel shutoff

manifold and the fuel return tee fitting, located in front of
the engine control module.
Remove the P-clips.

the outlet of the fuel shutoff manifold.
the inlet to the aftertreatment injector. In some
applications, access to the aftertreatment injector is
difficult and requires removal of the exhaust adapter pipe.

WARNING
cleaning, follow the manufacture's recommendations
WARNING
personal injury.
Clean the aftertreatment injector coolant lines with a
safety solvent.
Inspect the aftertreatment injector coolant line threads for

Make sure the aftertreatment injector coolant lines are
clear of debris.
Use compressed air to flush the lines and remove any
loose dirt particles.
Check the o-ring for cuts and wear. Replace if necessary.

Clean the aftertreatment injector fuel lines with a safety

solvent.
Inspect the threads and banjo fittings on the

aftertreatment injector fuel lines. Replace is necessary.
Make sure that the aftertreatment injector fuel lines are
clear of debris.
Inspect the face of the banjo connection for sealing

surface damage.
Inspect the straight thread fittings and fuels lines for
cracks, bends or other damage.
WARNING
cleaning, follow the manufacture's recommendations
WARNING
personal injury.
Clean the aftertreatment injector coolant lines with a
safety solvent.
Inspect the aftertreatment injector coolant line threads for

Make sure the aftertreatment injector coolant lines are
clear of debris.
Check the o-ring for cuts and wear. Replace if necessary.
Clean the aftertreatment injector fuel lines with a safety

solvent.
Inspect the threads and banjo fittings on the

aftertreatment injector fuel lines. Replace if necessary.
Make sure the aftertreatment injector fuel lines are clear
of debris.
Inspect the face of the banjo connector for sealing surface

damage.
Inspect the straight thread fittings and fuels for cracks,
bends or other damage.
Install
Connect the aftertreatment injector coolant supply line to
the aftertreatment injector and the EGR cooler.
Connect the aftertreatment injector coolant return line to

the oil cooler.
the aftertreatment injector.
Connect the aftertreatment injector fuel supply line to the

aftertreatment injector.
outlet of the union fitting, located just above the EGR
valve.
Install the P-clips.

inlet of the union fitting, located just above the EGR valve.
outlet of the fuel shutoff manifold.
Connect the fuel return line to the fuel shutoff valve

manifold and the fuel control module.
Torque Value:
O-ring joint 24 Nm [ 212 in-lb ]
Torque Value:
Banjo joint 15 Nm [ 133 in-lb ]
Install the two capscrews to attach the aftertreatment fuel

shutoff manifold to the bracket on the engine.

inlet of the shutoff manifold.
Torque Value:
Banjo joint 34 Nm [ 25 ft-lb ]
fuel rifle.
Torque Value:
O-ring joint 24 Nm [ 212 in-lb ]

Connect the aftertreatment injector coolant supply line to
the aftertreatment injector and the coolant heater housing.

the coolant return line to the coolant return manifold.
the aftertreatment injector.

aftertreatment injector.
outlet of the fuel shutoff manifold.
Connect the fuel return line to the fuel shutoff valve

manifold and the fuel return tee fitting, located in front of
the engine control module.
Install the P-clips
Torque Value:
O-ring fitting 24 Nm [ 212 in-lb ]
Torque Value:
Banjo fitting 15 Nm [ 133 in-lb ]

inlet of the shutoff valve manifold.
fuel rifle.
Finishing Steps
Connect the wiring harness to pressure sensor, shutoff
valve, and fuel drain valve.
Install the fuel filter.

Aftertreatment Fuel Shutoff Manifold Signature, ISX, and QSX15 Eng [...]
Aftertreatment Fuel Shutoff Manifold

(011-052)
Preparatory Steps
WARNING
personal injury.
Make sure the area around the fuel shutoff manifold is
clear of debris. Use compressed air to clean the area
and remove any loose dirt particles.
Disconnect the wiring harness from the aftertreatment
fuel shutoff valve, aftertreatment fuel drain valve, and
aftertreatment pressure sensor.
Remove the aftertreatment fuel injector lines from the
fuel shutoff manifold. Refer to Procedure 011-051 in
Section 11.
Remove
WARNING
personal injury.
Fuel Shutoff Manifold - Make sure the area around the fuel
shutoff manifold is clear of debris.
Use compressed air to clean the area and remove any

Remove the fuel shutoff manifold.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Fuel Shutoff Manifold
Remove the aftertreatment fuel shutoff valve (1),

aftertreatment fuel drain valve (2), and aftertreatment
pressure sensor (3) with a 1-1/8 inch open end wrench.
WARNING
personal injury.
Fuel Shutoff Manifold - Make sure the area around the fuel
shutoff manifold is clear of debris.
Use compressed air to clean the area and remove any

Remove the fuel shutoff manifold.
Remove the aftertreatment fuel shutoff valve (1),

aftertreatment fuel drain valve (2), and aftertreatment
pressure sensor (3) with a 1-1/8 inch open end wrench.

WARNING
WARNING
personal injury.
Shutoff Valve, Drain Valve, and Pressure Sensor - Clean
the shutoff valve, drain valve, and pressure sensor with
safety solvent.
Inspect the o-ring for cuts or wear. Replace the o-ring if
necessary.
Inspect the threads for damage.
Replace damaged components if necessary.
WARNING
WARNING
personal injury.
Shutoff Manifold - Clean the shutoff manifold with safety
solvent.
Use compressed air to clean the shutoff manifold and
remove any debris.
Make sure the filter screen and orifice are in the fuel inlet
side of the shutoff valve manifold.
Inspect the threads of the shutoff manifold for damage. If
threads are damaged, replace the shutoff manifold.

surfaces, or a reduced diameter (capscrew stretching).
WARNING
WARNING
personal injury.
Shutoff Valve, Drain Valve, and Pressure Sensor - Clean
the shutoff valve, drain valve, and pressure sensor with
safety solvent.
Inspect the o-ring for cuts or wear. Replace the o-ring if
necessary.
Inspect the threads for damage.
Replace damaged components if necessary.
WARNING
WARNING
personal injury.
Shutoff Manifold - Clean the shutoff manifold with safety
solvent.
Use compressed air to clean the shutoff manifold and
remove any debris.
Make sure the filter screen and orifice are in the fuel inlet
side of the shutoff valve manifold.
Inspect the threads of the shutoff manifold for damage. If
threads are damaged, replace the shutoff manifold.

surfaces, or a reduced diameter (capscrew stretching).
Install
NOTE: The pressure sensor and shutoff valve are located
on the same side of the shutoff manifold.
NOTE: The pressure sensor is mounted above the shutoff
valve.
Install the pressure sensor, the fuel shutoff valve, and the
fuel drain valve.
Torque Value:
Pressure Sensor 14 Nm [ 124 in-lb ]
Torque Value:
Fuel Shutoff Valve 14 Nm [ 124 in-lb ]
Torque Value:
Fuel Drain Valve 14 Nm [ 124 in-lb ]


NOTE: The pressure sensor and shutoff valve are located
on the same side of the shutoff manifold.
NOTE: The pressure sensor is mounted above the shutoff
valve.
Install the pressure sensor, the fuel shutoff valve, and the
fuel drain valve.
Torque Value:
Pressure Sensor 14 Nm [ 124 in-lb ]
Torque Value:
Fuel Shutoff Valve 14 Nm [ 124 in-lb ]
Torque Value:
Fuel Drain Valve 14 Nm [ 124 in-lb ]

Finishing Steps
Install the aftertreatment injector lines. Refer to
Connect the wiring harness to the fuel shutoff valve,
fuel drain valve and pressure sensor. Use the following
procedure in the Electronic Control System
Troubleshooting and Repair Manual, Bulletin 4021560.
Aftertreatment Fuel Injector Flow Signature, ISX, and QSX15 Eng [...]
Aftertreatment Fuel Injector Flow

(011-054)
Initial Check
WARNING
WARNING
WARNING
Depending on the circumstance, diesel fuel is
flammable. When inspecting or performing service or
repairs on the fuel system, to reduce the possibility of
fire and resulting severe personal injury, death or
property damage, never smoke or allow sparks or
flames (such as pilot lights, electrical switches, or
welding equipment) in the work area.
Drain the engine cooling system. For ISX engines, use
the following procedure in the Signature, ISX, QSX15
Service Manual, Bulletin 3666239. Refer to Procedure
008-018 in Section 8. For ISM engines, use the
following procedure in the ISM, ISMe, and QSM11
Disconnect the fuel line to aftertreatment fuel injector.
Disconnect the coolant lines to the aftertreatment fuel
injector. Refer to Procedure 011-051 in Section 11.
Remove the aftertreatment fuel injector from the
exhaust adapter pipe. Refer to Procedure 011-042 in
Section 11.
Setup
Remove the fibrous insulator from the aftertreatment fuel
injector face.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector Flow
Connect the fuel extension line, Part Number 4918519, to

the aftertreatment fuel injector fuel supply line that was
connected to the injector.
Connect the aftertreatment fuel injector to the fuel line

extension.
CAUTION
Do not connect a 12-VDC supply to the injector as this
will cause permanent damage to the injector.
Connect the aftertreatment fuel injector electrical harness
extension, Part Number 4918518, to the engine harness
and the aftertreatment fuel injector.
On ISX applications, install a threaded plug, Part Number

3089567, at the coolant outlet on the EGR cooler.
Install a threaded plug, Part Number 4918690, in the
coolant hose.
On ISM applications, install two threaded plugs, Part

Number 4918690, in the coolant inlet and outlet hoses.
Block the opening in the exhaust adapter pipe.

Install the cover plate, Part Number 4918522, with two
capscrews, Part Number 3913638.
Obtain a clear graduated cylinder (large enough to hold

the aftertreatment injector) that is marked in cubic
centimeters; example: graduated beaker, Part Number
3823705, or equivalent. A measurement cup that is
marked in milliliters (ml) or ounces (oz) can also be used.
The measuring device must be capable of measuring
between 0 ml [0.0 oz] and 500 ml [17.0 oz] in 10 ml [0.34
oz] increments.
Place the aftertreatment fuel injector in the graduated
cylinder or cup.
NOTE: It is usually easier to capture the fuel in a clean
container and transfer the fuel to the measuring device for
the final measurement.
Cover the aftertreatment fuel injector and graduated

cylinder so the fuel spray is contained.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector Flow
Turn the keyswitch to the ON position.

Use INSITE electronic service tool to perform the
aftertreatment "Reset All" function.
This function can be found under the Advanced ECM
Data, Aftertreatment Maintenance screen in INSITE
electronic service tool.
Flow Test
NOTE: This test should only be performed after
completing the "Reset All" as described above.
Start the engine and allow it to idle for 5 minutes.
Use INSITE electronic service tool to select System Test
in the test mode section of the Aftertreatment Shutoff
Valve and Injector Override Test.
Use INSITE electronic service tool to enter a time delay,
if needed.
Click the Start button when ready to perform the test.
Click the OK button when the warning windows pop up, if
the conditions are met.
INSITE electronic service tool will start the test and will
inject fuel for 2 minutes and 30 seconds. INSITE
electronic service tool will automatically disable the
injector at the end of the test. If the test needs to be
stopped before finishing, click the Stop button.
Record the amount of fuel that was collected in the

graduated cylinder during the 2 minutes and 30 seconds
test period.
Perform the test 3 times and average the results of the
three tests.
The average amount of fuel collected must be between
200 and 400 ml [6.8 and 13.5 oz].
Clean the tip of the aftertreatment fuel injector. Refer to

NOTE: The aftertreatment injector is to be cleaned at this
step, regardless of the flow in the previous step.
If the average amount collected before cleaning is not

within the specified limits, perform the flow test a second
time.
Record the amount of fuel that was collected in the
graduated cylinder during the 2 minutes and 30 seconds
test period.
Perform the test 3 times and average the results of the
three tests.
The average amount of fuel collected must be between
200 and 400 ml [6.8 and 13.5 oz].
If the average amount collected is not within this
specification, return to the fault code troubleshooting tree
for next steps.
Leak Test
NOTE: This test does not need to be performed for Fault
Codes 2728, 2638, and 1691.
To perform the Aftertreatment Fuel Injector Leak Test,
start the engine and allow it to idle for 5 minutes.
Hold the aftertreatment fuel injector over the graduated
cylinder.
Use INSITE electronic service tool to select Injector Leak

in the test mode section of the Aftertreatment Shutoff
Valve and Injector Override Test.
Click the Start button to initiate the test.
Record the amount of fuel collected during the 1 minute
INSITE electronic service tool test.
If more than 60 ml [2 oz] of fuel is collected during the 1
minute INSITE electronic service tool test, replace the
aftertreatment fuel injector. Refer to Procedure 011-042 in
Section 11.
Return the collected fuel to the fuel tank.
Signature, ISX, and QSX15 Eng [...] Exhaust System Diagnostics
Finishing Steps
Drain the engine cooling system. For ISX engines, use
the following procedure in the Signature, ISX, QSX15
008-018 in Section 8. For ISM engines, use the
following procedure in the ISM, ISMe, and QSM11
Remove the injector spray tester service tool kit, Part
Number 4918517.
Install the aftertreatment fuel injector assembly onto
the adapter pipe. Refer to Procedure 011-042 in
Section 11.
Connect the fuel line to the aftertreatment fuel injector.
Fill the engine cooling system. For ISX engines,
reference the following procedure in the Signature,
ISX, QSX15 Service Manual, Bulletin 3666239. Refer
to Procedure 008-018 in Section 8. For ISM engines,
reference the following procedure in the ISM, ISMe,
Start the engine, check for leaks, and verify that all
fault codes are inactive.
Exhaust System Diagnostics (011-056)

General Information
The following procedure contains troubleshooting steps
and information regarding the aftertreatment system.
Leaks in the exhaust system can cause exhaust odor or

white smoke.
Inspect the exhaust piping for leaks, cracks, and loose
connections. Refer to Procedure 010-024 (Air Leaks, Air
Intake and Exhaust Systems) in Section 10.
Tighten the exhaust clamps, if necessary. Refer to the
OEM specifications and the correct torque value.
It may be necessary to perform a stationary (parked)
regeneration to locate exhaust leaks. Refer to Procedure
014-013 (Aftertreatment Testing) in Section 14.
Exhaust System Diagnostics Signature, ISX, and QSX15 Eng [...]
The ambient temperature affects the length of time it will

take to perform a stationary (parked) regeneration
because the engine must work harder to increase the
exhaust temperatures to the appropriate levels in cold
ambient temperatures.
In cold ambient temperatures (approximately -18C [0F]
or colder), stationary (parked) regeneration may take
longer to complete. In extremely cold ambient
temperatures, stationary (parked) regeneration may not
complete.
In these cases, it may be necessary to warm the engine
to operating temperature before starting the stationary
(parked) regeneration, or to move the vehicle to a location
with higher ambient temperatures.
The vehicle manufacturer has the option of installing two switches

that control aftertreatment function: the start switch and the permit
switch.
The start switch (called the Diesel Particulate Filter Regeneration
Start Switch in INSITE electronic service tool) is used to start a
stationary (parked) regeneration. The vehicle manufacturer may
also reference this switch as a "stationary regeneration switch,"
"start switch," or "parked regeneration switch".
The permit switch (called the Diesel Particulate Filter Permit
Switch in INSITE electronic service tool) is used to allow the
operator to disable active regeneration, if necessary. The vehicle
manufacturer may also reference this switch as an "inhibit switch,"
"stop switch," or "disable switch".
The start switch can be hardwired to the ECM, or it can be
multiplexed over J1939 multiplexing.
If the start switch is hardwired, it shares an ECM pin with the
diagnostic switch. When the switch is turned ON and the engine
is OFF, the ECM interprets this signal as the diagnostic switch.
When the switch is turned ON and the engine is running, the ECM
interprets this signal as the start switch.
If the start switch is J1939-multiplexed, the signal for this switch
is broadcast over the J1939 data link.
A J1939-multiplexed start switch signal has priority over a
hardwired start switch signal, therefore if the start switch is
enabled over J1939, the hardwired signal is ignored by the engine
ECM.
The default setting for the start switch is OFF. If the start switch
is enabled to INSITE electronic service tool, but no switch is
installed (either hardwired of J1939-multiplexed), the switch status
will remain OFF.
The position of the start switch can be monitored with INSITE
electronic service tool in the data monitor/logger screen.
The default setting for the permit switch is ENABLED.
If the permit switch is enabled with INSITE electronic service
tool, but no switch is installed (either hardwired or J1939
multiplexed), the switch status will remain OFF.
If the vehicle is operated for an extended period of time with the
permit switch OFF, fault codes for the above normal levels of
aftertreatment diesel particulate filter soot load may result (Fault
Codes 1921, 1922, and 2639).
If the aftertreatment diesel particulate filter soot load reaches the
moderately severe level (Fault Code 2639), and the permit switch
is OFF, the ECM will also log a Fault Code 2777.
If the permit switch is multiplexed, and therefore ENABLED, in the
J1939 section of Features and Parameters in INSITE electronic
service tool, it must also be enabled in the aftertreatment section
of Features and Parameters in INSITE electronic service tool. If
is is not, regeneration will be inhibited.
The permit switch can be hardwired to the ECM only in
emergency vehicle calibrations. For all other non-emergency
calibrations, the permit switch can only be J1939-multiplexed
over the J1939 data link.
In emergency vehicle calibrations where the permit switch is
hardwired, the permit switch replaces the governor type switch.
A J1939-multiplexed permit switch signal has priority over a
hardwired start switch signal, so if the permit switch is enabled
over J1939, the hardwired signal is ignored by the engine ECM.
The position of the permit switch can be monitored with INSITE
electronic service tool in the data monitor/logger screen:
When the permit switch is ON, active regeneration is
allowed.
When the permit switch is OFF, active regeneration is not
allowed.
If the aftertreatment exhaust gas temperature sensors are

not connected properly, or if the wiring in the harness
between the engine and aftertreatment is not correct, the
engine may experience frequent DPF lamp illuminations,
or stationary (parked) regenerations that do not complete.
Inspect the exhaust aftertreatment temperature sensor
connectors to verify they are connected to the correct
connector on the aftertreatment system wiring harness.
Two of the temperature sensors have identical wiring
harness connectors. Because the sensors are the same
part number, it is possible to install the wiring harness
connectors to the wrong sensor.
To verify the correct sensor locations, use INSITE
electronic service tool to monitor the following parameters
with the ignition key ON, but with the engine not running.
Aftertreatment Diesel Oxidation Catalyst Inlet
Temperature Sensor Signal Voltage (V)
Aftertreatment Diesel particulate Filter Inlet
Temperature Sensor Signal Voltage (V)
Aftertreatment Diesel Particulate Filter Outlet
Temperature Sensor Signal Voltage (V).
Unplug each of the aftertreatment exhaust gas
temperature sensors, one at a time.
If the voltage changes when the sensor is unplugged, the
wiring harness connector is connected to the correct
sensor.
If the voltage does not change when the sensor is
unplugged, switch the connector location to the other
temperature sensor, unplug it, and check for a voltage
change.
An incorrectly assembled aftertreatment wiring harness
can not be checked by unplugging each of the
aftertreatment exhaust gas temperature sensors.
The only method to check for a misassembled
aftertreatment wiring harness is to check the wiring
harness connectors for correct pin installation. Refer to
the engine wiring diagram for connector pin identification
and location.
When performing a stationary (parked) regeneration,

monitor the exhaust temperatures in the aftertreatment to
determine why a stationary (parked) regeneration will
not complete.
Possible causes for stationary (parked) regenerations that
will not complete include:
Misassembled aftertreatment wiring harness
Aftertreatment exhaust gas temperature sensors
installed in the wrong location
A plugged aftertreatment diesel oxidation catalyst
A malfunctioning turbocharger.
A normal stationary (parked) regeneration will follow the
pattern shown.
The dashed line is for the aftertreatment diesel
oxidation catalyst inlet temperature sensor.
The dotted line is for the aftertreatment diesel
particulate filter inlet temperature sensor.
The solid line is for the aftertreatment diesel
particulate filter outlet temperature sensor.
When the stationary (parked) regeneration begins (1), all
three temperatures should be approximately the same,
and should increase at the same rate.
The wiring to the aftertreatment temperature sensors
appears to be correct in this example because they all
read approximately the same temperature at the
beginning of the stationary (parked) regeneration and
increase at the same rate.
Aftertreatment injection begins when all three
temperatures reach approximately 288C [550F] (2).
Once aftertreatment injection begins, the aftertreatment
diesel oxidation catalyst inlet temperature may vary
slightly, but will typically remain between 260 and 399C
[500 and 750F].
The aftertreatment diesel particulate filter inlet and outlet
temperatures will increase to approximately 482 to 649C
[900 to 1200F]. The temperatures may vary during the
stationary (parked) regeneration as the amount of fuel
injected during aftertreatment injection is changed to
maintain a constant temperature.
The aftertreatment diesel particulate filter inlet and outlet
temperatures will remain at this temperature for the
duration of the stationary (parked) regeneration.
This graph illustrates a stationary (parked) regeneration

where the inlet of the aftertreatment diesel oxidation
catalyst is blocked.
In this condition, the engine speed will increase to the
stationary (parked) regeneration speed of 1000 to 1400
rpm.
Raising the aftertreatment temperature to the
aftertreatment injection temperature may take longer to
complete than normal if the inlet to the aftertreatment
diesel oxidation catalyst is plugged, restricting some of the
exhaust flow.
Once aftertreatment injection begins (2), the
aftertreatment diesel particulate filter inlet and outlet
temperatures will differ greatly due to the plugged
aftertreatment diesel oxidation catalyst being unable to
oxidize the injected fuel. The aftertreatment diesel
particulate filter has some capability to oxidize the injected
fuel, but can not maintain this condition without damaging
the filter material over time. It is possible that white smoke
would be present from the vehicle tailpipe during this
condition.
The wiring to the aftertreatment temperature sensors
read approximately the same temperature at the
beginning of the stationary (parked) regeneration and they
increase at the same rate.
The possible cause of this condition is a plugged
aftertreatment diesel oxidation catalyst. Refer to
Procedure 011-049 (Aftertreatment Diesel Oxidation
Catalyst) in Section 11 to inspect the aftertreatment diesel
oxidation catalyst.

where the engine can not build enough heat to start
aftertreatment injection.
The engine speed will likely increase to the stationary
(parked) regeneration speed of 1000 to 1400 rpm, but
because the aftertreatment temperatures do not increase
enough to start aftertreatment injection, the stationary
(parked) regeneration will not complete.
The wiring to the aftertreatment temperature sensor
read approximately the same temperature for the same
conditions.
Possible causes of this issue include:
A malfunctioning turbocharger. Refer to Procedure
010-134 (Variable Geometry Turbocharger Actuator,
Electric) in Section 10 to verify the turbocharger
sector gear has full travel.
Low ambient temperatures. Move the vehicle to a
location with higher ambient temperatures.

where the wiring to the aftertreatment temperature
sensors is incorrect.
stationary (parked) regeneration speed of 1000 to 1400
rpm.
Aftertreatment injection will not occur in this condition
because the aftertreatment diesel oxidation catalyst inlet
temperature does not reach the required temperature.
Because aftertreatment injection is not occurring, the
aftertreatment temperatures should not read differently.
The possible cause of this condition is an incorrectly
assembled aftertreatment wiring harness. See the
aftertreatment exhaust gas temperature sensor wiring
section of this procedure.
Aftertreatment Fuel Injector Coolant Test Signature, ISX, and QSX15 Eng [...]

where the connectors to the aftertreatment diesel
oxidation catalyst inlet temperature sensor and the
aftertreatment diesel particulate filter outlet temperature
sensor are reversed.
stationary regeneration speed of 1000 to 1400 rpm.
Aftertreatment injection may occur in this condition (2).
However, the aftertreatment diesel oxidation catalyst inlet
temperature increases after aftertreatment injection
begins, while the aftertreatment diesel particulate filter
outlet temperature remains constant.
The possible cause of this condition is that the connectors
to the aftertreatment diesel oxidation catalyst inlet
temperature sensor and the aftertreatment diesel
particulate filter outlet temperature sensor are reversed.
See the aftertreatment exhaust gas temperature sensor
wiring section of this procedure.
Aftertreatment Fuel Injector Coolant

Test (011-061)
Preparatory Steps
WARNING
WARNING
Drain the cooling system. Use the following procedure
in the Signature, ISX, and QSX15 Service Manual,
Section 8. Use the following procedure in the ISM,
ISMe, and QSM11 Service Manual, Bulletin
3666322.Refer to Procedure Procedure 008-018 in
Section 8.
Disconnect the fuel line to the aftertreatment fuel
Disconnect the coolant lines to the aftertreatment fuel
Remove the aftertreatment fuel injector from the
exhaust adapter pipe. Refer to Procedure 011-042 in
Section 11.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector Coolant Test
Setup
Plug one of the coolant connections with an M16 x 1.5
plug.
Fill the nozzle area with water.
Test
WARNING
personal injury.
Apply compressed air regulated at 241 kpa [35 psi] to the
opposite coolant connection.
If air bubbles are seen in the nozzle area, the
aftertreatment injector has a crack that is allowing coolant
to leak through.
The injector must be replaced.
Aftertreatment Fuel Injector Coolant Test Signature, ISX, and QSX15 Eng [...]
Finishing Steps
WARNING
Remove the plug and compressed air connection from
the coolant connection points.
Install the aftertreatment fuel injector assembly onto
the adapter pipe. Refer to Procedure 011-042 in
Section 11.
Connect the fuel line to the aftertreatment fuel injector.
Connect the coolant lines to the aftertreatment fuel
Connect the wiring harness to the aftertreatment
injector.
Fill the cooling system. Use the following procedure in
the Signature, ISX, and QSX15 Service Manual,
Section 8. Use the following procedure in the ISM,
ISMe, and QSM11 Service Manual, Bulletin
3666322.Refer to Procedure Procedure 008-018 in
Section 8.
Start the engine, check for leaks, and verify all fault
codes are inactive.
Section 12 - Compressed Air System - Group 12 Page 12-a
Section 12 - Compressed Air System - Group 12

Section Contents
Page
Air Compressor ...............................................................................................................................................12-9
Finishing Steps............................................................................................................................................. 12-12
Install............................................................................................................................................................12-10
Remove..........................................................................................................................................................12-9
Air Compressor Carbon Buildup .....................................................................................................................12-1
Clean..............................................................................................................................................................12-2
Initial Check....................................................................................................................................................12-1
Air Compressor Coolant Lines ........................................................................................................................12-3
Finishing Steps...............................................................................................................................................12-6
Initial Check....................................................................................................................................................12-3
Install..............................................................................................................................................................12-4
Remove..........................................................................................................................................................12-4
Air Compressor Cylinder Head, Single Cylinder ............................................................................................12-6
Finishing Steps...............................................................................................................................................12-8
Initial Check....................................................................................................................................................12-6
Install..............................................................................................................................................................12-7
Remove..........................................................................................................................................................12-7
Air Compressor Unloader and Valve Assembly .............................................................................................12-8
Air Governor (Air Compressor Pumps Continuously) ..................................................................................12-13
Initial Check..................................................................................................................................................12-13
Air Governor (Air Compressor Will Not Pump) .............................................................................................12-12
Remove.........................................................................................................................................................12-12
Air Leaks, Compressed Air System ..............................................................................................................12-14
Initial Check..................................................................................................................................................12-14
Air Pressure Relief Valve ..............................................................................................................................12-15
Initial Check..................................................................................................................................................12-15
Page 12-b Section 12 - Compressed Air System - Group 12

Signature, ISX, and QSX15 Eng [...] Air Compressor Carbon Buildup
Section 12 - Compressed Air System - Group 12 Page 12-1
Air Compressor Carbon Buildup

(012-003)
Initial Check
WARNING
bodily injury.
Open the drain cock on the wet tank to release
compressed air from the system.
WARNING
Air discharge lines can be very hot. Be sure the lines
are cool before handling to prevent personal injury.
Remove the air inlet and outlet connections from the air
compressor.
Measure the total carbon deposit thickness inside the air

discharge line as shown.
NOTE: The carbon deposit thickness must not exceed
1.6 mm [0.06 in].
WARNING
The air discharge line must be capable of
withstanding extreme heat and pressure to prevent
personal injury and property damage. Refer to the
OEM specifications.
NOTE: If the total carbon deposit thickness exceeds
specification, remove and clean, or replace the air
discharge line.
Continue to check for carbon buildup in the air discharge
line connections up to the first connection or wet tank.
Clean or replace any lines and fittings with carbon
deposits thicker than 1.6 mm [0.06 in]. Refer to the OEM
specifications for cleaning or replacement instructions.
Air Compressor Carbon Buildup Signature, ISX, and QSX15 Eng [...]
Page 12-2 Section 12 - Compressed Air System - Group 12
Clean
WARNING
Use skin and eye protection when handling caustic
solutions to reduce the possibility of personal injury.
WARNING
personal injury.
CAUTION
Do not use a sharp object to remove carbon. The
sealing surfaces can be damaged.
CAUTION
Avoid getting debris and solvents into the clearance
between the piston and bore.
CAUTION
Avoid the use of abrasive products similar to Scotch
Brite because any abrasive grit left after cleaning
will shorten the life of the air compressor.
Remove the compressor head and valve assembly. Refer
Remove carbon from the compressor head and valve

assembly components with solvent and a nonmetallic
brush.
Blow out passages with compressed air.
Clean the compressor cylinder.

Rotate the crankshaft until the piston is at the top of the
cylinder bore.
Remove any accumulated carbon and varnish by careful
scraping and light application of solvents.
Signature, ISX, and QSX15 Eng [...] Air Compressor Coolant Lines
Install the compressor head and valve assembly. Refer to

Air Compressor Coolant Lines

(012-004)
Preparatory Steps
WARNING
WARNING
WARNING
WARNING
personal injury.
in Section 8.
Use steam to clean the air compressor. Dry with
compressed air.
Initial Check
Inspect the coolant hoses for splits, cracks, hardening, or
other damage.
Inspect the metal coolant lines for kinks, corrosion,
cracks, or other damage.
Air Compressor Coolant Lines Signature, ISX, and QSX15 Eng [...]
Remove
Remove the coolant lines from the air compressor.
Inspect for Reuse

Inspect the drive clips or the connectors for damaged
threads.
Inspect the coolant hoses for splits, cracks, hardening, or
other damage.
Inspect the coolant lines for restrictions of coolant flow.
Replace the coolant lines if any damage is found.
Install
Use two elbows and run the locking nuts all the way up
prior to installation.
Start threading the elbows into the cylinder head.
Use a 24 mm open-end wrench to position the elbows.
Push the tube nut away from the bell flare on the U-shaped
coolant supply line.
Position the sealing grommet behind the bell flare.
Signature, ISX, and QSX15 Eng [...] Air Compressor Coolant Lines
Install the U-shaped coolant supply line into the coolant

supply elbow.
Verify the bell flare and grommet seat correctly in the
elbow.
Start threading the compression nut onto the elbow.
Install the other end of the coolant supply line into the
grommet in the cylinder block.
Push the tube nut away from the bell flare on the coolant
return line.
Position the sealing grommet behind the bell flare.
Install the coolant return line into the coolant return elbow.
Verify the bell flare and grommet seat correctly in the
elbow.
Start threading the compression nut onto the elbow.
Air Compressor Cylinder Head, Single Cylinder Signature, ISX, and QSX15 Eng [...]
Install the other end of the coolant return tube into the
grommet in the cylinder block.
Install the capscrews in the two locations designated by

the arrows.
Tighten the capscrews
Tighten the compression nuts and elbow locking nuts.
Finishing Steps
WARNING
Section 8.
Air Compressor Cylinder Head, Single

Cylinder (012-007)
Initial Check
Remove the air inlet and outlet lines from the air
compressor.
For Signature, ISX, and QSX15 engines, use this
procedure. Refer to Procedure 012-014 in Section 12.
For ISM, ISMe and QSM!1 engines, use this
procedure. Refer to Procedure 012-014 in Section 12.
Inspect the lines for signs of a coolant leak.
If signs of a leak are found, the cylinder head must be
replaced.
Signature, ISX, and QSX15 Eng [...] Air Compressor Cylinder Head, Single Cylinder
Preparatory Steps
WARNING
WARNING
Drain the cooling system. For Signature, ISX, and
QSX15 engines, use this procedure. Refer to
Procedure 008-018 in Section 8. For ISM, ISMe and
QSM!1 engines, use this procedure. Refer to
Remove
Remove the air governor or air governor signal line (if
equipped).
Remove the air inlet and outlet connections from the air
compressor.
Remove the four 8-mm capscrews.
Remove the air compressor head and gasket.
Install
Assemble the air compressor using a new gasket.
Install the head and gasket.
Install the four 8-mm capscrews.
Tighten the capscrews in the sequence shown. Use the
torque plus angle method.
Torque Value:
Step 1 25 Nm [ 221 in-lb ]
Air Compressor Unloader and Valve Assembly Signature, ISX, and QSX15 Eng [...]
If a new head assembly is being installed, tighten the five

small head cover bolts in the sequence shown.
Torque Value:
Step 1 6 Nm [ 53 in-lb ]
Finishing Steps
WARNING
Fill the cooling system. For Signature, ISX, and
QSX15 engines, use this procedure. Refer to
Procedure 008-018 in Section 8. For ISM, ISMe and
QSM!1 engines, use this procedure. Refer to
operation.
Air Compressor Unloader and Valve

Assembly (012-013)
Preparatory Steps
Remove the air governor or air governor signal line from
the air compressor.
Operate the engine to activate the air compressor.

If the air compressor is not pumping, replace the
compressor cylinder head. Refer to Procedure 012-007.
Signature, ISX, and QSX15 Eng [...] Air Compressor
Air Compressor (012-014)

Preparatory Steps
WARNING
WARNING
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
WARNING
personal injury.
in Section 8.
Use steam to clean the air compressor. Dry with
compressed air.
Remove the coolant lines from the air compressor.
Remove
Remove the air connections from the air compressor.
Remove or disconnect the air governor. Refer to the OEM
service manual.
Remove the air compressor support bracket and

capscrews.
Remove the four mounting capscrews and the air
compressor.
Discard the gasket.
Air Compressor Signature, ISX, and QSX15 Eng [...]

Inspect the compressor housing for cracks or other
damage.
Inspect the compressor drive gear for cracks or other
damage.
Make sure the gasket surfaces of the front gear housing

and the air compressor are clean and not damaged.
Install
Pin the engine crankshaft. Refer to Procedure 001-088 in
Section 1.
Rotate the gear on the air compressor until the mark on
the gear is in line with the V-notch on the air compressor
housing, located at the three o'clock position as viewed
from the front.
Loctite, Part Number 3824040 or equivalent, must be
used on the capscrews that mount the air compressor to
the gear housing. This seals the threads in the housing.
To evenly distribute the sealant as the capscrew is
torqued, a line of sealant should be placed along the
length of the capscrew.
Install the air compressor and the four capscrews onto the
front gear housing.
Signature, ISX, and QSX15 Eng [...] Air Compressor

Tighten the capscrews again.
Install the air compressor mounting brace and four

capscrews on the block beneath the air compressor. Start
threading all four capscrews.
Tighten the capscrews on the cylinder block and air

compressor.
Install the air discharge line.

Install the air inlet line.
Install the air governor (if removed). Connect the air
governor pressure signal line. Refer to the OEM service
manual.
Air Governor (Air Compressor Will Not Pump) Signature, ISX, and QSX15 Eng [...]
Finishing Steps
Install the air compressor coolant lines. Refer to
Air Governor (Air Compressor Will Not

Pump) (012-017)
Remove
Remove the air governor or air governor signal line from
the air compressor.
Inspect for Reuse

If the air compressor is pumping, the air governor is
malfunctioning and must be replaced. Refer to the
If the compressor does not pump with the governor

removed, the unloader valve is malfunctioning. Replace
the compressor cylinder head. Refer to Procedure
012-003.
Signature, ISX, and QSX15 Eng [...] Air Governor (Air Compressor Pumps Continuously)
Air Governor (Air Compressor Pumps

Continuously) (012-018)
Initial Check
Remove the air accessory air lines from the air
compressor governor and install pipe plugs in the air
governor unloader ports.
If the air compressor stops pumping (air pressure stops
rising) at the governed air pressure, there is a leak in an
accessory or an accessory air line. Refer to the equipment
manufacturer's instructions for troubleshooting and
repair.
If the air compressor does not stop pumping (air pressure

continues to rise) at the governed air pressure, connect a
regulated shop air pressure line to the air compressor
unloader valve port.
NOTE: Be sure the air pressure gauge is accurate, and

the supply lines and fittings are in good condition before
performing any air pressure checks.
Use a master gauge of known accuracy to check the air
pressure gauge.
Apply 690 kPa [100 psi] air pressure to the unloader port.
If the air compressor stops pumping (air pressure stops
rising), the air governor is malfunctioning and must be
repaired or replaced, or the air governor mounting gasket
is leaking. Refer to the manufacturer's instructions.
Air Leaks, Compressed Air System Signature, ISX, and QSX15 Eng [...]
If the air compressor continues to pump (air pressure

continues to rise), the unloader valve is malfunctioning
and must be replaced. Refer to Air Compressor Unloader
Valve, Procedure 012-013.
Remove the pipe plugs from the unloader ports used for
accessory air lines.
Install and tighten the accessory air lines.
Connect the line to the unloader valve.
Operate the engine and check for air leaks.
Air Leaks, Compressed Air System

(012-019)
Initial Check
WARNING
bodily injury.
Open the drain cock on the wet tank to release air from
the system. Close the drain cock after the pressure is
released.
Signature, ISX, and QSX15 Eng [...] Air Pressure Relief Valve

With the air compressor pumping between 550 to 690 kPa
[80 to 100 psi], use a solution of soapy water to check for
air leaks in the following areas:
Air compressor head gasket
Air compressor cover gasket
Hose and fitting leaks.
If air leaks are found, verify that the air compressor head
and cover bolts are torqued properly. Make sure hoses
and fittings are tight. Replace if necessary.
Air Pressure Relief Valve (012-024)

Initial Check
Remove the air governor or air governor line from the air
compressor. Remove the air intake line from the air
compressor cylinder head.
CAUTION
Do not hold hand too close to the intake port of the
air compressor. Personal injury can result.
Hold your hand 5 cm [2 in] from the air compressor intake
port. If air is coming out of the intake port, the pressure
relief valve is malfunctioning and the air compressor
cylinder head must be replaced. Refer to Procedure
If no air is felt from the intake port, check downstream air

system components for damage or restrictions.
Air Pressure Relief Valve Signature, ISX, and QSX15 Eng [...]
Install the air intake line to the cylinder head. Install the
air governor or air governor line to the air compressor.
Section 13 - Electrical Equipment - Group 13 Page 13-a
Section 13 - Electrical Equipment - Group 13

Section Contents
Page
Alternator .........................................................................................................................................................13-2
Driven by Cooling Fan Drive Belt..................................................................................................................13-5
Finishing Steps...............................................................................................................................................13-6
Initial Check....................................................................................................................................................13-2
Alternator Wiring Test...................................................................................................................................13-2
Alternator Voltage Output Check..................................................................................................................13-2
Alternator Current Output Test......................................................................................................................13-3
Install..............................................................................................................................................................13-6
Remove..........................................................................................................................................................13-5
Alternator Idler Pulley ...................................................................................................................................13-24
Clean............................................................................................................................................................13-24
Install............................................................................................................................................................13-25
Remove.........................................................................................................................................................13-24
Alternator Pulley .............................................................................................................................................13-8
Clean..............................................................................................................................................................13-9
Install..............................................................................................................................................................13-9
Remove..........................................................................................................................................................13-8
Alternator Spacer ..........................................................................................................................................13-22
Finishing Steps............................................................................................................................................. 13-24
Install............................................................................................................................................................13-23
Remove.........................................................................................................................................................13-22
Batteries ........................................................................................................................................................ 13-10
Initial Check..................................................................................................................................................13-10
Battery Cables and Connections .................................................................................................................. 13-11
Initial Check..................................................................................................................................................13-11
Belt Tensioner, Automatic (Alternator) .........................................................................................................13-20
Clean............................................................................................................................................................13-20
Install............................................................................................................................................................13-21
Automotive Applications............................................................................................................................. 13-21
Remove.........................................................................................................................................................13-20
Bracket, Idler Pulley and Alternator Belt Tensioner ....................................................................................13-25
Clean............................................................................................................................................................13-26
Finishing Steps............................................................................................................................................. 13-28
Industrial and Power Generation.................................................................................................................13-28
Install............................................................................................................................................................13-27
Page 13-b Section 13 - Electrical Equipment - Group 13

Remove.........................................................................................................................................................13-26
Drive Belt, Alternator ......................................................................................................................................13-7
Adjust.............................................................................................................................................................13-8
Install..............................................................................................................................................................13-7
Remove..........................................................................................................................................................13-7
Service Tools ...................................................................................................................................................13-1
Electrical Equipment.......................................................................................................................................13-1
Starter Magnetic Switch ................................................................................................................................13-12
Current Check...............................................................................................................................................13-12
Starter Solenoid .............................................................................................................................................13-15
Voltage Check...............................................................................................................................................13-15
Starter Switch ................................................................................................................................................13-14
Voltage Check...............................................................................................................................................13-14
Starting Motor ................................................................................................................................................13-17
Finishing Steps............................................................................................................................................. 13-19
Install............................................................................................................................................................13-18
All Except 50MT With Aluminum Flywheel Housing.....................................................................................13-18
50MT With Aluminum Flywheel Housing.....................................................................................................13-19
Remove.........................................................................................................................................................13-18
All Except 50MT With Aluminum Flywheel Housing.....................................................................................13-18
50MT With Aluminum Flywheel Housing.....................................................................................................13-18
Section 13 - Electrical Equipment - Group 13 Page 13-1
Service Tools
Electrical Equipment
Repair Location.

Refractometer
The Fleetguard refractometer is used to check the charge condition
CC-2800 of a conventional battery.
Clamp-On Current Probe

Used to measure AC and DC currents. This unit must be used with
3823574 digital multimeter, Part No. 3377161.
Digital Multimeter
Used to test various electrical circuits.
3377161
Harness and Wire Repair Kit

This kit contains various connectors and tools to repair wiring
3162899 harnesses.
Alternator Signature, ISX, and QSX15 Eng [...]
Page 13-2 Section 13 - Electrical Equipment - Group 13
Alternator (013-001)
Initial Check
Alternator Wiring Test
WARNING
cable last.
WARNING
Acid is extremely dangerous and can damage the
machinery and can also cause serious burns. Always
provide a tank of strong soda water as a neutralizing
agent when servicing batteries. Wear goggles and
protective clothing to avoid serious personal injury.
Systems that are 24 VDC must be connected into a
temporary 12 VDC configuration.
Attach the carbon-pile and clip-on ammeter as shown.
Adjust the load from the carbon-pile tester to the rated
performance of the alternator.
Measure the voltage drop in both the positive and negative
circuits.
Add these together and compare the sum to the table
below.
System Voltage Maximum Voltage Drop

12 0.5
24 1.0
Repair or replace the wiring as required to meet the above

specifications.
Alternator Voltage Output Check

Attach the multimeter to the alternator as shown in the
illustration.
With the batteries in a fully charged condition and all the
accessories off, start the engine and run it at high idle.
Allow time for the voltage to stabilize before taking any
readings.
Signature, ISX, and QSX15 Eng [...] Alternator
Measure the alternator output voltage.
System Voltage Maximum Output Voltage

Limit
12 15.5
24 31.0
Repair or replace the alternator or regulator if the voltage

limit exceeds the value in the table.
Refer to the manufacturer's specifications for minimum
voltage output.
Alternator Current Output Test

Connect the carbon-pile tester to the batteries in parallel.
If more than one wire is connected to the alternator output
terminal, clamp the ammeter around all wires.
Clamp the induction ammeter around the alternator output
wire.
The alternator must be turning at approximate rated

speed.
Most heavy-duty alternators are rated at 5000 rpm. Check
the manufacturer's specifications for the specific
alternator being tested.
Make sure that all vehicle electrical loads are turned off.
Start the engine and operate at high idle.
Check the speed of the alternator using a digital optical
tachometer. A slipping alternator drive belt can result in a
low output reading. The alternator output is directly related
to the speed it is turning.
Turn on the carbon-pile tester and adjust until the

ammeter reaches its highest reading. Record this value.
Turn off the carbon-pile tester and shut off the engine.
If reading on the ammeter is zero (no output), magnetize
the rotor with the alternator hooked up normally.
Momentarily connect a jumper lead from the battery
positive (+) to the alternator relay (R) or indicator (I)
terminal.
This procedure applies to both negative (-) and positive
(+) ground systems, and will restore the normal residual
magnetism.
Repeat the test. If the output is still zero, replace the
alternator.
If the alternator output is not within 10 percent of the rated
output (stamped on the alternator case), replace the
alternator.
Preparatory Steps
Driven by Cooling Fan Drive Belt
WARNING
cable last.
Remove the battery cables.
Remove the electrical connection from alternator.
Procedure 008-002.
WARNING
cable last.
Disconnect the battery cables.
Disconnect the electrical connections from the
alternator.
013-005.
Signature, ISX, and QSX15 Eng [...] Alternator
Remove
Remove the four alternator mounting capscrews.
Remove the alternator from the alternator spacers.

Loosen the alternator support link capscrews.
Remove the support link capscrew from the alternator.
Remove alternator to alternator support capscrews, nut,

washer, and alternator.

Inspect the alternator pulley for cracks or broken grooves.
Replace if pulley is damaged.
Install
Install the alternator and the four mounting capscrews.
No alignment is required for the alternator to the alternator
bracket.

Install the alternator, capscrew, washer, and nut to the
alternator mounting bracket. Tighten the nut.
Install the adjusting link and mounting capscrews. Tighten
the capscrews.
Finishing Steps
WARNING
cable last.
008-002.
Install the electrical connection to alternator.
Install the battery cables.
WARNING
cable last.
013-005.
Install the electrical connections to the alternator.
Connect the battery cables.
Signature, ISX, and QSX15 Eng [...] Drive Belt, Alternator
Drive Belt, Alternator (013-005)

Remove
Using a 1/2-inch drive ratchet and extension, force the belt
tensioner away from belt and remove the belt.
Inspect for Reuse

Inspect the belt for cracks, glazing, tears, or cuts. Replace
the belt if damage is found.
Install
Using a 1/2-inch drive ratchet and extension, force the belt
tensioner down, install belt, and release tensioner.
Check belt for proper fit into pulley grooves.
Alternator Pulley Signature, ISX, and QSX15 Eng [...]
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.
Alternator Pulley (013-006)

Remove
Remove the alternator belt. Refer to Procedure 013-005.
Remove the alternator pulley. Use a strap wrench to hold

the alternator pulley.
Use a ratchet or impact wrench to loosen the nut securing
the pulley to the shaft.
Remove the nut and pulley.
Signature, ISX, and QSX15 Eng [...] Alternator Pulley
Clean
WARNING
Clean the pulley with solvent.
Inspect for Reuse

Inspect the pulley for cracks and damaged grooves or
keyways. Replace the pulley if damage is found.
Install
Install key into shaft keyway (if equipped).
Install the alternator pulley with the shoulder of the pulley
towards the alternator.
Lubricate the threads with engine oil and install the nut.
Torque locking nut, hold the shaft with an allen wrench, if
necessary.
Install alternator belt. Refer to Procedure 013-005.

Batteries Signature, ISX, and QSX15 Eng [...]
Batteries (013-007)
Initial Check
If conventional batteries (not maintenance-free batteries)
are used, check the electrolyte level in each cell. If it is
low, add distilled water to bring the level up to the top of
all plates. Refer to the battery manufacturer's
specifications.
NOTE: If water is added to the battery, the battery must
be charged before any testing can be accomplished.
With conventional batteries, check the electrolyte specific
gravity with a hydrometer. To check the specific gravity,
the battery temperature will be 26.67C [80F]. All cells
will not be less than 1.230. The difference between high
and low readings will not exceed 0.050. If the readings
indicate a difference of more than 0.050, replace the
battery. If the readings indicate less than 0.050 difference
but one or more cells indicate less than 1.230, recharge
the battery.
Battery Specific Gravity at 26.67C [80F]

Specific Gravity State of Charge
1.260 to 1.280 100 percent
1.230 to 1.250 75 percent
1.200 to 1.220 50 percent
1.170 to 1.190 25 percent
1.100 to 1.130 Discharged
Check the eye on the maintenance-free battery. Refer to

the manufacturer's specifications.
NOTE: For conventional batteries, remove the vent caps

prior to removing surface charge. If a blue haze is
observed in any cell while removing the surface charge,
replace the battery. After the surface charge has been
removed, install all vent caps.
Remove the surface charge by attaching the battery to a
300-amp load for 15 seconds for heavy-duty batteries.
Signature, ISX, and QSX15 Eng [...] Battery Cables and Connections
Remove the load and wait 1 minute; if the battery voltage

is greater than or equal to 12.4 VDC, continue testing. If
the voltage is below 12.4 VDC, recharge or replace the
battery.
Load-test the batteries at 1/2 of the cold cranking amp

rating of the battery (rating at -18C [0F]) for 15 seconds.
Check the battery voltage and compare to the table below:
Temperature and Voltage Relationship

Temp (F) 70 60 50 40 30 20 10 0
Temp (C) 21 16 10 4 -1 -7 -12 -18
Minimum 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
Voltage (VDC)
Turn the load off.

Replace the battery if it does not meet the above
specifications.
Battery Cables and Connections

(013-009)
Initial Check
There are two possible heavy-duty battery connections:
Battery terminal and clamp (1)
Threaded battery terminal and nut (2).
Starter Magnetic Switch Signature, ISX, and QSX15 Eng [...]
WARNING
Batteries can emit explosive gases. To avoid personal
injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the
negative (-) battery cable first and attach the negative
Remove and inspect the battery cables and connections
for cracks or corrosion.
Replace broken terminals, connectors, or cables.
If the connections are corroded, use a battery brush or

wire brush to clean the connections until shiny.
Make sure all debris is removed from the connecting
surfaces.
WARNING
Install the cables and tighten the battery connections.
Coat the terminals with grease to prevent corrosion.
Starter Magnetic Switch (013-017)

Current Check
WARNING
Make sure the starter switch is in the OFF position to
prevent electrical shock.
Remove the cable connecting the magnetic switch to the
starter solenoid from the magnetic switch terminal.
Connect the leads of the digital multimeter, Part Number
3377161, to the two large switch terminals.
Signature, ISX, and QSX15 Eng [...] Starter Magnetic Switch
Set the multimeter to measure resistance (ohms).

With the starter switch off, the multimeter must indicate
resistance at infinity (open circuit).
Turn the starter switch to the START position.
The multimeter must indicate zero resistance (closed
circuit).
If the multimeter indicates resistance at infinity with the

starter switch in the START position:
Turn the starter switch off.
Remove the ground wire connected to one of the
small magnetic switch terminals.
Set the multimeter scale to indicate volts, 24 VDC or

more.
Connect the positive lead of the multimeter to the
magnetic switch ground terminal and the other lead
to the ground wire.
The multimeter must indicate vehicle electrical
system voltage.
If the multimeter does not indicate voltage, refer to

Procedure 013-018.
Starter Switch Signature, ISX, and QSX15 Eng [...]
Turn the starter switch to the OFF position.

Remove the multimeter leads.
Connect the starter solenoid cable to the magnetic
switch terminal and the ground wire to its
corresponding terminal on the magnetic switch.
Starter Switch (013-018)

Voltage Check
WARNING
Make sure the starter switch is in the OFF position to
prevent electrical shock.
Remove the wire connecting the starter switch to the
magnetic switch from the starter switch terminal.
Connect the positive lead of digital multimeter, Part
Number 3377161, to the starter switch terminal and the
negative lead to the chassis or an engine ground location.
Set the multimeter to indicate DC volts.

With the starter switch in the OFF position, there must
not be a voltage reading. If the meter indicates voltage,
the starter switch is malfunctioning and must be replaced.

The multimeter must indicate voltage in order for this
check to be normal.
Signature, ISX, and QSX15 Eng [...] Starter Solenoid
If there is not voltage:

Turn the starter switch to the OFF position.
Check the cable from the positive (+) voltage
terminal of the starter solenoid to the starter switch
for breaks.
Check for loose or corroded connections.
If the cable is good and the connections are clean and

tight, the starter switch is malfunctioning and must be
replaced.
Starter Solenoid (013-019)

Voltage Check
Use digital multimeter, Part No. 3377161, with the switch
set to indicate DC volts.
Connect the multimeter positive (+) lead to the starter
solenoid positive (+) cable terminal and the negative ( )
lead to a chassis or engine ground location.
The multimeter must show voltage with the starter switch
off to be normal.
If the multimeter does not indicate voltage, check the

cable connecting the starter solenoid and battery for
breaks. Also, check for loose or corroded connections.
Starter Solenoid Signature, ISX, and QSX15 Eng [...]
If the multimeter indicates voltage but the starter will not

operate, check the wire connecting the starter solenoid to
the starter switch for breaks, and also check for loose or
corroded connections.
If the wire connecting the starter solenoid and starter

switch is not loose or damaged and the starter will not
operate:
Remove the cable connecting the starter and starter
solenoid from the solenoid terminal.
Connect the multimeter positive (+) lead to the
solenoid positive (+) terminal and the negative ( )
lead to the chassis or an engine ground location.

If the multimeter indicates voltage, the starter
solenoid is malfunctioning and must be replaced.
If the multimeter does not indicate voltage, check the wire

connecting the starter solenoid to the magnetic switch for
breaks and loose or corroded connections.
Signature, ISX, and QSX15 Eng [...] Starting Motor
If the wire connecting the starter solenoid to the magnetic

switch is not loose or damaged and the starter will not
operate:
Check the cable connecting the starter solenoid to
the starting motor for breaks and loose or corroded
connections.
Check the cable connecting the starting motor to the

battery for breaks and loose or corroded
connections.
If the cables are not loose or damaged, the starting motor

is defective and must be replaced.
Starting Motor (013-020)

Preparatory Steps
All Applications
WARNING
cable last.
Remove the electrical connections from the
batteries.
Remove the electrical connections from the starting
motor.
Starting Motor Signature, ISX, and QSX15 Eng [...]
Remove
All Except 50MT With Aluminum Flywheel Housing
Remove the three capscrews, starting motor, and starting
motor spacer (if used).
50MT With Aluminum Flywheel Housing

Remove the three mounting capscrews, starting motor,
and starting motor spacer (if used), as well as the
necessary starting motor brackets.
Install
All Except 50MT With Aluminum Flywheel Housing
CAUTION
Make sure to use the same thickness of starting motor
spacer (if used) as the one removed to install the
starting motor to reduce the possibility of engine or
starting motor damage.
Install the starting motor, spacer (if applicable) and the
three mounting capscrews.
Torque Value:
5/8-11 x 1.75 in 140 Nm [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 Nm [ 148 ft-lb ]
capscrew
39 MT Starters 129 Nm [ 95 ft-lb ]
(Aluminum
Flywheel
Housing)
39 MT Starters 163 Nm [ 120 ft-lb ]
(Cast Iron
Flywheel
Housing)
Signature, ISX, and QSX15 Eng [...] Starting Motor
50MT With Aluminum Flywheel Housing
CAUTION
Make sure to use the same thickness of starting motor
spacer (if used) as the one removed to install the
starting motor to reduce the possibility of engine or
starting motor damage.
Install the starting motor, spacer (if applicable), and the
three mounting capscrews.
Torque Value:
5/8-11 x 1.75 in 140 Nm [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 Nm [ 148 ft-lb ]
capscrew
Assemble the upper bracket (1) to the block mounting stud

and to the starter motor end bracket. Tighten capscrews
and nuts finger tight.
Assemble the lower bracket (2) to the oil pan rail mounting
stud and to the starter motor end bracket.
Tighten the capscrews and nuts finger tight.
Tighten all capscrews and nuts.
Tighten all capscrews and nuts in the following sequence:

Torque Value:
(1) 45 Nm [ 33 ft-lb ]
(2) and (3) 23 Nm [ 17 ft-lb ]
(4) and (5) 41 Nm [ 30 ft-lb ]
Finishing Steps
All Applications
WARNING
cable last.
Install the electrical connections to the starting
motor.
Install the electrical connections to the batteries.
Belt Tensioner, Automatic (Alternator) Signature, ISX, and QSX15 Eng [...]
Belt Tensioner, Automatic (Alternator)

(013-021)
Remove
NOTE: 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.
All accessory belt routings are not depicted. Tensioner
and tensioner bracket locations are representative.
Remove the capscrew and belt tensioner from the bracket.
Clean
WARNING
cleaned.
Inspect for Reuse

With the engine turned off and the alternator belt installed,
verify 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 alternator belt must
be replaced. Check to make sure the correct belt part
number is being used if either condition exists.
Signature, ISX, and QSX15 Eng [...] Belt Tensioner, Automatic (Alternator)
Check the tensioner pulley and body for cracks. If any

cracks are noticed, the tensioner must be replaced.
cleaned.
Check that 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.
Inspect the tensioner for evidence of the pivoting

tensioner arm contacting the stationary circular base. If
there is evidence of these two areas contacting, the pivot
tube bushing has failed and the tensioner must be
replaced.
Install
Install the tensioner and capscrew.
Alternator Spacer Signature, ISX, and QSX15 Eng [...]
Using a 1/2-inch square drive, lift and hold the tensioner.

Install the drive belt and release the tensioner.
Alternator Spacer (013-036)

Preparatory Steps
Remove the following:
Cooling fan drive belt. Refer to Procedure 008-002.
Alternator. Refer to Procedure 013-001.
Remove
Remove the two alternator spacer mounting capscrews.
Remove the alternator spacers.
Signature, ISX, and QSX15 Eng [...] Alternator Spacer
WARNING
WARNING
WARNING
personal injury.
Clean the alternator spacers with solvents.
Inspect the alternator spacers for cracks. Replace the

spacers if cracks are found.
have any damage. Replace the alternators spacers if the
roll pins are loose or damaged.
Install
NOTE: No special alignment process is required for
alternator spacers to the alternator/refrigerant
Install the alternator spacers with roll pins and two
capscrews.
Alternator Idler Pulley Signature, ISX, and QSX15 Eng [...]
Finishing Steps
Install the following:
Alternator. Refer to Procedure 013-001.
Cooling fan drive belt. Refer to Procedure 008-002.
Alternator Idler Pulley (013-039)

Remove
Remove the mounting capscrew and idler pulley.
Clean
WARNING
WARNING
personal injury.
Clean the pulley with solvent and dry with compressed air.
Signature, ISX, and QSX15 Eng [...] Bracket, Idler Pulley and Alternator Belt Tensioner
Inspect for Reuse

Inspect the idler pulley for belt groove damage. The pulley
should rotate freely.
Replace the pulley if damage is found.
Install
Install the idler pulley and mounting capscrew.
Install the alternator belt. Refer to Procedure 013-005.
Bracket, Idler Pulley and Alternator

Belt Tensioner (013-040)
Preparatory Steps
Remove the alternator belt tensioner. Procedure 013-021.
Remove the alternator belt idler pulley. Refer to Procedure
013-039.
Bracket, Idler Pulley and Alternator Belt Tensioner Signature, ISX, and QSX15 Eng [...]

Remove the alternator belt tensioner. Refer to Procedure
013-021.
Remove the alternator belt idler pulley. Refer to Procedure
013-039.
Remove
Remove the tensioner and idler mounting bracket.

Remove the tensioner and idler mounting bracket.
Remove the spacer.
Clean
WARNING
WARNING
personal injury.
Clean the parts with solvent.
Signature, ISX, and QSX15 Eng [...] Bracket, Idler Pulley and Alternator Belt Tensioner
Inspect for Reuse

Inspect the bracket and spacer for cracks. Replace if
damaged.
Install
Install the mounting bracket.
Install the alternator belt pulley. Refer to Procedure

013-039.
Install the alternator belt tensioner. Refer to Procedure
013-021.

Install the spacer.
Install the mounting bracket.
Bracket, Idler Pulley and Alternator Belt Tensioner Signature, ISX, and QSX15 Eng [...]
Install the alternator belt idler pulley. Refer to Procedure

013-039.
013-021.
Finishing Steps
Install the alternator belt pulley. Refer to Procedure
013-039.
013-021.

Install the alternator belt idler pulley. Refer to Procedure
013-039.
013-021.
Section 14 - Engine Testing - Group 14 Page 14-a
Section 14 - Engine Testing - Group 14

Section Contents
Page
Aftertreatment Testing ..................................................................................................................................14-42
Finishing Steps............................................................................................................................................. 14-48
Setup............................................................................................................................................................14-46
Test...............................................................................................................................................................14-46
Crankcase Blowby, Measure .........................................................................................................................14-30
Initial Check..................................................................................................................................................14-34
Measure........................................................................................................................................................14-35
Dynamometer Worksheet ................................................................................................................................14-4
Worksheet.......................................................................................................................................................14-4
Engine Run-in (Chassis Dynamometer) ........................................................................................................14-12
Run-In Instructions........................................................................................................................................14-12
Engine Run-in (Engine Dynamometer) ..........................................................................................................14-25
Engine Run-in (Without Dynamometer) ........................................................................................................14-16
Engine Testing (Chassis Dynamometer) ........................................................................................................14-6
Setup..............................................................................................................................................................14-6
Test................................................................................................................................................................14-9
Engine Testing (Engine Dynamometer) ........................................................................................................14-17
Setup............................................................................................................................................................14-17
Test...............................................................................................................................................................14-22
Engine Testing (In Chassis) ..........................................................................................................................14-29
Setup............................................................................................................................................................14-29
Engine Testing (Portable Dynamometer or Load Bank) ...............................................................................14-29
Service Tools ...................................................................................................................................................14-1
Engine Testing................................................................................................................................................14-1
Page 14-b Section 14 - Engine Testing - Group 14

Section 14 - Engine Testing - Group 14 Page 14-1
Service Tools
Engine Testing
Repair Location.

Manometer
Use for measuring blowby and intake air restriction
ST-1111-3
Engine Lifting Fixture

Use to lift the engine.
3162871
Datalink Adapter Kit Inline II

Inline adapter and associated cables are used to connect a computer
3163682 to an engine datalink.
Engine Controller
Use to test engine separate from the chassis system.
3163890
Harness Extension
Extends engine controller harness, Part Number 3164242, 20 ft.
3163895
Benchtop Calibration Cable

Use with parent cable, Part Number 3163151, power adapter, Part
3164185 Number 3824102, and the Inline II adapter, Part Number 3163095.
Page 14-2 Section 14 - Engine Testing - Group 14

ISX/ISM Engine Controller Harness (10ft)
Use to connect the engine controller, Part Number 3163890, to a
3164242 CM870 ECM.
Fuel Measuring Device

Use to measure the rate of fuel consumption of a Cummins diesel
3376375 engine.
Digital Multimeter
Use to measure pressures, vacuums, and temperatures.
3377161
Blow-by Tool (0.354 orifice)

Used with manometer, Part Number ST-1111-3, to check engine
3822567 crankcase blow-by.
Pressure Gauge (0 to 60 psi)

Use to measure coolant pressure.
3822995
Dyno-Room Charge Air Cooler

Use to cool intake air when an air to air engine is used on an engine
3823978 dyno.
Thermocouple Module
This module converts the digital multimeter into a thermometer via
3824963 standard banana plugs.
Temperature Immersion Probe
3824965

INSITE Software Kit
This kit contains INSITE software for use with Cummins engines.
3886388 The kits are used to troubleshoot, program, and adjust electronic
features.
Dynamometer Worksheet Signature, ISX, and QSX15 Eng [...]
Dynamometer Worksheet (014-001)

Worksheet
With EGR
Date: Repair Oder Number: Operator:
ESN: CPL: ECM Code:
Complaint:
Parameter Code Specifications Actual Reading
Intake Air Restriction (in H2O)1, 2
Exhaust Restriction (in Hg)1, 2
Fuel Inlet Restriction (in Hg)1, 2
Fuel Drain Line Restriction (in Hg)1, 2
Engine Blowby (in H2O)1, 2
1 Record at advertised horsepower rpm and full load
2 Reference Specifications - Engine Testing
Engine Set Up for Dyno with INSITE Electronic Service Tool? (Circle One) Yes No
Road Speed Limit
Check Oil Level Low High OK Fuel Quality OK Not OK
(Circle One) (Circle One)
Engine Horsep EGR Turboch Fuel Rail Fuel Intake Intake Coolant Coolant Engine
Speed ower Valve arger Rate Fuel
Temper Manifol Manifol Temper Pressur Oil
or Position Control (lb/hr)1 Pressur ature d d ature e Pressur
Torque Valve e Air Pressur (psi) e
(psi) e
Comma Temper (psi)
nd ature (in Hg)
1 Be sure that the fuel rate is corrected for temperature, see table below.
Fuel Temperature Correction for Flow Rate
Less than 7C [45F] Flow meter is not accurate
7 to 13C [45 to 55 F] Subtract 2 percent from flow rate reading
13 to 20C [55 to 68F] Subtract 1 percent from flow rate reading
20 to 29C [68 to 85F] No Correction
29 to 42C [85 to 108F] Add 1 percent to flow rate reading
56C [132F] above Flowmeter not accurate
Signature, ISX, and QSX15 Eng [...] Dynamometer Worksheet
Pressure Conversions
1 in H20 = 0.074 in Hg = 0.036 psi
1 in Hg = 13.600 in H20 = 0.491 psi
1 psi = 2.036 in Hg = 27.680 in H20
NOTE: This Page Can Be Copied for Your Convenience.

Without EGR
Date: Repair Oder Number: Operator:
ESN: CPL: ECM Code:
Complaint:
Parameter Code Specifications Actual Reading

Intake Air Restriction (in H2O)1, 2
Exhaust Restriction (in Hg)1, 2
Fuel Inlet Restriction (in Hg)1, 2
Fuel Drain Line Restriction (in Hg)1, 2
Engine Blowby (in H2O)1, 2
1 Record at advertised horsepower rpm and full load
2 Reference Specifications - Engine Testing
Engine Set Up for Dyno with INSITE Electronic Service Tool? (Circle One) Yes No
Road Speed Limit:
Check Oil Level Low High OK Fuel Quality OK Not OK
(Circle One) (Circle One)
Engine Horsepowe Fuel Fuel Intake Intake Coolant Coolant Engine
r
Speed Rate Temperat Manifold Manifold Temperat Pressure Oil
or ure ure
(lb/hr)1 Air Pressure (psi) Pressure
Torque Temperat (in Hg) (psi)
ure
1 Be sure that the fuel rate is corrected for temperature, see table below.
Fuel Temperature Correction for Flow Rate
Less than 7C [45F] Flow meter is not accurate
7 to 13C [45 to 55 F] Subtract 2 percent from flow rate reading
13 to 20C [55 to 68F] Subtract 1 percent from flow rate reading
20 to 29C [68 to 85F] No Correction
56C [132F] above Flowmeter not accurate
Engine Testing (Chassis Dynamometer) Signature, ISX, and QSX15 Eng [...]
Pressure Conversions
1 in H20 = 0.074 in Hg = 0.036 psi
1 in Hg = 13.600 in H20 = 0.491 psi
1 psi = 2.036 in Hg = 27.680 in H20
NOTE: This Page Can Be Copied for Your Convenience.
Engine Testing (Chassis

Dynamometer) (014-002)
Setup
The performance of an engine installed in on-highway
vehicles can be tested on a chassis dynamometer.
NOTE: Due to driveline inefficiencies and engine-driven
accessories, the rated horsepower will be reduced by
approximately:
20 percent for single-axle vehicles
25 percent for tandem-axle vehicles.
The net horsepower available is called wheel horsepower.
NOTE: These percentages are used for engine run-in
only and are not to be used as absolute figures.
WARNING
Before installing or operating a vehicle on a chassis
dynamometer, follow all the vehicle manufacturer's
safety precautions.
CAUTION
Low-profile radial tires are more sensitive to heat than
bias ply tires. Excessive operating time at full load can
damage tires due to overheating. Check the tire
manufacturers's recommendations for the maximum
allowable chassis dynamometer operating time.
Signature, ISX, and QSX15 Eng [...] Engine Testing (Chassis Dynamometer)
The following are general safety precautions to be

observed while operating the chassis dynamometer.
Use tires that have more than 160 km [100 mi] on them.
Do not use new tires.
Do not use recapped tires or tires of different sizes or
designs.
Make sure the tires are inflated to the manufacturer's

specifications.
Remove all rocks or other material from the treads of
all tires that will be rotating on the dynamometer
rollers.
Make sure there is correct overhead clearance for

exhaust stacks, air deflectors, or other attachments
above the cab.
CAUTION
The tie-down chains must have slack to prevent
damage to the chassis dynamometer.
Carefully position the vehicle on the rollers.
Attach the tie-down chains to the rear of the vehicle,
and put wheel chocks in front of the front wheels.
Adjust the vehicle and dynamometer room exhaust

system to make sure all exhaust gases are removed
from the room.
Reference the chassis dynamometer and vehicle
manufacturer's recommendations and specifications
for testing procedures.
Check the engine coolant level to be sure it is filled to the

proper level.
WARNING
Check the coolant level only when the engine is
stopped. Wait until the coolant temperature is below
50C [120F] before removing the pressure cap.
Failure to do so can cause personal injury from heated
coolant spray.
CAUTION
Check the engine lubricating oil level to be sure it is filled

to the proper level.
NOTE: Use a known source of good quality Number 2

diesel fuel. Number 1 diesel fuels, along with most other
alternate fuels, are lighter (lower specific gravity, higher
API gravity) than Number 2 diesel fuel. The lighter the fuel,
the lower the energy content (BTU) per gallon (liter).
Test
To monitor engine performance correctly, record the
following parameters. To limit dynamometer operating
time, instrument the engine or use INSITE electronic
service tool to make as many checks as possible.
Engine speed (rpm)
Fuel rate
Intake manifold air temperature
Engine blowby
Engine coolant pressure
Engine coolant temperature
Rail fuel pressure. Use the following reference for ISM
applications. Refer to Procedure 005-016 in Section 5.
Use the following reference for ISX applications. Refer
Engine fuel temperature (if needed to correct fuel rate).
Fuel inlet restriction. Use the following reference for
ISM applications. Refer to Procedure 006-020 in
Section 6. Use the following reference for ISX
Fuel drain line restriction. Use the following reference
for ISM applications. Refer to Procedure 006-012 in
Intake manifold pressure. Use the following reference
applications. Refer to Procedure 010-024 in Section
10.
Intake air restriction. Use the following reference for
10.
Exhaust restriction. Use the following reference for
11.
Engine oil pressure. Use the following reference for
Engine Speed (rpm)

Use INSITE electronic service tool to monitor engine
speed.
Observe and record the engine speed.
Fuel Rate
Reference the Fuel Flow Measurement on Engine or
Chassis Dynamometer in this section.
NOTE: Adjust the fuel rate reading to compensate for
temperature variation, if required.
Fuel Inlet Temperature

C F
7.2 MIN 45
55.5 MAX 132
Intake Manifold Air Temperature Control - Chassis

Dynamometer test
When operating an engine on a chassis dynamometer,
lock the cooling fan in the ON position for best results.
If the unit does not have a manual fan switch, use
INSITE electronic service tool Set Up for Dynamometer
feature to lock the fan in the ON position. Refer to
Use INSITE electronic service tool to monitor the intake

manifold air temperature.
Observe and record the intake manifold air temperature.
The intake manifold air temperature must not exceed the
maximum allowable temperature. Reference the
Specifications - Engine Testing page in this section for the
maximum allowable intake manifold air temperature. The
engine protection system will disrupt performance if the
temperature exceeds this level. Maintain the intake
manifold air temperature below the maximum allowable
temperature during chassis dynamometer operation.
If the intake manifold air temperature exceeds the

maximum allowable temperature during the test, unload
the dynamometer and allow the engine to cool.
Shut the engine off and inspect the charge-air cooler fins
for obstructions to the airflow.
Check the fan drive. Make sure the fan is locked in the ON
position.
Remove any obstructions, such as a winterfront or debris.
Manually lock the shutters in the OPEN position, if
equipped.
Inspect the dynamometer room for an adequate supply of
suitably cool or outside air. Make sure that dynamometer
room air recirculation is not an issue.
Engine Blowby
Use blowby checking tool, Part Number 3822566 (ISM) or
Part Number 3822567 (ISX), and water manometer, Part
Number ST-1111-3, to measure the engine crankcase
pressure.
Install the blowby checking tool to the end of the blowby

tube. Install the water manometer to the blowby checking
tool. Operate the engine at advertised horsepower rpm at
full load. Observe and record the blowby.
Engine blowby must not exceed the maximum allowable
specifications. Refer to Procedure 014-010 in Section 14.
Engine Coolant Pressure

Use pressure gauge, Part Number 3822995, to measure
engine coolant pressure.
Observe and record engine coolant pressure.
Reference the Specifications - Engine Testing page in this
section for the maximum allowable coolant temperature.
Engine Run-in (Chassis Dynamometer) Signature, ISX, and QSX15 Eng [...]
Engine Coolant Temperature

coolant temperature.
Observe and record the engine coolant temperature.
Reference the Specifications - Engine Testing page in this
If the coolant temperature exceeds the maximum

allowable coolant temperature, unload the dynamometer
and allow the engine to cool.
Shut the engine off and inspect the radiator fins for
obstructions to the airflow.
position.
equipped.
suitable cool or outside air. Make sure that dynamometer
Engine Fuel Temperature

Use immersion probe, Part Number 3824965, with a
digital multimeter, Part Number 3377161, and a
thermocouple module, Part Number 3824963, to monitor
fuel temperature.
Observe and record the engine fuel temperature.
Engine Run-in (Chassis Dynamometer)

(014-003)
Run-In Instructions
Use the following procedure for general operating
procedures and safety precautions. Refer to Procedure
Operate the vehicle in a gear that produces a road speed
of 90 to 100 Km/h [55 to 60 mph] at advertised horsepower
rpm.
Signature, ISX, and QSX15 Eng [...] Engine Run-in (Chassis Dynamometer)
Use the Dynamometer Worksheet to record all of the

engine performance parameters. Refer to Procedure
014-001 in Section 14. Cummins Inc. recommends
monitoring block coolant pressure during run-in to aid in
early indication of a cooling system problem.
NOTE: INSITE electronic service tool must be used to

confirm that the ECM code on the ECM dataplate is the
same as the one installed in the ECM. There is an
associated fuel pump code with all ECM codes.
Use INSITE electronic service tool to obtain the ECM
code and the fuel pump code from the ECM dataplate.
During the test, if a sudden increase in blowby occurs or

if blowby exceeds the maximum allowable limit during any
run-in, return to the previous step of the test and continue
the run-in. If blowby does not reach an acceptable level
during the next step, discontinue the run-in and determine
the cause.
Do not proceed to the next step until a steady, acceptable
blowby reading is obtained.
NOTE: Blowby must be measured with the blowby
checking tool, Part Number 3822566 (ISM) or Part
Number 3822567 (ISX) and water manometer, Part
Number ST-1111-3.
Do not idle the engine for more than 5 minutes at any one
time during the first 160 km [100 mi] of operation.
Engine Run-in (Chassis Dynamometer) Signature, ISX, and QSX15 Eng [...]
Adjust the engine speed to 1200 rpm. Apply a test load

sufficient to develop 25 percent of advertised horsepower
of the engine.
Operate the engine at this speed and load level until the
coolant temperature reaches 70C [160F].
Check for leaks. Repair all leaks.
Check all gauges and record the data.
Do not proceed to the next step until the blowby becomes
stable and within specifications.
Open the throttle to obtain the engine speed at which

advertised horsepower is developed, and adjust the
dynamometer load to achieve 75 percent of advertised
horsepower on the engine.
Operate the engine at this speed and load level for 3
minutes.
Maintain the engine speed at which advertised

horsepower is developed. Move the throttle lever to its fully
opened position, and increase the dynamometer load until
100 percent advertised horsepower of the engine is
developed.
minutes.
Increase the dynamometer load until the engine speed

reduces to the engine's peak torque rpm.
minutes.
Signature, ISX, and QSX15 Eng [...] Engine Run-in (Chassis Dynamometer)
Reduce the dynamometer load until the engine speed

increases to the engine speed at which advertised
horsepower is developed.
minutes.
Remove the dynamometer load completely and reduce

the engine rpm to idle.
CAUTION
Do not shut off the engine immediately after the run-
in is completed. Allow the engine to cool by operating
it at 700 to 900 rpm for a minimum of three to five
minutes to avoid internal damage. This allows the
turbocharger and other components to cool.

Engine Run-in (Without Dynamometer) Signature, ISX, and QSX15 Eng [...]
Make sure all instrumentation is removed before removing

the vehicle from the dynamometer.
Engine Run-in (Without Dynamometer)

(014-004)
Run-In Instructions
On-Highway Applications
WARNING
Refer to Engine Testing - General Information and
Specifications- Engine Testing at the front of this
section before operating the engine to avoid internal
component damage.
Operate the vehicle pulling the heaviest available trailer
allowed for the first 80 to 160 Km [50 to 100 mi] after
rebuild. Operate the vehicle in the highest gear possible
within the normal operating rpm range of the engine. It will
be necessary to operate the engine at or near full throttle
at 75 to 85 percent of maximum horsepower rpm indicated
on the dataplate.
time during the first 160 Km [100 mi] of operation.
Signature, ISX, and QSX15 Eng [...] Engine Testing (Engine Dynamometer)
Off-Highway Applications
WARNING
Refer to Engine Testing - General Information and
Specifications- Engine Testing at the front of this
section before operating the engine to avoid internal
component damage.
Operate the engine under the highest load possible at full
throttle within the normal operating rpm range of the
engine for the first 3 hours of operation after rebuild.
time during the first 3 hours of operation after a rebuild.
Engine Testing (Engine Dynamometer)

(014-005)
Setup
NOTE: Make sure the dynamometer capacity is sufficient
to permit testing at 100 percent of the engine's rated
horsepower. If the capacity is not enough, the testing
procedure must be modified to the restrictions of the
dynamometer.
Use engine lifting fixture, Part Number 3162871, to install
the engine test stand. Align and connect the
dynamometer. Refer to the manufacturer's instructions for
aligning and testing the engine.
Coolant Plumbing
Connect the coolant supply to the water inlet connection.
Connect the coolant return to the water outlet connection.
Install the drain plugs and close all of the water drain
cocks.
Engine Testing (Engine Dynamometer) Signature, ISX, and QSX15 Eng [...]
Intake Air Temperature Control

The use of a remote aftercooler is mandatory whenever a
Cummins charge-air cooled engine is attached to an
engine dynamometer for the purpose of engine run-in,
performance testing, and/or engine diagnostics. Do not
attempt to run a Cummins charge-air cooled engine
without a means of controlling the intake manifold air
temperature. Dynamometer-room charge-air cooler, Part
Number 3823978, utilizes twin Big Cam III aftercooler
assemblies arranged for parallel air and water flow to cool
the intake air to acceptable levels.
The parallel airflow circuit heat exchangers provide

optimum performance by delivering air to the mixer at
temperatures no higher than 66C [151F] and with less
than the maximum allowable intake air pressure drop. The
remote aftercooler removes energy from the intake air
compressed and heated by the turbocharger to
temperatures as high as 210C [410F] and then cooled
to temperatures of 66C [151F] using city water at 16C
[61F].
1 Water in
2 Aftercooler number 1 (2 pass)
3 Aftercooler number 2 (2 pass)
4 Water out
5 Condensate
6 From turbocharger
7 To intake manifold
8 Thermocouple (fluke).
Water from a city tap line flows to the aftercooler via a 25.4
mm [1-inch] inner diameter neoprene hose. Testing has
shown that 45.4 liter [12 gal] per minute city water flow is
required (22.7 liter [6 gal] per minute per aftercooler core)
to adequately cool the intake air for the 435 through 500
horsepower-rated engines. A typical garden hose is not
suitable for this flow, due to the excessive restriction. A
low-restriction ball-type or gate valve is suitable for the
operation, provided that the required flow rates are
achieved.
Water returns to the drain or reservoir from the
aftercoolers via a 25.4 mm [1-inch] inner diameter hose.
A low-restriction gate valve or ball valve must be placed
on the drain line(s) to regulate water flow through the
aftercoolers. This provides the ability to maintain optimum
intake air temperature during the test or run-in procedure.
The condensate that will develop as the intake air is
cooled in the remote aftercooler is allowed to drain at all
times through a hole at the bottom of the tubular steel
manifold between the aftercoolers. This fitting must
remain unobstructed throughout each use of the
aftercoolers.
NOTE: Some air will escape through the condensate drain
opening, but it is insignificant compared to the total
airflow.
1 Air in from turbocharger compressor outlet
2 Lifting eye
3 Air out to engine intake manifold
4 Water in to aftercooler
5 Water out to drain
6 Condensate drain.
The airflow piping requires a 101.6 mm [4 in] inner

diameter aluminum steel piping. The flow circuit must
have as few bends as possible, maximizing the length of
straight sections. However, when bends are required, use
long elbows. Do not use square elbows or anything that
changes the airflow direction quickly. To reduce intake air
restriction, airflow direction changes must occur
gradually.
Air Compressor
NOTE: All air compressors manufactured by Cummins
Inc. must operate during the engine run-in. During the
performance check, all air compressors must be in the
unloaded or non-operating mode.
Connect a source of compressed air capable of producing
665 kPa [96 psi] to the air compressor unloader (1). This
air line must contain a valve between the air source and
the unloader.
NOTE: The compressed air load in the accompanying
illustration must be attached to the air compressor outlet
(2).
Use an air tank (2). Install an air regulator (3) capable of

maintaining 345 to 517 kPa [50 to 75 psi] of air pressure
at both minimum and maximum engine rpm.
Install a steel tube or high temperature hose (1).
Hose Temperature
C F
235 MIN 500
Connect the tube or hose (1) to the air compressor outlet.
Starting Motor
Inspect the voltage rating on the starting motor before
installing the electrical wiring.
WARNING
cable last.
Install the electrical wiring to the starting motor and
batteries, if used.
If another method of starting the engine is used, follow the
manufacturer's instructions to make the necessary
connections.
Engine Throttle Control

Engines operating on an engine dynamometer require the
engine harness be installed and connected to the engine.
Additionally, the engine controller harness, Part Number
3164242, and engine controller, Part Number 3163890,
must be used to properly control the engine during the
dynamometer run.
Connect the engine controller harness Deutsch
connector to the ECM, OEM port.
Return parameters to their original value when the test or

run-in is complete.
Connect battery power to the starter.
WARNING
cable last.
Connect the dynamometer test OEM wiring harness
starter solenoid lead (yellow) to the starter solenoid.
Connect the ground lead (black) to the starter or battery
negative (-) or ground side. Connect the +12-VDC power
lead (red) to either the starter or battery positive (+12-
VDC) side.
Connect the keyswitch panel data link cable to the

Cummins electronic service tool.
Use INSITE electronic service tool to set the engine up
the for dynamometer. Refer to Procedure 014-008 in
Section 14 for more information on this feature.
The setup is now complete, and the auto/manual throttle
can be used to control engine speed.
Test
To monitor engine performance correctly, record the
following parameters. To limit dynamometer operating
time, instrument the engine or use INSITE electronic
service tool to make as many checks as possible.
Engine speed (RPM)
Fuel rate
Intake manifold air temperature
Engine blowby
Engine coolant pressure
Engine coolant temperature
Rail fuel pressure. Use the following reference for ISM
Use the following reference for ISX applications. Refer
Engine fuel temperature (if needed to correct fuel rate)
Fuel inlet restriction. Use the following reference for
Fuel drain line restriction. Use the following reference
Intake manifold pressure. Use the following reference
10.
Intake air restriction. Use the following reference for
10.
Exhaust restriction. Use the following reference for
11.
Engine oil pressure. Use the following reference for
Engine Speed (rpm)

speed.
Observe and record the engine speed.
Fuel Rate
See the Fuel Flow Measurement on Engine or Chassis
Dynamometer in this section.
Adjust the fuel rate reading to compensate for
temperature variation if required.
Fuel Inlet Temperature

C F
7.2 MIN 45
55.5 MAX 132
Intake Manifold Air Temperature Control - Chassis

Dynamometer test
When operating an engine on a chassis dynamometer,
lock the cooling fan in the ON position for best results.
If the unit does not have a manual fan switch, use INSITE
electronic service tool/Set Up for Dynamometer feature to
lock the fan in the ON position. Refer to Procedure
Use INSITE electronic service tool to monitor the intake

manifold air temperature.
Observe and record the intake manifold air temperature.
The intake manifold air temperature must not exceed the
maximum allowable temperature. See the Specifications
- Engine Testing page in this section for the maximum
allowable intake manifold air temperature. The engine
protection system will disrupt performance if the
temperature exceeds this level. Maintain the intake
manifold air temperature below the maximum allowable
temperature during chassis dynamometer operation.
If the intake manifold air temperature exceeds the

maximum allowable temperature during the test, unload
the dynamometer and allow the engine to cool.
Shut the engine off and inspect the charge air cooler fins
for obstructions to the airflow.
position.
equipped.
suitably cool or outside air. Make sure that dynamometer
Engine Blowby
Use blowby checking tool, Part Number 3822566 (ISM) or
Part Number 3822567 (ISX), and water manometer, Part
Number ST-1111-3, to measure the engine crankcase
pressure.
Install the blowby checking tool to the end of the blowby

tube. Install the water manometer to the blowby checking
tool. Operate the engine at advertised horsepower rpm at
full load. Observe and record the blowby.
Engine blowby must not exceed the maximum allowable
specifications. Refer to Procedure 014-010 in Section 14.
Engine Coolant Pressure

Use pressure gauge, Part Number 3822995, to measure
engine coolant pressure.
Observe and record engine coolant pressure.
See the Specifications - Engine Testing page in this
section for the maximum allowable engine coolant
pressure.
Signature, ISX, and QSX15 Eng [...] Engine Run-in (Engine Dynamometer)
Engine Coolant Temperature

coolant temperature.
Observe and record the engine coolant temperature.
See the Specifications - Engine Testing page in this
If the coolant temperature exceeds the maximum

allowable coolant temperature, unload the dynamometer
and allow the engine to cool.
Shut the engine off and inspect the radiator fins for
obstructions to the airflow.
position.
equipped.
suitable cool or outside air. Make sure that dynamometer
Engine Fuel Temperature

Use immersion probe, Part Number 3824965, with a
digital multimeter, Part Number 3377161, and a
thermocouple module, Part Number 3824963, to monitor
fuel temperature.
Observe and record the engine fuel temperature.
Engine Run-in (Engine Dynamometer)

(014-006)
Run-In Instructions
Follow the general operating procedures and safety
precautions when performing the engine run-in. Refer to
Engine Run-in (Engine Dynamometer) Signature, ISX, and QSX15 Eng [...]
Use the Dynamometer Worksheet to record all of the

engine performance parameters. Refer to Procedure
Cummins Inc. recommends monitoring block coolant
pressure during run-in to aid in early indication of a cooling
system problem.
NOTE: INSITE electronic service tool must be used to

confirm that the ECM code on the ECM dataplate is the
same as the one installed in the ECM. There is an
associated fuel pump code with all ECM codes.
Use INSITE electronic service tool to obtain the ECM
code and the fuel pump code from the ECM dataplate.
During the test, if a sudden increase in blowby occurs or

if blowby exceeds the maximum allowable limit during any
run-in, return to the previous step of the test and continue
the run-in. If blowby does not reach an acceptable level
during the next step, discontinue the run-in and determine
the cause.
Do not proceed to the next step until a steady, acceptable
blowby reading is obtained.
NOTE: Blowby must be measured by the blowby checking
tool, Part Number 3822566 (ISM) or Part Number 3822567
(ISX), and water manometer, Part Number ST-1111-3.
time during the first 3 hours or 160 km [100 mi] of
operation.
Signature, ISX, and QSX15 Eng [...] Engine Run-in (Engine Dynamometer)
Adjust the engine speed to 1200 rpm. Apply a test load

sufficient to develop 25 percent of advertised horsepower
of the engine.
Operate the engine at this speed and load level until the
coolant temperature is 71C [160F].
Check for leaks. Fix all leaks.
stable within specifications.
Open the throttle to obtain the engine speed at which

advertised horsepower is developed, and adjust the
dynamometer load to achieve 75 percent of advertised
horsepower on the engine.
minutes.
Maintain the engine speed at which advertised

horsepower is developed. Move the throttle lever to its fully
opened position, and increase the dynamometer load until
100 percent advertised horsepower of the engine is
developed.
minutes.
Increase the dynamometer load until the engine speed

reduces to the engine's peak torque rpm.
minutes.
Engine Run-in (Engine Dynamometer) Signature, ISX, and QSX15 Eng [...]
Reduce the dynamometer load until the engine speed

increases to the engine speed at which advertised
horsepower is developed.
minutes.
Remove the dynamometer load completely.
CAUTION
Do not shut off the engine immediately after the run-
in is completed. Allow the engine to cool by operating
it at 700 to 900 rpm for a minimum of 3 to 5 minutes
to avoid internal damage. This allows the
turbocharger and other components to cool.

Make sure all instrumentation is removed before removing
the engine from the engine dynamometer.
Signature, ISX, and QSX15 Eng [...] Engine Testing (Portable Dynamometer or Load Bank)
Engine Testing (In Chassis) (014-008)

Setup
The Setup for Dynamometer function is used to prepare
the engine ECM for an advanced diagnostic test run on
the chassis dynamometer. For purposes of this test, the
maximum engine speed without Vehicle Speed Sensor
(VSS), the maximum vehicle speed in top gear, and the
maximum vehicle speed in lower gear are set to their
maximum values. The idle shutdown feature is disabled
and the fan is locked in the ON mode. All of these values
are automatically reset to their previous values when the
engine keyswitch is turned to the OFF position.
Maximum Engine Speed without VSS: 2500 rpm for

testing purposes, this speed is temporarily set to the
maximum value allowed.
Maximum Vehicle Speed in Top Gear: 120 mph for
Maximum Vehicle Speed in Lower Gear: 120 mph for
Gear-Down Protection: This feature is temporarily
disabled for testing purposes.
Fan Clutch: On.
Idle Shutdown: This feature is temporarily disabled
for testing purposes.
Some SAE J1939 electronic subsystems must be
disabled. The user has the ability to enable or disable the
SAE J1939 data link with the service tool.
Refer to the INSITE Help File for detailed setup for
dynamometer instructions.
Engine Testing (Portable

Dynamometer or Load Bank) (014-009)
General Information
When it is not possible to load an engine immediately after
rebuild or repair (for example, on-highway tractor that
must be bobtailed for delivery, a standby generator or
fire pump that can not be operated because of customer
restrictions, a fire truck that can not be loaded with the
water pump, etc.), the engine must be run in on a chassis
dynamometer, portable dynamometer, or load bank
following the recommendations outlined in the preceding
procedures.
Crankcase Blowby, Measure Signature, ISX, and QSX15 Eng [...]
Crankcase Blowby, Measure (014-010)

General Information
Excessive crankcase blowby can indicate an engine or
engine related component malfunction that allows
combustion gasses or air to enter the crankcase. This
results in the buildup of higher than normal crankcase
pressure, which results in increased levels of blowby.
This procedure describes how to measure crankcase
blowby and how to determine which component is
malfunctioning.
Blowby is typically measured for the following situations:
Verifying engine break-in after an engine rebuild
Troubleshooting for excessive lubricating oil out of the
crankcase breather tube, commonly referred to as oil
carryover (for open crankcase ventilation systems)
Troubleshooting oil in the air intake system (for closed
crankcase ventilation systems)
Troubleshooting high crankcase pressure (for engines
equipped with a crankcase pressure sensor)
Troubleshooting possible internal engine damage
(worn piston rings, valve stem seals or guides,
turbocharger, air compressor, etc.).
This procedure provides general guidelines for measuring
blowby relative to the above situations.
NOTE: Some illustrations in this procedure do not show
actual engine configurations. The procedure, however, is
the same.
Signature, ISX, and QSX15 Eng [...] Crankcase Blowby, Measure
It is important to note that the terms blowby and carryover

(oil out of the breather tube) are commonly used
interchangeably.
When measuring blowby, and there is an excessive
amount of oil coming out of the breather tube, the quantity
of oil can affect the blowby measurement.
The blowby measurement is affected by the oil collecting
on the orifice of the blowby measurement service tool.
This reduces the size of the orifice, which results in higher
than actual blowby measurements.
If this occurs, it will be necessary to:
Find a different location on the engine to measure
blowby (oil fill, oil fill cap, unused turbocharger drain
location, etc.)
Clean any oil residue from the breather and dry
thoroughly before measuring blowby
Determine if there is an issue causing the breather to
be flooded with oil, for example:
- Incorrect oil level
- Vehicle operation (excessive angularity, excessive
engine side to side movement)
- Internal engine components are deflecting oil toward
the breather cavity (piston cooling nozzles, accessory
oil drains, etc.)
Determine if another breather option is available for the
engine being serviced.
The tools used to measure blowby are similar in design.

The difference between the tools is in the size of the
orifice. Different size orifices are available to more
accurately measure blowby and to accommodate the wide
variety of engine configurations and ratings. This is due to
the fact thatengine blowby is dependent on the volume of
intake airflow.
For example:
If measuring blowby on two identically configured and
size engines, but the horsepower rating and rated
speed are different, the maximum blowby value
measured will be different.
The engine with the higher horsepower rating and rated
speed will have a higher volume of intake airflow, which
will result in higher blowby. This means that if the smaller
orifice blowby tool was used on the engine with a higher
horsepower rating and rated speed, the measurement can
exceed the limits of the pressure measuring tool.
Heavy Duty 15L Orifice Size
Blowby Tool Part Number
3822567 8.99 mm [0.354 in]
Heavy Duty 10.9 - 13L Orifice Size
Blowby Tool Part Number
3822566 7.67 mm [0.302 in]
To measure the crankcase blowby pressure, connect a
water manometer, Part Number ST1111-3 or equivalent,
pressure gauge or transducer to the blowby tool.
NOTE: Water manometer, Part Number ST1111-3, can
measure a maximum of 944 mm [36 in] of water.
The following chart shows the relationship of measured pressure to flow rate for a 8.99-mm [0.354-in] orifice.
Blowby Conversion Table with 8.99 mm [0.354 in] Orifice and Blowby
mm H2O [in H2O] Liter [cfm] per Minute
25.4 [1] 70 [1.766]
50.8 [2] 100 [3.531]
76.2 [3] 120 [4.238]
101.6 [4] 140 [4.944]
127 [5] 158 [5.580]
152.4 [6] 172 [6.074]
177.8 [7] 185 [6.533]
203.2 [8] 198 [6.992]
228.6 [9] 210 [7.416]
254 [10] 220 [7.769]
279.4 [11] 231 [8.158]
304.8 [12] 241 [8.511]
330.2 [13] 252 [8.899]
355.6 [14] 260 [9.182]
381 [15] 270 [9.535]
406.4 [16] 280 [9.888]
431.8 [17] 289 [10.206]
457.2 [18] 298 [10.524]
482.6 [19] 305 [10.771]
508 [20] 312 [11.018]
533.4 [21] 320 [11.301]
558.8 [22] 328 [11.583]
584.2 [23] 335 [11.830]
609.6 [24] 341 [12.042]
The following chart shows the relationship of measured pressure to flow rate for a 7.67-mm [0.302-in] orifice.
25.4 [1] 50 [1.766]
50.8 [2] 84 [2.966]
76.2 [3] 103 [3.637]
101.6 [4] 119 [4.202]
127 [5] 133 [4.697]
152.4 [6] 145 [5.121]
177.8 [7] 155 [5.474]
203.2 [8] 164 [5.792]
228.6 [9] 172 [6.074]
254 [10] 180 [6.357]
279.4 [11] 187 [6.604]
304.8 [12] 193 [6.816]
330.2 [13] 200 [7.063]
355.6 [14] 206 [7.275]
381 [15] 211 [7.451]
406.4 [16] 217 [7.663]
431.8 [17] 222 [7.840]
457.2 [18] 226 [7.981]
482.6 [19] 229 [8.087]
508 [20] 235 [8.299]
533.4 [21] 239 [8.440]
558.8 [22] 242 [8.546]
584.2 [23] 246 [8.687]
609.6 [24] 248 [8.758]
NOTE: If internal engine damage is suspected to be the
cause of the excessive blowby condition, other steps can
be taken to confirm this.
Measuring blowby must only be considered when
confirming engine break-in after a rebuild, or if another
symptom is present. These symptoms can include:
Excessive carryover (oil out of the crankcase breather
tube)
High crankcase pressure (for engines equipped with a
crankcase pressure sensor)
Low power
Oil consumption
Exhaust smoke.
If no other symptom is present, blowby measurements
need not be taken.
If internal engine damage is suspected to be the cause of

the excessive blowby condition, other steps can be taken
to confirm this. The steps include:
Confirm engine maintenance practices
Cut the oil filter open and check for debris
Take an oil sample and inspect for contamination. Use
the following procedure for ISM engines. Refer to
Procedure 007-044 in Section 7. Use the following
procedure for ISX engines. Refer to Procedure
Initial Check
NOTE: The location and type of crankcase breathers vary
by engine configuration (front gear train or rear gear train)
and/or engine application.
Prior to measuring blowby pressure, check the crankcase
breather tube for obstructions. Use the following
procedure for ISM engines. Refer to Procedure 003-002 in
Section 3. Use the following procedure for ISX engines.
If troubleshooting a complaint of excessive oil out of the
breather tube, it can be necessary to remove the breather
components to clean and remove any lubricating oil
buildup before performing any blowby measurements.
Check the engine oil level and, if necessary, proper

calibration of the dipstick. If the level is too high, it can
cause a higher than normal blowby pressure and/or
excessive carryover. Use the following procedure for ISM
engines. Refer to Procedure 007-009 in Section 7. Use the
following procedure for ISX engines. Refer to Procedure
Measure
Choose the appropriate blowby measurement service tool
to use for the engine being serviced.
Heavy Duty 15L Blowby Tool Part Orifice Size
Number
3822567 8.99 mm [0.354
in]
Heavy Duty 10.9 - 13L Blowby Tool Orifice Size
Part Number
3822566 7.67 mm [0.302
in]
To measure the crankcase blowby pressure, connect a

water manometer, Part Number ST1111-3, pressure
gauge, or transducer to the blowby measurement service
tool.
NOTE: The location of the crankcase breather tube can
vary by engine configuration and/or application.
Install the appropriate blowby service tool(s):
For typical open crankcase breather/ventilation
systems, connect the appropriate blowby service tool
to the end of the crankcase breather tube. Connect a
water manometer pressure gauge or transducer to the
blowby service tool.
For engines with closed crankcase ventilation systems
(without a crankcase ventilation filter), disconnect the
breather tube and plug the intake manifold or
turbocharger compressor housing port. Connect the
appropriate blowby service tool to the end of the
crankcase breather tube. Connect a water manometer
pressure gauge or transducer to the blowby service
tool.
Check the following for engine blowby contributon.

Operate the engine at rated speed and under load by
either:
For engine run-in, a chassis dynamometer or engine
dynamometer.
For engine testing, a chassis dynamometer or engine
dynamometer.
A stall speed test (for engines equipped with automatic
transmissions only).
CAUTION
When measuring blowby and there is an excessive
amount of oil coming out of the breather tube, the
quantity of oil can affect the blowby measurement.
For specific instructions for the appropriate engine test,
reference the appropriate procedure number listed below.
Operate the engine at rated rpm and full load until a steady
reading is obtained.
NOTE: When measuring blowby, the value can spike
initially as the engine reaches peak power and rated
speed. Wait for the blowby measurement to stabilize
before taking a reading.
NOTE: For engine run-in, if a sudden increase in blowby
occurs, or if blowby exceeds the maximum allowable limit
during any run-in step, return to the previous step and
continue the run-in. If blowby does not reach an
acceptable level, discontinue the run-in and determine the
cause.
Record the steady blowby measurement.
Remove the engine blowby service tool and water
manometer or pressure gauge, if the blowby is within
specification.
Check the following for turbocharger blowby contribution.

With the engine blowby service tool and water manometer
or pressure gauge still installed:
Isolate the turbocharger, if equipped, to determine if
the high blowby pressure is due to turbocharger seal
leakage
To measure the turbocharger blowby contribution,
disconnect the turbocharger oil drain line. For ISM
engines, use the following procedure. Refer to
Procedure 010-045 in Section 10. For ISX engines, use
the following procedure. Refer to Procedure 010-045
in Section 10.
This describes the preferred turbocharger isolation

method.
Install a hose assembly with two shutoff valves (A and B),
installed as shown in the illustration, between the
turbocharger and turbocharger drain line location in the
cylinder block. The valves must have a minimum inside
diameter of 19 mm [0.75 in]. Place the other hose in a 8
to 9 liter [2 to 5 gal] container.
NOTE: Some turbocharger oil drain tubes are a single one
piece tube. It can be necessary to create a turbocharger
isolation tool. Use a new or used turbocharger drain line
and cut a middle section out of the turbocharger drain line
to fit the check valves and hoses.
Close the valve (A) that allows oil to drain into the bucket.
Open the valve (B) that allows oil to drain into the engine.

either of the following:
dynamometer
WARNING
To reduce the possibility of personal injury, keep
hands, long hair, jewelry, and loose fitting or torn
clothing away from fans and other moving parts.
WARNING
Troubleshooting presents the risk of equipment
damage, personal injury, or death. Troubleshooting
must be performed by trained, experienced
technicians.
CAUTION
Do not operate the engine with valve (A) open and
valve (B) closed for more than 1 minute. Monitor the
amount of oil accumulating in the bucket. The engine
can run out of lubricating engine oil and severe engine
damage will occur.
Continue operating at rated speed and load.
Open valve (A) and close valve (B).
Record the blowby pressure reading.
CAUTION
Do not operate the engine for more than 1 minute.
Monitor the amount of oil accumulating in the
container. The engine can be run out of lubricating
engine oil and severe engine damage will result.
These steps describe the alternate turbocharger isolation
method:
With the turbocharger oil drain line disconnected from the
cylinder block, run the turbocharger drain line into a large
container.
Plug the turbocharger oil drain port in the cylinder block.
either:
dynamometer
Record the peak blowby pressure measurement.
Determine the turbocharger blowby pressure contribution

by determining the difference in the blowby pressure
measurement with the turbocharger drain isolated, valve
(A) open, and turbocharger drain not isolated, valve (A)
closed.
Blowby Pressure Differential
Turbocharger Blowby Maximum: 30 percent
Contribution
If the turbocharger blowby contribution is out of
specification, inspect the compressor and turbine areas of
the turbocharger for signs of an oil leak. Replace the
turbocharger, if necessary. For ISM engines, use the
following procedure. Refer to Procedure 010-033 in
Section 10. For ISX engines, use the following procedure.
NOTE: The air compressor governor/unloader location

can vary on each engine application. The air governor/
unloader can be air compressor mounted or chassis
mounted.
Disconnect the air signal line from the air compressor
governor/unloader air signal port.
Disconnect the air compressor discharge line and air
intake hose from the air compressor.
NOTE: On turbocharged air compressors, make sure to
plug the air intake hose going to the engine intake
manifold or the engine will not reach full power during test.
To unload the air compressor, determine the pressure

needed at the governor/unloader air signal port to start
and stop the air compressor from pumping.
NOTE: Typically, 621 kPa [90 psi] of air pressure is the set
point between starting and stopping of the air compressor
pumping. Refer to the OEM service manual.
Connect a regulated shop air pressure line, with pressure
gauge, to the air compressor governor/unloader air signal
port.
NOTE: When performing the test, make sure that the air
system pressure does not exceed the manufacturer's
maximum allowable pressure.
Run the engine and increase the signal pressure to the air
governor/unloader to determine when the air compressor
will stop pumping (system pressure stops rising at this
point). Record the signal line pressure.
Reduce the signal pressure to determine when system
pressure starts the air compressor pumping again (system
pressure will begin to rise again at this point). Record the
signal line pressure.
NOTE: Allow the air compressor to pump long enough to
build enough pressure in the system to release and
operate the air brakes.
With the regulated shop air pressure line still connected

to the air compressor governor/unloader air signal port,
regulate the signal pressure so that the air compressor
starts pumping (system pressure will begin to rise again
at this point). Use the pressure value recorded previously
as a set point.
either:
dynamometer
Continue operating the engine at rated speed and load.

Increase the signal pressure (system pressure stops rising
at this point). Use the pressure value recorded previously
as a set point.
Determine the air compressor blowby pressure

contribution by determining the difference in the blowby
pressure measurement with the air compressor pumping
and the air compressor not pumping.
Blowby Pressure Differential
Air Compressor Maximum: 30 percent
Contribution
If the air compressor blowby contribution is out of
specification, replace the air compressor. Refer to
WARNING
personal injury.
With the engine shut off, bleed the vehicle's air system
down by opening the draincock on the wet tank to release
compressed air from the system.
Disconnect the regulated shop air pressure line, with

pressure gauge, from the air compressor governor/
unloader air signal port.
Connect the air signal line. Refer to the OEM service
manual.
manometer or pressure gauge if the blowby is within
specification.
NOTE: On turbocharged air compressors, make sure to
remove the plug previously installed in the air intake hose
going to the engine's intake.
Connect the air compressor discharge line and air intake
hose from the air compressor.
Exhaust Brake Blowby Contribution:

NOTE: Not all vehicles are equipped with an exhaust
brake.
With the engine blowby service tool and water manometer
or pressure gauge still installed, measure blowby pressure
during exhaust brake operation, if equipped.
Operate the vehicle going down a long inclined road such
as a highway or interstate off ramp. Begin exhaust brake
operation at rated engine speed while measuring blowby
pressure during exhaust brake operation.
Aftertreatment Testing Signature, ISX, and QSX15 Eng [...]
Also, measure exhaust back pressure during exhaust

brake operation.
Operate the engine until a steady reading is obtained.
If blowby pressure is above specification during exhaust
brake operation and exhaust back pressure is above
specification, repair or replace the exhaust brake. See the
If the blowby pressure is above specification during
exhaust brake operation and the exhaust back pressure
is within specification, check the turbocharger blowby
contribution. Reference the turbocharger oil drain
isolation step previously in this procedure.
manometer or pressure gauge.
Remove the pressure gauge used to measure exhaust
back pressure during exhaust brake operation.
Install a plug in the test port.
Aftertreatment Testing (014-013)

General Information
The Snap-Acceleration Test is used to check the
aftertreatment diesel particulate filter for cracks or other
progressive damage, without removing the filter system.
It is used to test the functionality of the aftertreatment
The INSITE electronic service tool Aftertreatment Diesel
Particulate Filter Stationary Regeneration Test is used to:
Regenerate an aftertreatment diesel particulate filter
Recover the aftertreatment diesel oxidation catalyst
and aftertreatment diesel particulate filter after coolant
contamination
Check the aftertreatment diesel oxidation catalyst
efficiency
Check for the correct installation of the aftertreatment
temperature sensors
Reset the stored soot load in the engine ECM
Check the aftertreatment fuel injector, shutoff valve,
and drive train functionality.
Check for active fault codes prior to performing either of
these procedures. If any active fault codes are present,
follow the appropriate fault code troubleshooting tree.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Testing
The INSITE electronic service tool Aftertreatment Diesel

Particulate Filter Stationary Regeneration Test can be
used to regain functionality of the Aftertreatment Diesel
Oxidation Catalyst (DOC) and Aftertreatment Diesel
Particulate Filter (DPF) after either, or both, have been
exposed to coolant.
NOTE: If the DOC and DPF are suspected of having
coolant contamination, they do not need to be removed
and inspected. Consult the Preparatory Steps section of
this procedure for further details.
The temperatures that are achieved during the
Regeneration are high enough to evaporate the coolant
out of both components and return both components to
normal operating specifications.
NOTE: If these components are suspected of having
coolant contamination, do not perform the snap
acceleration test before performing the regeneration.
This section outlines the Exhaust System Outlet

Inspection.
Inspection of the exhaust system outlet can reveal the
condition of the aftertreatment diesel particulate filter. The
exhaust system outlet should appear clean with little to no
exhaust residue/soot buildup.
The aftertreatment diesel particulate filter is not 100
percent efficient. Some accumulation of exhaust residue/
soot is normal, and does not indicate a malfunctioning
A heavy buildup of exhaust residue/soot can indicate a
malfunction of the aftertreatment diesel particulate filter.
To determine if the exhaust residue/soot accumulation on
the exhaust system outlet is the result of a malfunctioning
aftertreatment diesel particulate filter, perform one of the
following:
1 Snap Acceleration Test as outlined in this procedure.
2 Clean the last 152 to 254 mm [6 to 10 in] of the exhaust
system outlet. Operate the vehicle for one shift or trip
and inspect the exhaust system outlet for exhaust
residue/soot accumulation.
3 Inspect the aftertreatment diesel particulate filter.
Snap Acceleration Test

The vehicle transmission must be in neutral.
The vehicle parking brake must be applied.
Start and idle the engine.
Rapidly depress the accelerator pedal from 0 percent to
100 percent. This can be performed multiple times, if
necessary.
During this test, visually check for black smoke exiting the
exhaust stack, as the engine is accelerated from low idle
to high idle
NOTE: In some applications, a snap acceleration test may
not provide the conditions necessary to reveal a
malfunctioning aftertreatment diesel particulate filter. If
there is a heavy buildup of exhaust residue/soot on the
exhaust system outlet and a snap acceleration does not
reveal a condition outlined in the following steps, it can be
necessary to perform:
A stall test. Refer to Procedure 014-008 in Section 14.
A brief acceleration run under partial to full load.
Refer to the Catalyst and Aftertreatment Particulate Filter
Reuse Guidelines, Bulletin 4021600, for pass or fail
guidelines.
If gray smoke or faint black smoke is present, refer to the

Catalyst and Aftertreatment Particulate Filter Reuse
Guidelines, Bulletin 4021600, for pass or fail guidelines.
White smoke during the snap-acceleration test does not
indicate a failure. No repair is necessary.
Preparatory Steps
WARNING
During regeneration, exhaust gas temperature could reach 800C [1500F]
and exhaust system surface temperature can exceed 700C [1300F], which
is hot enough to ignite or melt common materials, and cause severe burn
injuries. The exhaust and exhaust components can remain hot after the vehicle
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.
To perform a stationary regeneration, connect INSITE electronic service tool and
check for active fault codes. If any fault codes are present other than Fault Codes
2639 or 1921, go to Section TF for any fault code troubleshooting before proceeding.
Do not perform a stationary regeneration with active fault codes other than Fault
Codes 2639 or 1921, unless guided to do so by the fault code troubleshooting.
NOTE: If the stationary regeneration is being performed to recover either the DOC,
the DPF, or both after coolant contamination, the DOC does not need to be removed
or inspected unless there are active fault codes that require inspection as part of the
fault code troubleshooting steps.
NOTE: Unless there are complaints of black smoke during operation and the
exhaust stack is black, the DPF does not need to be removed or inspected during
this process.
Before performing a stationary regeneration, follow the steps listed below:
1 Select an appropriate location to park the vehicle.
a On a surface that will not burn or melt under high temperatures (such as clean
concrete or gravel, not grass or asphalt)
b Away from anything that can burn, melt, or explode
- Nothing within 0.6 m [2 ft] of the exhaust outlet
- Nothing that can burn, melt, or explode within 1.5 m [5 ft] (such as gasoline,
wood, paper, plastics, fabric, compressed gas containers, hydraulic lines)
- No gas or vapors nearby that could burn, explode, or contribute to a fire (such
as LP gas, gasoline vapors, oxygen, nitrous oxide).
2 Park the truck securely.
a Set the parking brake.
b Place transmission in Park, if provided; otherwise in Neutral.
c Set wheel chocks at the front and rear of at least one tire.
3 Set up a safe exhaust area.
a If bystanders might enter the area, set up barriers to keep people at least 1.5
m [5 ft] from the exhaust outlet during regeneration.
b When indoors, attach an exhaust discharge pipe rated for at least 800C [1500
F]
c Keep a fire extinguisher nearby.
4 Check exhaust system surfaces.
a Confirm that nothing is on or near the exhaust system surfaces (such as tools,
rags, grease, or debris).
5 Prepare for engine speed changes during regeneration.
a Do not operate any PTO-powered devices. Disconnect these devices before
starting regeneration.
b Stay clear of the engine compartment.
6 Begin the stationary regeneration. This can be performed in two ways:
a Vehicles equipped with a stationary regeneration switch in the cab must also
have the stationary regeneration switch parameter enabled in the ECM. The
stationary regeneration switch can be a stand-alone switch, or can be combined
with a diagnostic switch, at the choice of the vehicle manufacturer.
b The INSITE electronic service tool can be used to perform regeneration by
starting the Aftertreatment Diesel Particulate Filter Regeneration Test.
c In either case, the engine will create enough heat to regenerate the aftermarket
diesel particulate filter. Engine speed will increase and the turbocharger can
whistle loudly during the regeneration process. Once the aftermarket diesel
particulate filter is regenerated, the engine will automatically return to normal
idle speed.
7 Monitor the area.
a Make sure that the vehicle and surrounding area are monitored during
regeneration. If any unsafe condition occurs, shut off the engine immediately.
To stop a stationary regeneration, engage the clutch, brake, or throttle pedal; or turn
off the engine.
Once regeneration is complete, exhaust gas and exhaust surface temperatures will
remain elevated for 3 to 5 minutes.
Setup
Start and idle the engine.
Prior to the Aftertreatment Diesel Particulate Filter
Regeneration Test, inspect the exhaust piping for leaks,
cracks, and loose connections.
For ISM engines, use the following procedure. Refer to
For ISX engines, use the following procedure. Refer to
Tighten the exhaust clamps if necessary.
Consult the OEM specifications for the correct torque
value.
Any leaks in the exhaust system will cause the
Aftertreatment Diesel Particulate Filter Regeneration Test
to be less efficient in reducing the soot load of the filter.
Test
The Aftertreatment Diesel Particulate Filter Regeneration
Test can be found under the ECM Diagnostic Test menu
in the INSITE electronic service tool.
If INSITE electronic service tool is not available, some

vehicles can be equipped with a stationary regeneration
switch in the cab. The switch can be a stand-alone switch
or can be combined with the diagnostic switch. Check with
the OEM for the location and availability of the switch.
NOTE: In order for the stationary regeneration switch to
function, the stationary regeneration switch must be
enabled in the ECM.
Unlike the Aftertreatment Diesel Particulate Filter
Regeneration Test with the INSITE electronic service
tool, this switch will only start a stationary regeneration if
the soot load of the filter is high enough. This is indicated
by the aftertreatment lamp being illuminated or flashing.
NOTE: A stationary regeneration can not be initiated
through the use of the cab switch if regeneration inhibit is
enabled. INSITE electronic service tool must then be
used to initiate the stationary regeneration.
NOTE: If the Aftertreatment Diesel Particulate Filter

Regeneration Test will not initiate, use the Stationary
Regeneration - Will Not Start troubleshooting symptom
tree.
When the test is started, the engine idle speed will be
raised automatically to the required level. Expected
engine speed can reach between 1000 and 1500 rpm.
The engine will then, through the engine controls, operate
in a manner to build exhaust heat. The turbocharger can
emit a slight whining noise during the test. This is
normal.
The Aftertreatment Diesel Particulate Filter Regeneration
can take up to two and one half hours to complete,
depending on the soot loading of the filter as well as
conditions of the environment, such as but not limited to
the temperature and humidity.
Once the Aftertreatment Diesel Particulate Filter
Regeneration Test is complete, the engine will
automatically return to normal idle speed.
During the Aftertreatment Diesel Particulate Filter

Regeneration Test, the following items will be monitored:
Aftertreatment Injector Status - Informs the user when
fuel is being injected, in small quantity, into the
exhaust system upstream of the diesel oxidation
catalyst
Aftertreatment Diesel Particulate Filter outlet
temperature
Aftertreatment Diesel Particulate Filter inlet
temperature
Aftertreatment Diesel Oxidation Catalyst inlet
temperature
Aftertreatment Diesel Particulate Filter Soot Load -
Informs the user of the current soot load of the filter:
- Normal - No regeneration is necessary
- Above Normal; Least Severe Level - A stationary
regeneration can be performed
- Above Normal; Moderately Severe Level - A stationary
regeneration can be performed
- Above Normal; Most Severe Level - A stationary
regeneration must not be performed unless the filter
was cleaned or a new filter has been installed and the
troubleshooting steps indicate to perform.
CAUTION
During the stationary regeneration, the exhaust gas
temperature can reach 800C [1500F] and the
surface temperature can exceed 700C [1300F].
The stationary regeneration can take up to 2-1/2 hours to
complete, depending on the soot loading of the filter. At
any time the stationary regeneration can be aborted by
clicking on the Stop button in the INSITE electronic
service tool.
The stationary regeneration will be aborted if:
A fault becomes active
The accelerator is depressed
The clutch pedal is depressed
The brake pedal is depressed
The transmission is put into gear.
NOTE: If a stationary regeneration can not be initiated or
is aborted, and the engine has a low power complaint,
Pass or Fail Criteria
Pass: Aftertreatment Testing Procedure 014-013 in
Section 14 has passed, if there is no visible black
smoke and the stationary regeneration completes with
no aftertreatment fault codes being generated.
Fail: Aftertreatment Testing Procedure 014-013 in
Section 14 has failed, if there is visible black smoke
and/or aftertreatment fault codes are generated.
Repair the cause of the black smoke and/or correct the
fault codes.
Finishing Steps
Allow the engine and exhaust system to cool down.
Temperatures can maintain an elevated state for several
minutes.
Check to make sure the diesel particulate filter lamp is
not illuminated.
NOTE: If the diesel particulate filter lamp is illuminated
and Fault Code 2639 or 1921 are still active, a second
regeneration will be needed. If the fault is still active after
a second regeneration, the filter needs to be cleaned of
ash or soot. Refer to Procedure 011-041 in Section 11.
Check for any active fault codes. If active fault codes are
present, use Section TF for fault code troubleshooting.
Use INSITE electronic service tool to clear all inactive
fault codes.
Section 16 - Mounting Adaptations - Group 16 Page 16-a
Section 16 - Mounting Adaptations - Group 16

Section Contents
Page
Engine Lifting Brackets ...................................................................................................................................16-2
Finishing Steps...............................................................................................................................................16-4
Install..............................................................................................................................................................16-3
Remove..........................................................................................................................................................16-2
Engine Mounts ...............................................................................................................................................16-41
Install............................................................................................................................................................16-44
Remove.........................................................................................................................................................16-43
Engine Support Bracket, Front .......................................................................................................................16-4
Finishing Steps...............................................................................................................................................16-6
Install..............................................................................................................................................................16-6
Remove..........................................................................................................................................................16-4
Flywheel ..........................................................................................................................................................16-7
Finishing Steps............................................................................................................................................. 16-13
Initial Check....................................................................................................................................................16-7
Bore Runout.................................................................................................................................................16-7
Face Runout................................................................................................................................................16-8
Install............................................................................................................................................................16-12
Remove.........................................................................................................................................................16-10
Flywheel Housing ..........................................................................................................................................16-14
Finishing Steps............................................................................................................................................. 16-23
Install............................................................................................................................................................16-17
Measure........................................................................................................................................................16-18
Bore Alignment...........................................................................................................................................16-18
Face Alignment..........................................................................................................................................16-21
Remove.........................................................................................................................................................16-14
Flywheel Housing, REPTO ............................................................................................................................16-24
Finishing Steps............................................................................................................................................. 16-40
Install............................................................................................................................................................16-29
Measure........................................................................................................................................................16-36
Bore Alignment...........................................................................................................................................16-36
Face Alignment..........................................................................................................................................16-38
Remove.........................................................................................................................................................16-24
Flywheel Ring Gear .......................................................................................................................................16-41
Install............................................................................................................................................................16-41
Remove.........................................................................................................................................................16-41
Service Tools ...................................................................................................................................................16-1
Mounting Adaptations......................................................................................................................................16-1
Page 16-b Section 16 - Mounting Adaptations - Group 16

Section 16 - Mounting Adaptations - Group 16 Page 16-1
Service Tools
Mounting Adaptations
Repair Location.

Dial Gauge Attachment
Used to check the bore and face of the flywheel and flywheel housing
ST-1325 relative to the center line of the crankshaft.
Crack Detection Kit

Used to check or inspect components for cracks.
3375432
Dial Indicator and Sleeve Assembly

Used with dial indicator attachment, Part No. ST-1325, for checking
3376050 the bore and face of the flywheel and flywheel housing.
Flywheel Socket - 21 mm 12 point

Used to remove capscrews.
3162813
Guide Pin Kit

This kit contains various size guide pins that are used during
3163157 assembly and/or disassembly to align parts and aid in the control of
parts.
Barring Tool
This tool provides a way of barring over most engines when making
3163160 valve and injector adjustments or checking engine timing.
Engine Lifting Brackets Signature, ISX, and QSX15 Eng [...]
Page 16-2 Section 16 - Mounting Adaptations - Group 16
Engine Lifting Brackets (016-001)

Preparatory Steps
Remove the retaining brace bracket. Refer to
Procedure 001-081.
Remove
NOTE: Newer models use three mounting capscrews.
Remove the four capscrews and the rear lifting bracket.
Remove the four capscrews and the front lifting bracket.

Signature, ISX, and QSX15 Eng [...] Engine Lifting Brackets
WARNING
WARNING
WARNING
bodily injury.
Clean with steam or solvent.
Inspect the lifting brackets for cracks or damage.

Inspect the capscrew threads for damage.
Install
Install the front bracket and four capscrews.
Install the rear bracket and four capscrews.
Engine Support Bracket, Front Signature, ISX, and QSX15 Eng [...]
Finishing Steps
Install the retaining brace bracket. Refer to
Procedure 001-081.
Engine Support Bracket, Front

(016-002)
Preparatory Steps
WARNING
Use a hoist or lifting fixture to support the front of the
engine.
Remove the fan and water pump drive belt. Refer to
Procedure 008-003.
Remove the fan and water pump belt tensioner if a
low mount tensioner is used. Refer to Procedure
008-080.
Remove the vibration damper and the crankshaft
pulley. Refer to Procedure 001-052.
Remove
WARNING
Remove the two capscrews that attach the support to the
equipment frame.
Use the hoist to lift the weight of the engine off the front
support.
Signature, ISX, and QSX15 Eng [...] Engine Support Bracket, Front
Remove the six mounting capscrews and the front engine

support.
Remove the rubber engine mounts.
WARNING
WARNING
WARNING
personal injury.
Clean the parts with steam or solvent.
Dry the parts with compressed air.
Inspect the engine mounts for cracks or deterioration.

Engine Support Bracket, Front Signature, ISX, and QSX15 Eng [...]
Inspect the engine support bracket for cracks or damage.

Inspect the capscrew threads for damage.
Install
Install the engine support bracket and the six mounting
capscrews.
Torque: 97 Nm + 60 deg [72 ft-lb + 60 deg]
Install the rubber engine mounts into the crossmember.
WARNING
Lower the front of the engine to the rubber engine mounts.
The capscrew holes in the support bracket must be
aligned with the capscrew holes in the engine mounts.
Install the two capscrews in the support bracket and
engine mount. Tighten to the manufacturer's
specifications.
Remove the lifting fixture or the hoist from the engine.
Finishing Steps
Install the vibration damper and the crankshaft
pulley. Refer to Procedure 001-052.
Install the fan and water pump drive belt tensioner.
Procedure 008-003.
Signature, ISX, and QSX15 Eng [...] Flywheel
Flywheel (016-005)
Initial Check
Bore Runout
Use dial indicator gauge (1), Part Number 3376050, or
equivalent, and dial gauge attachment (2), Part Number
ST-1325, to inspect the flywheel bore (3) and face (4)
runout.
Install the attachment to the flywheel housing.
Install the gauge on the attachment.
Install the contact tip of the indicator against the inside of
the flywheel bore.
Use the compressor drive or barring device to rotate the

crankshaft one complete revolution (360-degrees).
Measure the bore runout.
Flywheel Bore Runout

mm in
0.127 MAX 0.005
If the total indicator reading is greater than the

specification, remove the flywheel.
Inspect the flywheel mounting surface for dirt or damage.

Flywheel Signature, ISX, and QSX15 Eng [...]
Inspect the crankshaft for dirt or damage.
Install the flywheel and inspect the bore runout again.
Replace the flywheel if the runout does not meet

specifications.
Face Runout
Install the contact tip of the indicator against the flywheel
face as close to the outside as possible to inspect the face
(4) runout.
Push the flywheel forward to remove the crankshaft end
thrust.
Use the compressor drive or barring device to rotate the

crankshaft one complete revolution (360-degrees) while
keeping the crankshaft end thrust pushed forward.
The total indicator reading must not exceed the following

specifications:
Flywheel Face Runout Total Indicator Reading

Maximum (Total Indicator
Flywheel Radius (A)
Reading) of Flywheel Face
203 mm [8 in] 0.203 mm [0.008 in]
254 mm [10 in] 0.254 mm [0.010 in]
305 mm [12 in] 0.305 mm [0.012 in]
356 mm [14 in] 0.356 mm [0.014 in]
406 mm [16 in] 0.406 mm [0.016 in]
Preparatory Steps
WARNING
cable last.
WARNING
Disconnect the batteries or air starter to prevent
accidental engine starting.
Remove the transmission, clutch, and all related
components. See the equipment manufacturer's
instructions.
Remove
WARNING
Use two M6 x 1.5 guide studs to prevent the flywheel from
rotating. Remove two capscrews and install the guide
studs.
Use a hoist, two t-handles, and a lifting sling. Install the
tee-handles. Remove the remaining ten capscrews.
Remove the flywheel.
Use a soft faced mallet to tap the flywheel from the
crankshaft, if necessary. Damage to the clutch surface
can occur if a hard faced hammer is used.
Remove the pilot bearing spacer from the rear of the

crankshaft.
Use a mandrel and hammer to remove the pilot bearing
from the flywheel.
WARNING
WARNING
WARNING
personal injury.
Use a wire brush to clean the crankshaft pilot bore.
Use a wire brush to clean the flywheel pilot bore.
Clean with steam or solvent.
Inspect for nicks or burrs.

Use a fine crocus cloth to remove small nicks and burrs.
WARNING
Do not use a cracked or resurfaced flywheel. These
can break, causing serious personal injury or property
damage.
Use the crack detection kit, Part Number 3375432, to
check for cracks in the flywheel. Follow the instructions
provided with the kit.
Inspect the flywheel ring gear teeth for cracks and chips.
If the ring gear teeth are cracked or broken, the ring gear
must be replaced. Refer to Procedure 016-008 (Flywheel
Ring Gear) in Section 16.
Inspect the pilot bearing spacer for cracks or damage,

replace if necessary.
Install
Install the pilot bearing spacer into the rear of the
crankshaft with the spacer lip oriented outward.
NOTE: A small amount of clean Lubriplate 105 multi-
purpose lubricant, or its equivalent, can be used to help
keep the pilot bearing spacer in position until the flywheel
is assembled.
CAUTION
The flywheel mounting capscrews must be a minimum
of SAE Grade 8 with rolled threads. Use identical
replacements to avoid possible flywheel failure
resulting in personal injury or property damage.
Lubricate the threads and underneath the heads of the
capscrews with clean 15W-40 oil. Allow the excess oil to
drip off the parts. Do not lubricate the threads of the
crankshaft.
WARNING
lift the component.
Use two M6 x 1.5 guide studs during assembly.
Install the flywheel. The flywheel must be firmly against
the crankshaft.
Install the ten capscrews.

Remove the t-handles and the guide studs.
Install the remaining two capscrews into the holes from
which the guide studs were removed.
Tighten the capscrews in two steps, use the sequence
shown.
Step2 250 Nm [ 184 ft-lb ]
Use a mandrel and hammer to install the pilot bearing.

The pilot bearing must be installed even with the pilot bore
surface.
Finishing Steps
WARNING
WARNING
cable last.
Perform the bore runout check and face runout
check located in this procedure.
Install the clutch discs, pressure plate, transmission,
and driveline, if equipped, in reverse order of
removal. See the manufacturer's instructions.
Align the universal joints on each end of the
driveshaft to prevent vibration.
Connect batteries and air starter.
Start the engine and check the operation of the
equipment.
Flywheel Housing Signature, ISX, and QSX15 Eng [...]
Flywheel Housing (016-006)

Preparatory Steps
WARNING
WARNING
lift the component.
WARNING
WARNING
WARNING
Adequately support the engine to prevent damage and
personal injury.
Disconnect the batteries and air starter to prevent
accidental engine starting.
components. Refer to the equipment manufacturer's
instructions.
Remove the flywheel. Refer to Procedure 016-005.
Drain the oil. Refer to Procedure 007-037.
Remove the oil pan. Refer to Procedure 007-025.
Remove the rear crankshaft seal. Refer to Procedure
001-024.
Remove the starting motor. Refer to Procedure
013-020.
Remove the rear engine mounts from the flywheel
housing.
Remove
Remove the two top exterior capscrews from the flywheel
housing.
Install two guide studs.
Signature, ISX, and QSX15 Eng [...] Flywheel Housing
WARNING
avoid personal injury, use a hoist or get assistance.
Use a hoist and lifting sling. Install the lifting sling around
both sides of the upper housing. Adjust the hoist until
there is tension in the lifting sling. Remove the remaining
capscrews.
Use a mallet to tap the flywheel housing off the two

locating dowels.
Remove two capscrews, cover plate, and gasket. Discard

the gasket.
CAUTION
Immediately upon removal of the flywheel housing
assembly, a plug must be inserted into the cylinder
block oil passage drillings. Failure to insert the oil
passage plug can result in a bearing failure,
crankshaft failure, or both.
The reusable plug, Part Number 4918321, is included in
Protective Plug Kit, Part Number 4918319. This plug is
necessary to prevent debris from entering the lubrication
system during the repair.
Plug the block oil passage with plug Part Number
4918321.
Firmly push plug into oil passage to prevent all debris from
entering the lubricating system when cleaning the gasket
surface.

CAUTION
gasket sealing surfaces. Main or connecting rod
into the lubrication system. Therefore, use of power
tools combined with abrasive pads to clean gasket
surfaces is not recommended.
Clean the gasket surfaces by hand with a gasket scraper
or cleaning pad Part Number 3823258
If the residual gasket material can not be felt with a finger,
the surface is ready to accept the new gasket.
WARNING
WARNING
personal injury.
WARNING
bodily injury.
Steam-clean or use solvent to clean the housing.
Inspect all surfaces for nicks, burrs, or cracks.

Use a fine crocus cloth to remove small nicks and burrs.
Inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are
damaged.
Install
Remove the protective plug from the block oil passages.
Make sure debris does not enter the lubrication system.
Use a clean shop towel to carefully wipe out the oil
passage and inspect to make sure no debris is left in the
passage.
Install the cover plate and two capscrews. Tighten the

capscrews.
Install two guide studs into the cylinder block to help

support and align the housing during installation.
Position the flywheel housing gasket to the rear of the
engine block using the guide pins.
Install the flywheel housing over the guide studs.

Lubricate the threads and underneath the heads of the
capscrews with clean 15W-40 lubricating oil.
Install capscrews 1, 2, 3, and 4, and tighten in the
sequence shown.
The flywheel housing is located on the block by two ring

dowels from the factory. If a flywheel housing is removed,
it can be reinstalled with the ring dowels in place, but
alignment must be checked with the following alignment
procedure.
If the alignment does not meet specification, the ring
dowels must be removed and the housing must be
realigned without the ring dowels.
CAUTION
The flywheel housing bore and surface must be in
alignment with the crankshaft to prevent possible
damage to the engine, the clutch, or the transmission.
Measure the flywheel housing alignment.
Measure
Bore Alignment
Attach a dial indicator to the crankshaft. Use mounting tool
Part Number ST-1325 and indicator Part Number
3376050.
The dial indicator can be mounted by any method that
holds the extension bar of the indicator rigid so it does
not sag. If the bar sags or the indicator slips, the readings
obtained will be inaccurate.
Position the indicator in the 6:00 o'clock position and the
gauge at zero.
Slowly rotate the crankshaft. Record the readings

obtained at the 9:00 o'clock, 12:00 o'clock, and 3:00
o'clock positions as (a), (b), and (c) in the concentricity
work sheet. Recheck zero at the 6:00 o'clock position.
The values for (a), (b), and (c) can be positive or negative.
Refer to the accompanying figure to determine the correct
sign when recording these values.
CAUTION
Do not force the crankshaft beyond the point where
the bearing clearance has been removed. Do not pry
against the flywheel housing. These actions can
cause false bearing clearance reading.
Rotate the crankshaft until the dial indicator is at the 12-
o'clock position and zero the gauge.
Use a pry bar to raise the rear of the crankshaft to its upper
limit. Record the value as (d) in the concentricity work
sheet. This is the vertical bearing clearance adjustment
and will always be positive.
Use the concentricity work sheet (see the accompanying

illustration) to determine the total vertical and horizontal
values.
The total horizontal is equal to the 9:00 o'clock reading (1)
minus the 3 :00 o'clock reading (c).
The total vertical is equal to the 12:00 o'clock reading (b)
plus the bearing clearance (d).
Example:
6:00 o'clock = reference = 0
9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Using the work sheet and the numbers from the example,
the total horizontal value equals 0.006, and the total
vertical value equals 0.005.
Mark the total horizontal value on the horizontal side of the

chart and the total vertical on the vertical side of the chart.
Use a straightedge to find the intersection point of the total
horizontal and total vertical values. The intersection point
must fall within the shaded area for the flywheel housing
concentricity to be within specification.
Using the total horizontal and total vertical values from the
previous example, the intersection point falls within the
shaded area. Therefore, the flywheel housing
concentricity is within specification.
Use the accompanying chart for SAE 1, 2, and 3 flywheel
housings.
Use the accompanying chart for SAE 0 and flywheel

housings.
Use the accompanying chart for SAE 00 flywheel

housings.
If the intersection point falls outside the shaded area, the

ring dowels must be removed and the housing
repositioned.
The ring dowels are not required to maintain concentricity
of the housing; the clamping force of the capscrews holds
the housing in place.
After the ring dowels are discarded, install the flywheel
housing on the engine.
To position the housing, tighten the capscrews enough to
hold the flywheel housing in place, but loose enough to
enable small movement when struck lightly with a mallet.
Recheck the concentricity. When concentricity is within
specification, tighten the capscrews to the specified value.
Face Alignment
CAUTION
The dial indicator tip must not enter the capscrew
holes, or the gauge will be damaged.
Install a dial indicator as illustrated.
The extension bar for the indicator must be rigid for an
accurate reading. It must not sag. Position the indicator
at the 12:00 o'clock position. Adjust the dial until the
needle points to zero.
Slowly rotate the crankshaft. Record the readings at the

3:00 o'clock, 6:00 o'clock, and 9:00 o'clock positions.
The crankshaft must be pushed toward the front of the
engine to remove the crankshaft end clearance each time
a position is measured.
Continue to rotate the crankshaft until the indicator is at

the 12:00 o'clock position. Check the indicator to make
sure that the needle points to zero. If it does not, the
readings will be incorrect.
Determine the total indicator runout.

Total Indicator Runout (Example)
Position Runout
12:00 o'clock 0.00 mm [0.000 in]
3:00 o'clock +0.08 mm [+0.003 in]
6:00 o'clock -0.05 mm [-0.002 in]
9:00 o'clock +0.08 mm [+0.003 in]
Total Indicator Runout = 0.13 mm [0.005 in]
The maximum allowable total indicator reading is

determined by the diameter of the housing bore. If out of
specifications, replace the housing.
SAE Bore Diameter Total Indicator
Number Runout Maximum
00 787.40 to 787.65 mm 0.30 mm [0.012 in]
[30.88 to 31.00 in]
0 647.70 to 647.95 mm 0.25 mm [0.010 in]
[25.50 to 25.51 in]
584.2 to 584.4 mm 0.25 mm [0.010 in]
[23.000 to 23.008 in]
1 511.18 to 511.30 mm 0.20 mm [0.008 in]
[20.125 to 20.130 in]
2 447.68 to 447.80 mm 0.20 mm [0.008 in]
[17.652 to 17.630 in]
3 409.58 to 409.70 mm 0.20 mm [0.008 in]
[16.125 to 16.130 in]
Install the remaining capscrews. Tighten all capscrews in

two steps using the sequence shown.
Step2 197 Nm [ 145 ft-lb ]
Finishing Steps
WARNING
WARNING
lift the component.
Install the rear engine mounts on the flywheel
housing.
Install the starting motor capscrews, starter, and
spacer. Refer to Procedure 013-020.
Install the rear crankshaft seal. Refer to Procedure
001-024.
Install the oil pan. Refer to Procedure 007-025.
Fill the oil. Refer to Procedure 007-037.
Install the flywheel. Refer to Procedure 016-005.
Install the transmission, clutch, and all related
instructions.
Connect the batteries and air starter.
Flywheel Housing, REPTO Signature, ISX, and QSX15 Eng [...]
Flywheel Housing, REPTO (016-007)

Preparatory Steps
WARNING
compartment before servicing batteries. To reduce
the possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-) battery
cable last.
WARNING
WARNING
WARNING
Disconnect the batteries or air supply to the starter
to prevent accidental engine starting.
Drain the oil. Refer to Procedure 007-025
(Lubricating Oil Pan) in Section 7.
instructions.
Remove the flywheel. Refer to Procedure 016-005
(Flywheel) in Section 16.
Remove the starter motor. Refer to Procedure
013-020 (Starting Motor) in Section 13.
Remove
Remove the three capscrews from the rear of the oil pan.
Signature, ISX, and QSX15 Eng [...] Flywheel Housing, REPTO
WARNING
Remove the 10 10-mm capscrews from the hydraulic
housing.
Remove the hydraulic housing from the REPTO flywheel
housing.
Remove the spray nozzle from the oil supply line hole.
Remove the 12 capscrews (1) from the seal carrier.

Remove the seal carrier (2) from the REPTO flywheel
housing.
Remove oil seal (4) and discard. Refer Procedure 001-024
(Crankshaft Seal, Rear) in Section 1.
Remove the o-ring (3) from the groove on the REPTO
flywheel housing.
Remove the four plugs (1) and o-rings (2) from the REPTO
flywheel housing.
Remove the crankshaft gear.

Remove the idler gear shaft capscrew and washer.
Remove the three guide pins.
If the idler gear shaft can not be removed with the handle,
a slide hammer similar to Snap-On, Part Number CJ114,
can be used.
Position the replacer idler plate, Part Number 3164762, on
the idler gear shaft. Install and tighten the two idler gear
capscrews. Install the handle, Part Number 3163089.
Remove the idler shaft, idler gear, and bearing from the
REPTO flywheel housing.
Remove two capscrews from the REPTO flywheel

housing.
Install the two guide pins, Part Number 3164764.
Install the two eye bolts, Part Number 3164767, on the top
of the REPTO flywheel housing. Install the lifting slings to
the eye hooks. Adjust the hoist until there is tension in the
lifting sling.
Remove the remaining capscrews.
WARNING
Use a mallet to tap the REPTO flywheel housing off the
two locating dowels. Remove and discard the gasket.
CAUTION
Immediately upon removal of the flywheel housing
assembly, a plug must be inserted into the cylinder
block oil passage drillings. Failure to insert the oil
passage plug can result in a bearing failure,
crankshaft failure, or both.
The reusable plug, Part Number 4918321, is included in
Protective Plug Kit, Part Number 4918319. This plug is
necessary to prevent debris from entering the lubrication
system during the repair.
Plug the block oil passage with plug Part Number
4918321.
Firmly push the plug into the oil passage to prevent all
debris from entering the lubricating system when cleaning
the gasket surface.

CAUTION
gasket sealing surfaces. Main or connecting rod
into the lubrication system. Therefore, use of power
tools combined with abrasive pads to clean gasket
surfaces is not recommended.
Clean the gasket surfaces by hand with a gasket scraper
or cleaning pad, Part Number 3823258. If the residue
gasket material can not be felt with a finger, the surface
is ready to accept the new gasket.
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the REPTO flywheel
housing.
Inspect all surfaces for nicks, burrs, or cracks.

Use a crocus cloth to remove small nicks and burrs.
Inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are
damaged.
Inspect the idler shaft, bearing, and gear for nicks, burrs,
or cracks. Replace if damaged.
Inspect the four o-rings from the plugs and the one large
o-ring from the REPTO flywheel housing for cuts or tears.
Replace the o-rings if damaged.
Install
Remove the protective plug from the block oil passages.
Make sure no debris enters the lubrication system.
Use a clean shop towel to carefully wipe out the oil
passage and inspect to make sure no debris is left in the
passage.
Install the two guide pins (3), Part Number 3164764, into
the cylinder block.
Position the flywheel housing gasket to the rear of the
cylinder block using guide pins.
WARNING
Install the two eye hooks (4) in the top of the REPTO
flywheel housing. Install the lifting slings to the eye hooks
and push the REPTO flywheel housing onto the two
guides pins (3).
Install the six short capscrews (2) and four long capscrews
(1) in the locations shown.
Remove the two guide pins and install the two other long
capscrews.
Tighten capscrews (1), (2), (9) and (10).

Tighten the remaining capscrews in the sequence shown.
CAUTION
The REPTO flywheel housing bore and face must be
in alignment with the crankshaft to prevent possible
damage to the engine, the clutch, or the transmission.
Use the measure step in this procedure to align the
housing.

Step2 197 Nm [ 145 ft-lb ]
Install the three oil pan capscrews.

Install the large o-ring seal (1) and the small o-ring seal (2)
onto the idler shaft.
Assemble the replacer idler shaft plate and handle.

Install the two capscrews in the idler shaft holes and
tighten.
Use clean 15W-40 oil to lubricate the idler shaft.
The two cones (2) are loose and will fall out if not
contained.
Make sure the gear (4), two bearing snap rings (1), and the
two cups (3) are pressed in place before inserting the
assemblies through the center or sides of the REPTO
flywheel housing openings.
Use clean 15W-40 oil to lubricate the bearing snap rings,
cones, cups, idler shaft, and gear.
Make sure the idler shaft plug (1) is facing upward when
installing it into the bore.
Install the gear and bearing assembly through the center
or sides of the REPTO flywheel housing holes. Position
the bearing races together and insert the idler shaft with
the tool through the first bear bore. The running clearance
is 0 to 0.025 mm [0.000 to 0.001 in].
Make sure the idler shaft is properly aligned and seated
against the shoulder of the internal bore.
Repeat the procedure if installing a second gear.

Remove the two capscrews, replacer idler plate, and
handle from the idler shaft.
Lubricate the threads and under the capscrew head with
clean 15W-40 oil.
Install the washer and capscrew and tighten capscrew.
A second idler gear can be installed or an insert shaft can

be used without the idler gear and roller.
Install the o-rings onto the insert shaft. Lubricate the o-
rings with clean 15W-40 oil.
Install the insert shaft into the flywheel housing hole where
the cover plate will be installed (opposite pump location).
Align the hole with the tapped hole in the block.
Lubricate the threads and under the capscrew head with
clean 15W-40 oil.
Install the washer and capscrew and tighten capscrew.
Install the three guide pins, Part Number 3164765, equally

spaced through the crankshaft gear and into the
crankshaft.
Rotate the idler gears, as necessary, to mesh the
crankshaft gear with the idler gear(s).
Install the crankshaft gear.
Make sure the o-rings are properly seated into the groove
before installation.
Use clean 15W40 oil to lubricate the o-rings.
Install four plugs (1) with o-rings (2) into the REPTO
flywheel housing holes.
Install the o-ring in the REPTO flywheel housing groove.

Install the seal carrier over the two dowels pins on the
REPTO flywheel housing.
Install the 12 capscrews.

Tighten the capscrews in the sequence shown to secure
the seal carrier.
Install the three flywheel mounting capscrews and

spacers. Tighten the flywheel mounting capscrews.
Remove the three flywheel mounting capscrews and
spacers.
CAUTION
The rear crankshaft seal must be pressed evenly into
the bore. If the crankshaft and crankshaft seal is not
pressed evenly into the bore, the oil seal can cause
equipment damage.
Install the rear crankshaft oil seal over the rear crankshaft
seal replacer, Part Number 3164780, and onto the three
guide pins.
Install three flywheel mounting capscrews (without the
washers) through the three holes in the rear crankshaft
seal replacer.
CAUTION
To reduce the possibility of damage to the oil seal and
crankshaft, never use a hammer or mallet to install the
rear crankshaft oil seal.
Do not use lubricants during the installation process.
Apply a 10 percent soap solution to the outer ribbed
surface of the rear crankshaft oil seal.
Tighten the flywheel mounting capscrews no more than
revolution at a time, alternating capscrews in a
clockwise pattern, until the rear crankshaft seal replacer,
Part Number 3164780, seats against the REPTO flywheel
housing.
Remove the rear crankshaft seal replacer and the three

flywheel mounting capscrews.
Install the flywheel. Refer to Procedure 016-005 (Flywheel)
in Section 16.
If one side of the REPTO flywheel housing cover access

hole does not use a hydraulic housing, the opening
must be covered in conjunction with the oil supply line
hole and plugging the straight thread plug hole.
Install the 1/8-inch pipe plug (1) into the oil supply line
hole. Make sure the pipe plug is flush with the mounting
surface.
Install the straight thread plug (2) into the flywheel housing
hole. Make sure pipe plug is flush with the mounting
surface.
Install the diamond seal (1) on the REPTO flywheel

housing cover access hole.
Apply a small amount of RTV on the two ends (2) where
the diamond seal comes together and a small amount of
15W-40 oil on the diamond seal.
Install the cover plate to the REPTO flywheel housing
cover access hole. Install the 10 capscrews and tighten.
Make sure the idler gear is locked in position. Use a dial

gauge to check the backlash.
Idler Gear to Crankshaft Gear Backlash

mm in
0.15 MIN 0.006
0.28 MAX 0.011
If the backlash is not within specifications, replace the
idler gear, REPTO hub gear, or both.
NOTE: The spray nozzle and diamond seal are only

installed if a hydraulic housing is used.
Install the spray nozzle (1) into the oil supply line hole.
Tighten the spray nozzle.
Install the diamond seal (2) on the REPTO flywheel
housing cover access hole.
Apply a small amount of RTV on the two ends (3) where
the diamond seal comes together and a small amount of
clean 15W-40 oil on the diamond seal.
Apply clean 15W-40 oil on the gear teeth and bearings.

Install the hydraulic housing over the dowel pins. The gear
inside the hydraulic housing is free to rotate and will locate
the position of the idler gear as the hydraulic housing is
being installed over the dowel pins.
Install the 10 capscrews and tighten in the sequence

shown.
Verify that backlash exists between the Hydrive housing

gear and idler gear by inserting a tool into the spline to
help rotate the gear.
A small amount of backlash must be present, although
obtaining a measurement is not required.
If no backlash is present, disassemble the Hydrive
housing from the flywheel housing, and assemble the
Hydrive housing to the opposite flywheel housing
mounting pad and check for backlash.
If no backlash is present when assembled on either
flywheel housing mounting pad, the Hydrive housing
must be replaced.
If backlash is present on only one side, the flywheel
Install the threaded plug (1) in the bottom hole of the

hydraulic housing. Tighten the threaded plug.
Install the oil line hose on the straight connectors. Tighten
the hose and check for leaks.
Measure
Bore Alignment
Attach a dial indicator to the crankshaft. Use mounting
tool, Part Number ST-1325, and indicator Part Number
3376050.
The dial indicator can be mounted by any method that
holds the extension bar of the indicator rigid so it does
not sag. If the bar sags or the indicator slips, the readings
obtained will not be accurate.
Position the indicator in the 6:00 o'clock position and the
gauge at zero.
Slowly rotate the crankshaft. Record the readings

obtained at the 9:00 o'clock, 12:00 o'clock, and 3:00
o'clock positions as (a), (b), and (c) in the concentricity
work sheet. Recheck zero at the 6:00 o'clock position.
The values for (a), (b), and (c) can be positive or negative.
Refer to the accompanying figure to determine the correct
sign when recording these values.
CAUTION
Do not force the crankshaft beyond the point where
the bearing clearance has been removed. Do not pry
against the flywheel housing. These actions can
cause false bearing clearance reading.
Rotate the crankshaft until the dial indicator is at the 12-
o'clock position and zero the gauge.
Use a pry bar to raise the rear of the crankshaft to its upper
limit. Record the value as (d) in the concentricity work
sheet. This is the vertical bearing clearance adjustment
and will always be positive.
Use the concentricity work sheet (see the accompanying

illustration) to determine the total vertical and horizontal
values.
The total horizontal is equal to the 9:00 o'clock reading (1)
minus the 3 :00 o'clock reading (c).
The total vertical is equal to the 12:00 o'clock reading (b)
plus the bearing clearance (d).
Example:
6:00 o'clock = reference = 0
9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Use the work sheet and the numbers from the example.
The total horizontal value equals 0.006, and the total
vertical value equals 0.005.
Mark the total horizontal value on the horizontal side of the

chart and the total vertical on the vertical side of the chart.
Use a straightedge to find the intersection point of the total
horizontal and total vertical values. The intersection point
must fall within the shaded area for the flywheel housing
concentricity to be within specification.
Using the total horizontal and total vertical values from the
previous example, the intersection point falls within the
shaded area. Therefore, the flywheel housing
concentricity is within specification.
Use the accompanying chart for SAE 1, 2, and 3 flywheel
housings.
Use the accompanying chart for SAE 0 and flywheel

housings.
Use the accompanying chart for SAE 00 flywheel

housings.
If the intersection point falls outside the shaded area, the

ring dowels must be removed and the housing
repositioned.
The ring dowels are not required to maintain concentricity
of the housing; the clamping force of the capscrews holds
the housing in place.
After the ring dowels are discarded, install the flywheel
housing on the engine.
To position the housing, tighten the capscrews enough to
hold the flywheel housing in place, but loose enough to
enable small movement when struck lightly with a mallet.
Recheck the concentricity. When concentricity is within
specification, tighten the capscrews to the specified value.
Face Alignment
CAUTION
The dial indicator tip must not enter the capscrew
holes, or the gauge will be damaged.
Install a dial indicator as illustrated.
The extension bar for the indicator must be rigid for an
accurate reading. It must not sag. Position the indicator
at the 12:00 o'clock position. Adjust the dial until the
needle points to zero.
Slowly rotate the crankshaft. Record the readings at the

3:00 o'clock, 6:00 o'clock, and 9:00 o'clock positions.
The crankshaft must be pushed toward the front of the
engine to remove the crankshaft end clearance each time
a position is measured.
Continue to rotate the crankshaft until the indicator is at

the 12:00 o'clock position. Check the indicator to make
sure that the needle points to zero. If it does not, the
readings will be incorrect.
Determine the total indicator runout.

Total Indicator Runout (Example)
Position Runout
12:00 o'clock 0.00 mm [0.000 in]
3:00 o'clock +0.08 mm [+0.003 in]
6:00 o'clock -0.05 mm [-0.002 in]
9:00 o'clock +0.08 mm [+0.003 in]
Total Indicator Runout = 0.13 mm [0.005 in]
The maximum allowable total indicator reading is

determined by the diameter of the housing bore. If out of
specifications, replace the housing.
SAE Bore Diameter Total Indicator
Number Runout Maximum
00 787.40 to 787.65 mm 0.30 mm [0.012 in]
[30.88 to 31.00 in]
0 647.70 to 647.95 mm 0.25 mm [0.010 in]
[25.50 to 25.51 in]
584.2 to 584.4 mm 0.25 mm [0.010 in]
[23.000 to 23.008 in]
1 511.18 to 511.30 mm 0.20 mm [0.008 in]
[20.125 to 20.130 in]
2 447.68 to 447.80 mm 0.20 mm [0.008 in]
[17.652 to 17.630 in]
3 409.58 to 409.70 mm 0.20 mm [0.008 in]
[16.125 to 16.130 in]
Install the remaining capscrews. Tighten all capscrews in

two steps using the sequence shown.
Step2 197 Nm [ 145 ft-lb ]
Finishing Steps
WARNING
WARNING
compartment before servicing batteries. To reduce
the possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-) battery
cable last.
Install the starting motor. Refer to Procedure
013-020 (Starting Motor) in Section 13.
Connect the batteries or air starter supply.
Fill the engine with clean oil. Refer to Procedure
007-025 (Lubricating Oil Pan) in Section 7.
Install the transmission, clutch, and all related
instructions.
Signature, ISX, and QSX15 Eng [...] Engine Mounts
Flywheel Ring Gear (016-008)

Remove
CAUTION
Do not use a cutting torch to heat the ring gear. The
flywheel can be damaged.
Heat the outside of the ring gear with a heating torch.
Use a blunt chisel and a hammer to remove the gear from
the flywheel.
Install
Heat the new ring gear in an oven heated to 316C [600
F] for a minimum of 1-hour.
NOTE: Do not overheat the ring gear. The metal hardness
will be changed.
WARNING
Wear protective gloves when handling parts that have
been heated to prevent personal injury.
Remove the gear from the oven and install it on the
flywheel before it cools.
NOTE: If an oven is not available, use a heating torch to
heat the inside diameter of the new ring gear to 316C
[600F]. Use a Tempilstik crayon, or its equivalent, to
check the gear temperature before installing it on the
flywheel.
Engine Mounts (016-010)

General Information
Some vibration exists in all piston type engines, due to the pulsating power inputs and reciprocating components.
Some of these vibrations are internal to the engine and are compensated, or balanced, by opposing forces within the
engine structure. These are generally not of interest to vibration isolation designs. The vibrations that are offset or
balanced internally will cause shaking moments and forces that must be reacted to by the engine mounts. If these
moments and forces are not adequately reduced by the engine mounting and isolation systems, they can cause
customer dissatisfaction and/or damage, due to component fatigue.
The effectiveness of an engine mounting system in isolating the vehicle structure from engine vibration depends on
the relationship between the frequency of the vibration coming from the engine and the natural frequency of the engine
mounting system. The mounting system effectiveness is commonly measured with the term transmissibility.
Transmissibility is the amount of engine vibration which is transmitted through the mounting system to the vehicle
structure.
Transmissibility values greater than one indicate the engine mounting system is actually transmitting more vibration
into the vehicle structure than is coming from the engine. This is possible if the natural frequency of the mounting
Engine Mounts Signature, ISX, and QSX15 Eng [...]
system is close to the frequency of the engine vibration. This can result in the mounting system operating at or near
resonance, with a resulting magnification of the input vibration. This is obviously an undesirable situation.
Transmissibility values of less than one indicate the mounting system is transmitting only a fraction of the vibration
input from the engine, thus isolating the vehicle from engine vibration. Good engine mounts will reduce the amount
of engine vibration transmitted to the chassis frame by at least 50 percent at idle.
Stiffness (durometer) and size of the isolator, along with the weight of the engine or component applied, are the
determining factors when designing a mounting system. An isolator that is correct for one engine may not be right
for another. Likewise, because of weight differential, a particular isolator designed for the rear of an engine probably
will not be ideal for the front. Hard engine mounts will give little or no isolation, and can actually magnify the vibration
transmitted to the chassis.
The following are illustrations of typical FRONT engine mounts.
1. Bolt 5. Bonded metal center
2. Supported member 6. Locknut
3. Snubbing washer (or flat bracket surface of equal 7. Supporting member
diameter 8. Rubber mount.
4. Rebound tail
The following are illustrations of typical REAR engine mounts.

Signature, ISX, and QSX15 Eng [...] Engine Mounts
Remove
WARNING
The engine lifting equipment must be designed to lift
the engine and transmission as an assembly without
causing personal injury.
WARNING
Use a hoist or lifting fixture to support the engine.
NOTE: When removing the engine mount fasteners, note
the location of any shims or spacers used.
Remove the capscrews from the engine mounts.
NOTE: Certain applications will require loosening of the
rear engine mount fasteners to allow removal of the front
engine support bracket.
Inspect for Reuse

CAUTION
Damaged engine mounts and brackets can cause
engine misalignment. Drivetrain component damage
can result in excessive vibration complaints.
Inspect all rubber-cushioned mounts for cracks and other
damage. Look for interference or contact between metal
components.
Inspect all mounting brackets for cracks and damaged
bolt holes.
Inspect the mounting capscrew to make sure it is not too
long, which will not provide enough preload on the mount.
Replace any damaged parts as necessary.
NOTE: Damaged engine mounts, brackets, and mounting
hardware can cause the engine to move out of alignment
and damage the driveline components in the equipment.
This can result in vibration complaints.
Engine Mounts Signature, ISX, and QSX15 Eng [...]
Inspect the capscrew for the following:

Damaged threads
Rust or corrosion-caused pitting
Nicked, bent, stretched, or galled.
The capscrew must be replaced if it has any of the listed
damages.
For barrel mounts, inspect for signs of contact between

the side brackets and the front engine support bracket.
Contact between the engine mount and side brackets can
cause vibration complaints. If contact is found, replace the
front engine support bracket.
Install
NOTE: Make sure to install any shims or spacers in the
same location as removed.
Align the engine in the chassis.
Install the engine mount fasteners and tighten. Refer to
the OEM for torque specifications.
Remove the lifting fixture or hoist from the engine lifting
brackets.
Connect all engine and chassis mounted accessories that
were removed.
Section 20 - Vehicle Braking - Group 20 Page 20-a
Section 20 - Vehicle Braking - Group 20

Section Contents
Page
Engine Brake Assembly ..................................................................................................................................20-1
Adjust.............................................................................................................................................................20-4
Initial Check....................................................................................................................................................20-2
Engine Brake Solenoid.................................................................................................................................20-2
Engine Brake Rocker Lever..........................................................................................................................20-3
Resistance Check...........................................................................................................................................20-1
Voltage Check.................................................................................................................................................20-1
Engine Brake Control Valve ..........................................................................................................................20-13
Install............................................................................................................................................................20-14
Remove.........................................................................................................................................................20-13
Engine Brake Piston ......................................................................................................................................20-15
Install............................................................................................................................................................20-16
Remove.........................................................................................................................................................20-15
Engine Brake Solenoid Valve ........................................................................................................................20-10
Finishing Steps............................................................................................................................................. 20-11
Install............................................................................................................................................................20-11
Remove.........................................................................................................................................................20-10
Engine Brake Wiring Harness .......................................................................................................................20-11
Install............................................................................................................................................................20-13
Threaded Brake Pass-Through...................................................................................................................20-13
Non-Threaded Brake Pass-Through............................................................................................................20-13
Remove.........................................................................................................................................................20-11
Threaded Brake Pass-Through...................................................................................................................20-11
Non-Threaded Brake Pass-Through............................................................................................................20-12
Page 20-b Section 20 - Vehicle Braking - Group 20

Signature, ISX, and QSX15 Eng [...] Engine Brake Assembly
Section 20 - Vehicle Braking - Group 20 Page 20-1
Engine Brake Assembly (020-004)

Resistance Check
CAUTION
Do not connect the engine breakout cable to the
engine wiring harness connector. Connecting the
engine brake breakout cable to the engine wiring
harness will give a false reading when checking the
resistance.
Disconnect the engine wiring harness connector from the
cylinder head pass-through connector.
Connect one end of the engine brake breakout cable, Part
Number 3163150, to the cylinder pass-through connector.
NOTE: The black test port on the engine brake breakout

cable box is the common ground for all three solenoids.
The white test ports (1, 2, and 3) are used to test the
resistance of the corresponding brake solenoids (1, 2, and
3).
NOTE: The ignition key must be in the OFF position.

Check the resistance of each solenoid.
12 volt
Cold engine - 8 to 10 ohms
Hot engine - 16 to 20 ohms.
24 volt
Cold engine - 32 to 40 ohms
Hot engine - 60 to 80 ohms.
NOTE: If not within specification, using the engine brake
breakout tool, the engine brake wiring harness and
solenoids must be checked separately to identify the
faulty component. Refer to Procedure 020-012 (Engine
Brake Solenoid Valve) in Section 20. Refer to Procedure
020-015 (Engine Brake Wiring Harness) in Section 20.
Voltage Check
Number 3163150, to the cylinder pass-through connector
and the other end to the engine wiring harness connector.
Engine Brake Assembly Signature, ISX, and QSX15 Eng [...]
Page 20-2 Section 20 - Vehicle Braking - Group 20
Connect the red alligator clip of the engine brake breakout

cable to battery voltage and the black alligator clip to
ground.
NOTE: The black test port on the engine brake breakout

cable box is the common ground for all three solenoids.
The white test ports (1, 2, and 3) are used to read the
voltage of the corresponding brake solenoids 1, 2, and 3.
NOTE: The ignition key must be in the ON position.

Check the voltage of each solenoid.
The voltage should be 12-VDC for each solenoid.
NOTE: If not within specification, using the engine brake
breakout tool, the engine brake wiring harness and
solenoids must be checked separately to identify the
faulty component. Refer to Procedure 020-012 (Engine
Brake Solenoid Valve) in Section 20. Refer to Procedure
020-015 (Engine Brake Wiring Harness) in Section 20.
Initial Check
Engine Brake Solenoid
Number 3163150, to the cylinder pass-through connector
and the other end to the engine wiring harness connector.
NOTE: The ignition key must be in the OFF position.

Button No. 1 actuates solenoid No. 1 and brake
Number 1.
Button No. 2 actuates solenoid No. 2 and brakes
Number 2 and 3.
Button No. 3 actuates solenoid No. 3 and brakes
Number 4, 5, and 6.
Press the engine brake breakout cable box button (1, 2,

or 3) to activate the corresponding engine brake solenoid
(1, 2, or 3).
Listen for a clicking sound when activating the brake
solenoid. If no clicking sound can be heard when the
button is pressed, the corresponding solenoid valve and
the engine brake wiring harness must be checked
separately to identify the faulty component. Refer to
Procedure 020-012 (Engine Brake Solenoid Valve) in
Section 20. Refer to Procedure 020-015 (Engine Brake
Wiring Harness) in Section 20.
Engine Brake Rocker Lever

003-011 (Rocker Lever Cover) in Section 3.
Install the splash shield , Part Number 3163092, to reduce

the amount of oil being thrown by the fuel pump drive gear.
Start the engine.
Press the engine brake breakout cable box button (1, 2,

or 3) to activate the corresponding engine brake solenoid
(1, 2, or 3).
Check the corresponding engine brake lever(s) and
solenoid for the following:
Engine brake piston deployment
Leakage from upper seals of solenoid.
Replace parts as needed. Refer to Procedure 020-012
(Engine Brake Solenoid Valve). Refer to Procedure
020-017 (Engine Brake Control Valve). Refer to Procedure
020-019 (Engine Brake Piston) in Section 20.
Adjust
All overhead adjustments must be made when the engine
is cold (any stabilized coolant temperature at 60C [140
F] or below).
CAUTION
Do not use solvent to clean the rocker cover gasket.
Solvent can damage the gasket material and cause it
to swell.
Remove the rocker lever cover and gasket. Refer to
NOTE: Early engine vibration dampers are marked with

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

cover.
compressor drive.
WARNING
damage.
The crankshaft rotation is clockwise, as viewed from the
(1-2-3-4-5-6).
Without Air Compressor:

Loosen the capscrews and rotate the cover or remove the
oil fill tube, if equipped.
Use a 1 1/2-inch socket, push the barring gear into the

gear mesh and bar engine over counterclockwise.
NOTE: Rock the barring device back and forth until it
disengages.

NOTE: The intake valve rocker lever is always the long
lever on the valve rocker lever shaft.
NOTE: Early engine vibration dampers are marked with

BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The
engine brakes must be set at the appropriate mark on
these engines. Newer engine vibration dampers are
marked with only A, B, or C, and are adjusted with the
valves and injector on the same cylinder.
The valves, brakes, and the injectors on the same cylinder
are adjusted at the same index mark on the vibration
damper.
Signature, ISX and QSX15

Brake Adjustment Sequence
Bar Engine in Direction of Pulley Brake

Rotation Position
Start A 1
Advance to B 5
Advance to C 3
Advance to A 6
Advance to B 2
Advance to C 4
Rotate the compressor drive or barring device in the

direction of engine rotation, clockwise. Align the A mark
on the vibration damper with the pointer on the gear cover.

NOTE: Both sets of valves are closed when the rocker
levers and the brake lever are loose. If both sets of valves
are not closed, rotate the compressor drive gear one
complete revolution, and align the A mark on the front
damper with the pointer again.
CAUTION
To get maximum brake operating efficiency and to
prevent engine damage, the brake adjustment
instructions must be followed.
For older engines, locate the engine brake set marks on
the outside of the vibration damper.
The set marks are BRAKE SET 1-6, and BRAKE SET 2-5,
and BRAKE SET 3-4.
Rotate the compressor drive or barring device in the

direction of engine rotation, clockwise. Align the A mark
on the vibration damper with the pointer on the gear cover.

NOTE: Both sets of valves are closed when the rocker
levers and the brake lever are loose. If both sets of valves
are not closed, rotate the compressor drive gear one
complete revolution, and align the A mark on the front
damper with the pointer again.
Press the engine brake lever down to verify that the

camshaft follower is in contact with the camshaft.
Loosen the locknut on the brake lever adjusting screw,

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

mm in
7.00 NOM 0.276
Tighten the adjusting screw until drag on the feeler gauge

is felt. Proper drag means that there is no motion of the
brake lever camshaft follower against the cam lobe.
Hold the engine brake lever adjusting screw, and tighten

the locknut.
Remove the feeler gauge.
CAUTION
Engine damage can occur if running clearance is not
within specifications.
Check the running clearance:
1. Rotate the engine brake rocker lever to the detent
(neutral) position.
2. Check the clearance (1) between the engine brake
lever actuator piston and the crosshead guide pin.
Engine Brake Lever Running Clearance

mm in
0.635 MIN 0.025
2.790 MAX 0.110
If the running clearance does not fall in the given
specifications, loosen the rocker lever shaft and rotate the
rocker lever shaft, slightly, in the direction required to
bring the running clearance within specifications.
Recheck the brake running clearance.
NOTE: The rocker lever shafts must be adjusted so that
all three engine brake levers fall within the given running
clearance specification.
Repeat the process to adjust all engine brakes according

to the chart shown earlier in this procedure.
Install the rocker lever cover and gasket. Refer to

Procedure 014-013 (Aftertreatment Testing) in Section 14.
Engine Brake Solenoid Valve Signature, ISX, and QSX15 Eng [...]
Engine Brake Solenoid Valve (020-012)

Preparatory Steps
003-011.
Remove
Disconnect the engine brake wiring harness from the
solenoid.
Use a 3/4 inch socket to remove the solenoid from the
manifold.
Discard the three solenoid o-rings.
Inspect for Reuse

Check the resistance of each solenoid with the wiring
harness disconnected from the solenoid.
Measure the resistance from the terminal to the body of
the solenoid, as indicated in the illustration.
12-VDC
Cold Engine 5 to 20 ohms
Hot Engine 5 to 20 ohms
24-VDC
Cold Engine 32 to 40 ohms
Hot Engine 60 to 80 ohms
Replace the solenoid if not within specifications.
Inspect the engine brake wiring harness, if the solenoids
are within specifications.
Signature, ISX, and QSX15 Eng [...] Engine Brake Wiring Harness
Install
Lubricate the seal rings with clean engine oil.
Install the upper (1) and center (2) seal ring on the
solenoid.
Coat the inside of the manifold with oil and place the lower
seal ring (3) in the bottom of the manifold.
Install the solenoid into the manifold.
Tighten the solenoid.
Connect the engine brake wiring harness to the solenoid.
Finishing Steps
003-011.
Operate the engine and check for proper operation and
leaks.
Engine Brake Wiring Harness

(020-015)
Remove
Threaded Brake Pass-Through
NOTE: Early engines used a threaded brake pass-through
connector. A retaining nut was used to hold the pass-
through connector in place. Current production engines
utilize a clip to retain the pass-through connector.
Remove rocker lever cover. Refer to Procedure 003-011.
Disconnect the engine wiring harness from the brake
pass-through.
Remove the pass-through retaining nut.
Remove the brake pass-through connector from the
cylinder head.
Engine Brake Wiring Harness Signature, ISX, and QSX15 Eng [...]
Non-Threaded Brake Pass-Through

Disconnect the engine wiring harness from the brake
harness pass-through connector.
Remove the brake pass-through retaining clip.
Remove the pass-through connector from the head.
NOTE: The engine brake harness can be laid over the side
of the engine to service overhead components. It is not
necessary to remove the brake pass-through connector.
Disconnect the solenoid wires.
With your hands about 18 inches apart, grasp the engine
brake wiring harness support bracket and pull it up and
out of the cylinder head.
Inspect for Reuse

With the wiring harness isolated from the solenoids,
inspect the wiring harness for broken wires or connectors.
Check the engine brake wiring harness for shorts. Refer

to fault codes 388, 392, and 393 in the Fuel Systems
Troubleshooting and Repair manual for procedures on
checking harness resistance.
Signature, ISX, and QSX15 Eng [...] Engine Brake Control Valve
Install
Threaded Brake Pass-Through
Install the engine brake wiring harness support bracket
into the cylinder head.
Connect the solenoid wires.
Install and connect the brake pass-through connector to

the cylinder head.
Install and connect the brake pass-through retaining nut.
Install and connect the engine wiring harness to the brake
pass-through.
Non-Threaded Brake Pass-Through

Install and connect the brake pass-through connector to
the cylinder head.
Install and connect the brake pass-through retaining clip.
Install and connect the engine wiring harness.
Install and connect the rocker lever cover. Refer to
Procedure 003-011.
Engine Brake Control Valve (020-017)

Remove
003-011.
Engine Brake Control Valve Signature, ISX, and QSX15 Eng [...]
WARNING
The control valve is spring-loaded. To avoid personal
injury, apply thumb pressure to the control valve
cover, slowly remove cover until spring pressure
ceases, and then remove the valve.
Use snap ring pliers to remove the snap ring and control
valve from rocker lever assembly.
Inspect for Reuse

Inspect the brake lever for wear in the control valve
counterbore area.
Replace the brake lever if the counterbore wear extends
beyond the snap ring groove diameter.
Inspect the control valve spring for breakage and free

length.
Spring Free Length

mm in
44.45 NOM 1.75
Replace the control valve spring if the free length is less
than the specification.
Install
Move the control valve in the bore to insure free
movement.
Lubricate the control valve assembly.
Install the control valve into rocker lever assembly and
snap ring.
Signature, ISX, and QSX15 Eng [...] Engine Brake Piston
Engine Brake Piston (020-019)

Remove
003-011.
Rotate the engine to the appropriate valve set mark.
Loosen the locknut and back off exhaust valve lash

adjusting screw. Refer to Procedure 003-004.
Remove exhaust valve crosshead and crosshead guide
pin.
Remove the engine brake valve lash adjusting screw

locknut.
Turn the piston adjusting screw clockwise until piston
comes out of the Jake Brake lever, catch it with your
hand.
NOTE: If the actuator piston is seized or stuck in the lever,
replace the Jake Brake lever.
Engine Brake Piston Signature, ISX, and QSX15 Eng [...]
Inspect for Reuse

Inspect the actuator piston face and the lever piston bore
for wear. Replace the Jake Brake Lever, if excessive
wear is found on either the actuator piston or the lever
piston bore. Refer to Procedure 003-009 for rocker lever
inspection.
NOTE: Normal wear creates a uniform pattern around the
piston face. A piston exhibiting normal wear can be used
again, if proper running clearance can be obtained.
Install
Place the piston into the rocker arm.
Holding the piston in place, turn the adjusting screw
counterclockwise until the piston is seated. Install the
locknut.
Install the exhaust valve crosshead and crosshead guide

pin.
Adjust the appropriate exhaust valve and engine brake
lever. Refer to Procedure 003-004.

Cummins Service Publications Electronic Books on CD-ROM
Enclosed, weve included on CD-ROM, an electronic copy of this publication in Adobe Acrobat format (PDF) for your
personal use and reference. Before you begin to use the CD-ROM, please read the Cummins Service Publications
Electronic Books on CD-ROM Information printed section, beginning on the next page. This section includes
information about this CD-ROM including System Requirements, Local Administrative Rights requirements, How to Use,
Helpful Support Tips and other information.
Cummins Service Publications Electronic Books on CD-ROM Information
The enclosed CD-ROM provides you with the capability to view this publication electronically as well as perform searches.
This CD-ROM is copy protected and will not allow Printing, Changing of Content, Extracting Content or Commenting /
Annotating of the PDF file.
This CD-ROM is read only, and you will not be able to copy files from the CD-ROM and have them open or function in any
manner. The only method to view the electronic publication is from the original CD-ROM.
This CD-ROM is intended for use by the owner of the printed publication only. Copying or distribution of content from this
CD-ROM is expressly prohibited. This CD-ROM will not function from a network server CD-ROM drive. It will function
only in a CD-ROM drive directly connected to your computer.
For Microsoft Windows NT 4.0, Microsoft Windows 2000 or Microsoft Windows XP, this CD-ROM requires that
you have Local Administrative rights in order to use. See the System requirements section for additional details.
System Requirements:
Use of the Cummins Service Publications Electronic Books on CD-ROM requires Adobe Acrobat, Adobe Acrobat Reader,
or Adobe Reader software to be pre-installed on your computer. This product has been tested for compatibility with
Adobe Acrobat software versions 5.0, 6.0 and 7.0. It may function properly with versions later than Adobe Acrobat 7.0,
but testing has not been performed. Acrobat Reader is available as a free download from www.adobe.com.
The Cummins Service Publications Electronic Books on CD-ROM product requires the following system
components:
Microsoft Windows Auto-Play must be enabled on your computer (it is enabled by default when Windows is installed)
CD-ROM Drive
Color Monitor with at least 800x600 resolution graphics
Microsoft Windows XP Professional or Microsoft Windows 2000 Professional. This CD-ROM may be compatible with
Microsoft Windows 98 SE, Microsoft Windows NT 4.0, or Microsoft Windows XP Home Edition, but testing has not
been performed.
Recommended memory, processor speed and available hard-disk space is in accordance with respective Microsoft
Operating System Guidelines, as well as Adobe Acrobat system requirements listed later in these instructions.
Note: The Cummins Service Publications Electronic Books on CD-ROM product is not Macintosh compatible.
About required Local Administrative Rights:
The copy protection system used on this product requires direct access to CD-ROM drives in order to authenticate copy
protected discs.
In order to allow the software to enable direct access to CD-ROM drives rights under Microsoft Windows, if you are using
Microsoft Windows NT 4.0, Microsoft Windows 2000 or Microsoft Windows XP, your logon account/profile must have
Local Administrative Rights on the computer you will be using your Cummins Service Publications Electronic Book on CD-
ROM with. If this computer is set up in Restricted Mode, and your logon account/profile does not have Local
Administrative Rights, then, with approval of your I.T. department or the owner of your computer, you can choose from the
following options to allow the Cummins Service Publications Electronic Book on CD-ROM to function properly:
Have your computer account enabled to have Local Administrative rights and then you can run the Cummins Service
Publications Electronic Book on CD-ROM - OR -
Have a user with Local Administrative Rights logon to your computer and run the CD-ROM one time. By doing this,
the necessary files will be loaded to your computer and your computer will be enabled to have direct access to CD-
ROM drives. Then restart this computer. It is very important to restart the computer after you have done this. For all
future needs, you can run the Cummins Service Publications Electronic Book on CD-ROM under your own account,
without requiring your logon account/profile to have Local Administrative Rights. (Note: This needs to be done only
once for any Cummins Service Publications Electronic Book on CD-ROM and then does not need to be done again
for other Cummins Service Publications Electronic Book on CD-ROM titles you may own.)
(continued)
About the Copy Protection Software:
This product may upgrade the proprietary copy protection software files it uses that are placed on your computer
system to a new version, if an older version exists on your computer. If you have CD-ROM copy protected items from
other companies and they use older versions of the same HexaLock copy protection software that the Cummins
Service Publications Electronic Books on CD-ROM uses, it may render them incompatible for use on your computer.
Adobe Acrobat Reader 5.0 system requirements:

PC Compatible computer w/ Intel Pentium processor
One of the following Microsoft Windows Operating Systems:
Microsoft Windows 98 SE
Microsoft Windows Millennium Edition
Microsoft Windows NT 4.0 with Service Pack 5
Microsoft Windows 2000
Microsoft Windows XP
64MB of RAM
24MB of available hard-disk space
Additional 70MB of hard-disk space for Asian fonts (optional)
(Asian fonts are not required for Cummins Service Publications Electronic Books on CD-ROM product.)
Adobe Reader 6.0.1 system requirements:

Microsoft Windows 98 SE
Microsoft Windows Millennium Edition
Microsoft Windows NT 4.0 with Service Pack 6
Microsoft Windows 2000 with Service Pack 2
Microsoft Windows XP Professional or Home Edition
Microsoft Windows XP Tablet PC Edition
32MB of RAM (64MB recommended)
60MB of available hard-disk space
Microsoft Internet Explorer 5.0.1, 5.5, 6.0, or 6.1
Adobe Reader 7.0 system requirements:

Microsoft Windows 2000 with Service Pack 2
Microsoft Windows XP Professional or Home Edition
Microsoft Windows XP Tablet PC Edition
128MB of RAM
Up to 90MB of available hard-disk space
Microsoft Internet Explorer 5.5 or higher
How to Use the Cummins Service Publications Electronic Book on CD-ROM:

To use the CD-ROM, simply insert the CD-ROM into your computer and it should automatically run, open Adobe Acrobat
and open the Electronic Book. (This happens with Microsoft Windows Auto-Play functionality, and Adobe Acrobat pre-
loaded by you on your computer).
(continued)
Helpful Support Tips:
If Windows Auto-Play is not enabled, try re-enabling it, or navigate with Windows Explorer to your CD-ROM drive and
double click on the CD-ROM drive letter to open it. Then double-click on the program named clickhere. (Do not
attempt to directly open the PDF file by clicking on the PDF document.)
In rare occasions, after inserting the CD-ROM you may receive a notice from Adobe Acrobat that it could not open
the PDF because it is either not a supported file type or the file has been corrupted. This can occur in rare occasions
due to application timing issues. If this occurs there are several options to remedy the situation: 1) Simply click OK on
the notice, eject the CD-ROM and re-insert it to have it restart the program, or 2) Click OK on the notice and navigate
with Windows Explorer to your CD-ROM drive and double click on the CD-ROM drive letter to open it. Then double-
click on the program named clickhere. (Do not attempt to directly open the PDF file by clicking on the PDF
document) or 3) Click OK on the notice, eject the CD-ROM, restart your computer and after the system has restarted,
re-insert the CD-ROM and have it automatically run.
If the Cummins Service Publications Electronic Books on CD-ROM does not function, see the prior section on About
required Local Administrative Rights: in this documentation and verify you have Local Administrative Rights on your
computer in order to run the CD-ROM.
Special Instructions for Cummins PowerSweep PC Users:

(This only applies to Cummins Inc. & Distributor Employees):
Cummins PowerSweep PC users that DO NOT have Local Administrative rights to their PC will require a HexaLock patch
software installation. If you are a Cummins Inc. or Distributor Employee who wants to use these CD-ROMs, and you have
a PowerSweep PC please order the HexaLock software from the Cummins Software Shelf. The Software Shelf
personnel will contact you to arrange installation. Software will be installed remotely by Software Shelf personnel. Once
software is installed, first reboot your PC, then attempt to read your encrypted CD-ROM manual while Cummins Software
Shelf personnel are still on the telephone.
Electronic Book Technical Support:

Support for this product is available from Monday through Friday weekly, excluding Holidays, from 8 a.m. to 5 p.m.
You may call (502) 540-4981 for telephone support. For e-mail support, please e-mail ebooksupport@merrickind.com.
CD-ROM Media Replacement Options:

Up to 90 days from date of purchase:
Within the first 90 days from your date of purchase, if your copy of an Electronic Book on CD-ROM does not function, and
after a Cummins Electronic Book Technical Support Technician has confirmed the situation and authorized its
replacement by providing you an RMA#, you may send back the CD-ROM for a free replacement. To do so, you must
package the CD-ROM and ship/mail, with postage pre-paid by you, to the below address. You must also include a
photocopy of the original invoice for proof of purchase of the publication clearly indicating the bulletin # and the purchase
date. The RMA# must be on the address information of the package. If the proof of purchase copy of the invoice is not
enclosed, your request will not be able to be processed and will not be returned. Delivery of the replacement will be
shipped to you at no charge. Allow 3 to 4 weeks for your receipt of replacement copy. Note: Return only the non-
functional CD-ROM, do not return the entire printed publication. The replacement CD-ROM maintains the original
purchase/invoice date for the purposes of this replacement policy. This policy is subject to change at any time, without
notice. For a copy of the most current replacement options policy, please e-mail ebooksupport@merrickind.com with your
request.
Media Replacement Ship to Address:

Attn: Cummins Service Publications Electronic Books Technical Support
RMA#: XXXXXX (where XXXXXX is the RMA#)
808 E. Liberty Street
Louisville, KY 40204 U.S.A.
Cummins Service Publications Electronic Books on CD-ROM are Copyright Cummins Inc.
Adobe Acrobat Reader is a registered trademark of Adobe Systems Incorporated.
Microsoft, Windows, and Windows NT are registered trademarks of Microsoft Corporation.
Intel and Pentium are trademarks of Intel Corporation.
HexaLock is Copyright HexaLock, Ltd.
All other names and products used herein are trademarks for their respective owner.
Section L - Service Literature Page L-a
Section L - Service Literature

Section Contents
Page
Additional Service Literature ............................................................................................................................L-1
General Information..........................................................................................................................................L-1
Cummins Customized Parts Catalog ................................................................................................................L-3
General Information..........................................................................................................................................L-3
Ordering the Customized Parts Catalog.............................................................................................................L-3
Ordering by Telephone...................................................................................................................................L-3
Ordering On-Line...........................................................................................................................................L-3
Service Literature Ordering Location ...............................................................................................................L-2
Contact Information...........................................................................................................................................L-2
Page L-b Section L - Service Literature

Signature, ISX, and QSX15 Eng [...] Additional Service Literature
Section L - Service Literature Page L-1
Additional Service Literature

General Information
The following publications can be purchased:
Bulletin Number Title of Publication
3666259 Troubleshooting and Repair Manual, Electronic Control System, Signature, ISX and QSX15
Engines
3666393 Troubleshooting and Repair Manual, Generator-Drive Control System, QSX15, QSK45, and QSK60
Engines
3666394 Troubleshooting and Repair Manual, PowerCommand Control, QSX15, QSK45, and QSK60
Engines
4021334 Troubleshooting and Repair Manual, CM870 Electronic Control System, Signature, and ISX
Engines
4021560 ISM CM876 / ISX CM871 Electronic Control System, Troubleshooting and Repair Manual
3666268 Signature and ISX Wiring Diagram
3666414 QSX15 Industrial Wiring Diagram
3666349 QSX15 Generator Drive Wiring Diagram
3666466 QSX15 PowerCommand Wiring Diagram
4021341 Signature and ISX CM870 Control Module Wiring Diagram
4021575 ISX CM871 Wiring Diagram
3666311 Operation and Maintenance Manual - Signature and ISX Engines
4021345 Owner's Manual, Signature, and ISX Engines
3666251 ISX CM871 Operation and Maintenance Manual
3379000 Air for Your Engines
3379001 Fuels for Cummins Engines
3387266 Cold Weather Operation
3666132 Coolant Requirements and Maintenance Bulletin
3666209 Cooling System Maintenance Extended Interval
3810340 Cummins Engine Oil Recommendations
Service Literature Ordering Location Signature, ISX, and QSX15 Eng [...]
Page L-2 Section L - Service Literature
Service Literature Ordering Location

Contact Information
Region Ordering Location

United States and Canada Cummins Distributors
or
Credit Cards at 1-800-646-5609
or
Order online at www.powerstore.cummins.com
All Other Countries Cummins Distributors or Dealers
Signature, ISX, and QSX15 Eng [...] Cummins Customized Parts Catalog
Section L - Service Literature Page L-3
Cummins Customized Parts Catalog

General Information
Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic
versions of parts catalogs that support general high volume parts content; Cummins Customized catalogs contains
only the new factory parts that were used to build your engine.
The catalog cover, as well as the content, is customized with you in mind. You can use it in your shop, at your worksite,
or as a coffee table book in your RV or boat. The cover contains your name, company name, address, and telephone
number. Your name and engine model identification even appears on the catalog spine. Everybody will know that
Cummins created a catalog specifically for you.
This new catalog was designed to provide you with the exact information you need to order parts for your engine. This
will be valuable for customers that do not have easy access to the Cummins Electronic Parts Catalog or the Cummins
Parts Microfilm System.
Additional Features of the Customized Catalog include:
Engine Configuration Data
Table of Contents
Separate Option and Parts Indexes
Service Kits (when applicable)
ReCon Part Numbers (when applicable)
Ordering the Customized Parts Catalog
Ordering by Telephone
North American customers can contact their Cummins Distributor or call Gannett Direct Marketing Services at
1-800-646-5609 and order by credit card. Outside North America order on-line or make an International call to Gannett
at (++)502-454-6660.
Ordering On-Line
The Customized Parts Catalog can be ordered On-Line from the Cummins Powerstore by credit card.
Contact GDMS or the CUMMINS POWERSTORE for the current price; Freight may be an additional expense.
Information we need to take your Customized Parts Catalog Order. This information drives the cover content of the
CPC.
Customer Name
Street Address
Company Name (optional)
Telephone no.
Credit Card No.
Cummins Engine Serial Number (located on the engine data plate)
Please identify the required media: Printed Catalog, CD-ROM, or PDF File
Unfortunately not all Cummins Engines can be supported by this parts catalog. Engines older than 1984 or newer
than 3 months may not have the necessary parts information to compile a catalog. We will contact you if this occurs
and explain why we are unable to fill your order.
Customized Parts Catalogs are produced specifically for a single customer. This means they are not returnable for a
refund. If we make an error and your catalog is not useable, we will correct that error by sending you a new catalog.
Cummins Customized Parts Catalog Signature, ISX, and QSX15 Eng [...]
Page L-4 Section L - Service Literature
Notes
Section V - Specifications Page V-a
Section V - Specifications
Section Contents
Page
Air Intake System ............................................................................................................................................V-77
Specifications.................................................................................................................................................V-77
Air Intake System - Group 10 - Specifications ...............................................................................................V-45
Charge-Air Cooler.................................................................................................................................................... V-45
Turbocharger............................................................................................................................................................V-45
Turbocharger Wastegate Actuator...........................................................................................................................V-45
Turbocharger Wastegate Valve Body...................................................................................................................... V-46
Turbocharger, Variable Geometry Actuator............................................................................................................. V-46
Air Intake System - Group 10 - Torque Values ..............................................................................................V-47
Air Intake Connection...............................................................................................................................................V-50
Air Leaks, Air Intake and Exhaust Systems............................................................................................................. V-47
Turbocharger............................................................................................................................................................V-47
Turbocharger Control Shutoff Valve Filter Head......................................................................................................V-51
Turbocharger Coolant Hoses...................................................................................................................................V-49
Turbocharger Wastegate Actuator...........................................................................................................................V-50
Turbocharger Wastegate Controller.........................................................................................................................V-50
Turbocharger, Variable Geometry Actuator............................................................................................................. V-51
Turbocharger, Variable Geometry Actuator Air Supply Line....................................................................................V-51
Turbocharger, Variable Geometry Control Valve Air Supply Line............................................................................V-51
Variable Geometry Turbocharger Actuator, Electric.................................................................................................V-52
Variable Geometry Turbocharger Cross Shaft.........................................................................................................V-52
Capscrew Markings and Torque Values .........................................................................................................V-85
Capscrew Markings and Torque Values - Metric..............................................................................................V-85
Capscrew Markings and Torque Values - U.S. Customary...............................................................................V-86
General Information........................................................................................................................................V-85
Compressed Air System .................................................................................................................................V-80
Cummins 18.7 CFM Model...........................................................................................................................V-80
Compressed Air System - Group 12 - Torque Values ....................................................................................V-62
Air Compressor........................................................................................................................................................ V-62
Air Compressor Coolant Lines................................................................................................................................. V-62
Cooling System ...............................................................................................................................................V-75
Automotive Applications...............................................................................................................................V-75
Industrial and Generator Drive..................................................................................................................... V-76
Cooling System - Group 08 - Specifications ..................................................................................................V-36
Coolant Thermostat..................................................................................................................................................V-36
Fan Hub, Belt Driven................................................................................................................................................V-36
Water Pump............................................................................................................................................................. V-36
Cooling System - Group 08 - Torque Values .................................................................................................V-38
Belt Tensioner, Automatic (Water Pump).................................................................................................................V-41
Coolant Filter Valve..................................................................................................................................................V-38
Coolant Thermostat..................................................................................................................................................V-38
Coolant Thermostat Housing....................................................................................................................................V-38
Cooling System........................................................................................................................................................V-39
Fan Drive Idler Pulley Assembly.............................................................................................................................. V-39
Fan Hub, Belt Driven................................................................................................................................................V-40
Fan Pulley................................................................................................................................................................ V-42
Fan Support..............................................................................................................................................................V-42
Water Inlet Connection.............................................................................................................................................V-42
Water Pump............................................................................................................................................................. V-40
Water Pump Cartridge..............................................................................................................................................V-42
Cylinder Block - Group 01 - Specifications ......................................................................................................V-1
Bearings, Connecting Rod.........................................................................................................................................V-1
Bearings, Main...........................................................................................................................................................V-1
Connecting Rod..........................................................................................................................................................V-1
Page V-b Section V - Specifications
Crankshaft..................................................................................................................................................................V-2
Cylinder Liner.............................................................................................................................................................V-3
Engine Base Timing...................................................................................................................................................V-5
Piston.........................................................................................................................................................................V-4
Piston Rings...............................................................................................................................................................V-4
Vibration Damper, Viscous.........................................................................................................................................V-4
Cylinder Block - Group 01 - Torque Values .....................................................................................................V-6
Bearings, Connecting Rod.........................................................................................................................................V-6
Bearings, Main...........................................................................................................................................................V-6
Block Stiffener Plate.................................................................................................................................................V-11
Bracket, Accessory.....................................................................................................................................................V-9
Bracket, Retaining Brace............................................................................................................................................V-8
Connecting Rod..........................................................................................................................................................V-6
Crankshaft Adapter....................................................................................................................................................V-6
Crankshaft Pulley.......................................................................................................................................................V-7
Crankshaft Seal, Front...............................................................................................................................................V-7
Crankshaft Seal, Rear................................................................................................................................................V-7
Engine Base Timing.................................................................................................................................................V-10
Gear Cover, Lower.....................................................................................................................................................V-8
Gear Cover, Upper.....................................................................................................................................................V-8
Gear Housing, Front...................................................................................................................................................V-8
Piston Cooling Nozzle................................................................................................................................................V-8
Vibration Damper, Viscous.........................................................................................................................................V-8
Cylinder Head - Group 02 - Specifications .....................................................................................................V-12
Cylinder Head...........................................................................................................................................................V-12
Overhead Camshaft End Clearance, Injector...........................................................................................................V-14
Overhead Camshaft End Clearance, Valve............................................................................................................. V-14
Overhead Camshaft, Injector................................................................................................................................... V-14
Overhead Camshaft, Valve......................................................................................................................................V-13
Cylinder Head - Group 02 - Torque Values ....................................................................................................V-15
Cylinder Head...........................................................................................................................................................V-15
Overhead Camshaft, Injector................................................................................................................................... V-15
Overhead Camshaft, Valve......................................................................................................................................V-15
Valve Guide Seal, Cylinder Head.............................................................................................................................V-15
Drive Belt Tension ..........................................................................................................................................V-82
Tension Chart.................................................................................................................................................V-82
Drive Units - Group 09 - Torque Values .........................................................................................................V-43
Alternator/Refrigerant Compressor Mounting Bracket............................................................................................. V-44
Belt Tensioner, Refrigerant Compressor, Automatic................................................................................................V-43
Idler Pulley, Refrigerant Compressor.......................................................................................................................V-43
Refrigerant Compressor...........................................................................................................................................V-43
Refrigerant Compressor Mounting Bracket..............................................................................................................V-43
Electrical Equipment - Group 13 - Torque Values .........................................................................................V-63
Alternator..................................................................................................................................................................V-63
Alternator Idler Pulley...............................................................................................................................................V-64
Alternator Pulley.......................................................................................................................................................V-63
Alternator Spacer..................................................................................................................................................... V-64
Belt Tensioner, Automatic (Alternator).....................................................................................................................V-64
Bracket, Idler Pulley and Alternator Belt Tensioner..................................................................................................V-64
Starting Motor...........................................................................................................................................................V-63
Electrical System ............................................................................................................................................V-79
Engine Testing ................................................................................................................................................V-81
Engine Testing - Group 14 - Specifications ...................................................................................................V-65
Engine Testing (Chassis Dynamometer)..................................................................................................................V-65
Engine Testing (Engine Dynamometer)...................................................................................................................V-65
Exhaust System ..............................................................................................................................................V-78
Automotive Applications...............................................................................................................................V-78
Industrial and Generator Drive..................................................................................................................... V-78
Automotive With CM871...............................................................................................................................V-78
Exhaust System - Group 11 - Specifications ................................................................................................. V-53
Section V - Specifications Page V-c
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes............................................................V-53

Exhaust Restriction..................................................................................................................................................V-53
Exhaust System - Group 11 - Torque Values .................................................................................................V-54
Aftertreatment Adapter Pipe.....................................................................................................................................V-58
Aftertreatment Diesel Oxidation Catalyst.................................................................................................................V-59
Aftertreatment Diesel Particulate Filter.....................................................................................................................V-58
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting Bracket..........................................V-58
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes............................................................V-59
Aftertreatment Fuel Injector......................................................................................................................................V-58
Aftertreatment Fuel Injector Flow.............................................................................................................................V-61
Aftertreatment Fuel Shutoff Manifold........................................................................................................................V-60
Aftertreatment Injector Lines....................................................................................................................................V-59
Aftertreatment Inlet and Outlet.................................................................................................................................V-59
EGR Connection Tubes...........................................................................................................................................V-55
EGR Cooler..............................................................................................................................................................V-54
EGR Cooler Connection...........................................................................................................................................V-55
EGR Cooler Coolant Lines.......................................................................................................................................V-57
EGR Differential Pressure Sensor Adapter..............................................................................................................V-56
EGR Differential Pressure Sensor Tubes.................................................................................................................V-56
EGR Mixer................................................................................................................................................................V-55
EGR Valve................................................................................................................................................................V-55
EGR Valve Coolant Lines.........................................................................................................................................V-57
EGR Valve Mounting Bracket...................................................................................................................................V-58
Exhaust Gas Pressure Sensor Adapter...................................................................................................................V-58
Exhaust Gas Pressure Sensor Tube........................................................................................................................V-56
Exhaust Manifold, Dry..............................................................................................................................................V-54
Heat Shield...............................................................................................................................................................V-57
Fraction, Decimal, Millimeter Conversions ....................................................................................................V-83
Conversion Chart............................................................................................................................................V-83
Fuel System ....................................................................................................................................................V-73
Fuel System - Group 05 - Torque Values .......................................................................................................V-20
Fuel Inlet Pre-Filter...................................................................................................................................................V-26
Fuel Lift Pump..........................................................................................................................................................V-21
Fuel Pump................................................................................................................................................................V-20
Fuel Pump Pulsation Damper..................................................................................................................................V-20
Fuel Shutoff Valve....................................................................................................................................................V-20
Integrated Fuel System Module (IFSM)...................................................................................................................V-21
General Engine ................................................................................................................................................V-72
Automotive with CM870...............................................................................................................................V-72
Automotive With CM871...............................................................................................................................V-72
Injectors and Fuel Lines - Group 06 - Specifications ....................................................................................V-28
Fuel Filter (Spin-On Type)........................................................................................................................................V-28
Fuel Inlet Restriction.................................................................................................................................................V-28
Injectors and Fuel Lines - Group 06 - Torque Values ....................................................................................V-29
ECM Cooling Plate, Fuel Cooled..............................................................................................................................V-29
Fuel Drain Line Restriction.......................................................................................................................................V-29
Injector......................................................................................................................................................................V-29
Lubricating Oil System ...................................................................................................................................V-74
Lubricating Oil System - Group 07 - Specifications ......................................................................................V-30
Lubricating Oil Cooler...............................................................................................................................................V-30
Lubricating Oil Filter Bypass Valve...........................................................................................................................V-30
Lubricating Oil High Pressure Relief Valve..............................................................................................................V-30
Lubricating Oil Pump................................................................................................................................................V-30
Lubricating Oil System - Group 07 - Torque Values ......................................................................................V-33
Lubricating Oil Cooler...............................................................................................................................................V-33
Lubricating Oil Cooler Element.................................................................................................................................V-33
Lubricating Oil Dipstick Tube....................................................................................................................................V-33
Lubricating Oil Fill Tube............................................................................................................................................V-35
Lubricating Oil Filter Bypass Valve...........................................................................................................................V-33
Lubricating Oil Filter Head Adapter..........................................................................................................................V-34
Page V-d Section V - Specifications
Lubricating Oil Pan...................................................................................................................................................V-34

Lubricating Oil Pump................................................................................................................................................V-34
Lubricating Oil Suction Tube (Block-Mounted).........................................................................................................V-34
Lubricating Oil System.............................................................................................................................................V-34
Lubricating Oil Thermostat.......................................................................................................................................V-35
Mounting Adaptations - Group 16 - Specifications ........................................................................................V-66
Flywheel...................................................................................................................................................................V-66
Flywheel Housing, REPTO.......................................................................................................................................V-66
Mounting Adaptations - Group 16 - Torque Values .......................................................................................V-67
Engine Lifting Brackets.............................................................................................................................................V-67
Flywheel...................................................................................................................................................................V-67
Flywheel Housing.....................................................................................................................................................V-67
Flywheel Housing, REPTO.......................................................................................................................................V-67
Newton-Meter to Foot-Pound Conversions ....................................................................................................V-87
Pipe Plug Torque Values ................................................................................................................................V-88
Torque Table..................................................................................................................................................V-88
Rocker Levers - Group 03 - Specifications ....................................................................................................V-16
Overhead Set...........................................................................................................................................................V-16
Rocker Lever Assembly...........................................................................................................................................V-16
Rocker Levers - Group 03 - Torque Values ...................................................................................................V-18
Crankcase Breather (External).................................................................................................................................V-18
Crankcase Breather (Internal)..................................................................................................................................V-18
Overhead Set...........................................................................................................................................................V-18
Rocker Lever Assembly...........................................................................................................................................V-19
Rocker Lever Cover.................................................................................................................................................V-19
Tap-Drill Chart - U.S. Customary and Metric .................................................................................................V-89
Vehicle Braking - Group 20 - Specifications ..................................................................................................V-70
Engine Brake Assembly...........................................................................................................................................V-70
Engine Brake Control Valve.....................................................................................................................................V-70
Vehicle Braking - Group 20 - Torque Values .................................................................................................V-71
Engine Brake Assembly...........................................................................................................................................V-71
Engine Brake Solenoid Valve...................................................................................................................................V-71
Engine Brake Wiring Harness..................................................................................................................................V-71
Weights and Measures - Conversion Factors ................................................................................................V-84
Signature, ISX, and QSX15 Eng [...] Cylinder Block - Group 01 - Specifications
Section V - Specifications Page V-1
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Cylinder Block - Group 01 - Specifications

Bearings, Connecting Rod (001-005)
Standard Connecting Rod Bearing 2.366 mm MIN 0.093 in
Thickness
2.378 mm MAX 0.094 in
Bearings, Main (001-006)

Standard Main Bearing Shell Thickness 3.196 mm MIN 0.126 in
3.214 mm MAX 0.127 in
Crankshaft End Clearance - New or 0.10 mm MIN 0.004 in

Reground
0.50 mm MAX 0.020 in
Connecting Rod (001-014)

Connecting Rod Crankshaft Bore Inside 98.801 mm MIN 3.890 in
Diameter
98.839 mm MAX 3.891 in
Connecting Rod Piston Pin Bushing Inside 63.55 mm MIN 2.502 in

Diameter
63.57 mm MAX 2.503 in
Connecting Rod Length 261.45 mm MIN 10.293 in

261.55 mm MAX 10.297 in
Maximum Connecting Rod Bend (Bushing 0.021 mm MAX 0.0008 in

Installed)
Cylinder Block - Group 01 Signature, ISX, and QSX15 Eng [...]
Page V-2 Section V - Specifications
Ref.No./
Steps
.
Maximum Connecting Rod Twist (Bushing 0.05 mm MAX 0.002 in

Installed)
Crankshaft (001-016)
Crankshaft Connecting Rod Journal Outside 93.98 mm MIN 3.700 in
Diameter
94.02 mm MAX 3.702 in
Crankshaft Main Bearing Journal Outside 126.98 mm MIN 4.999 in

Diameter
127.02 mm MAX 5.001 in
Crankshaft Thrust Face Width 54.95 mm MIN 2.163 in

55.05 mm MAX 2.167 in
Flange Diameter Location (1) 164.964 MIN 6.495

165.035 MAX 6.497
165.525 MAX 6.517

139.63 MAX 5.497
140.04 MAX 5.513
Crankshaft Pilot Outside Diameter 49.985 mm MIN 1.968 in

50.015 mm MAX 1.969 in
Signature, ISX, and QSX15 Eng [...] Cylinder Block - Group 01
Ref.No./
Steps
.
Total Indicator Runout 0.200 mm MAX 0.008 in
Adjacent Journal Runout 0.075 mm MAX 0.003 in
Rear Oil Seal Flange Total Indicator Runout 0.03 mm MAX 0.0012 in
Front Oil Seal Crankshaft Adapter Diameter 0.05 mm MAX 0.002 in

Runout
Cylinder Liner (001-028)

Cylinder Liner Pitting Depth 1.60 mm MAX 0.060 in
Cylinder Liner Inside Diameter 137.14 mm MAX 5.40 in
Cylinder Top Press Fit Outside Diameter 160.98 mm MAX 6.34 in

Ref.No./
Steps
.
Cylinder Liner Recession (Groove-Top 0.36 mm MIN 0.014 in

Cylinder Liners)
0.51 mm MAX 0.019 in
Cylinder Liner Protrusion (Flat-Top Cylinder 0.18 mm MIN 0.007 in
Liners)
0.33 mm MAX 0.014 in
Piston (001-043)
Articulated Piston Pin Bore Inside Diameter 63.56 mm MIN 2.502 in
(Crown)
63.58 mm MAX 2.503 in
Articulated Piston Pin Bore Inside Diameter 63.513 mm MIN 2.5005 in
(Skirt)
63.525 mm MAX 2.5010 in
Piston Pin Outside Diameter 63.4670 MIN 2.4987 in

mm
63.4999 MAX 2.5000 in
mm
Articulated Piston Pin Length 109.5 mm MIN 4.311 in
110.0 mm MAX 4.331 in
Single-Piece Piston Pin Length 84.6 mm MIN 3.331 in
85.1 mm MAX 3.350 in
Piston Rings (001-047)
Articulated Piston Ring Gap
Top 0.33 MIN 0.013
0.53 MAX 0.021
Second 1.87 MIN 0.074
2.13 MAX 0.084
Oil 0.21 MIN 0.008
0.51 MAX 0.020
Single-Piece Piston Ring Gap
Top 0.33 MIN 0.013
0.53 MAX 0.021
Second 0.97 MIN 0.038
1.23 MAX 0.048
Oil 0.21 MIN 0.008
0.51 MAX 0.020
Vibration Damper, Viscous (001-052)
Vibration Damper Eccentricity 0.28 mm MAX 0.011 in
Vibration Damper Wobble Measurement 0.28 mm MAX 0.011 in

Ref.No./
Steps
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Engine Base Timing (001-088)

Lower Idler Shaft Outside Diameter 88.88 mm MIN 3.4992 in
88.89 mm MAX 3.4997 in
Adjustable Idler Shaft Outside Diameter 88.88 mm MIN 3.4992 in
88.89 mm MAX 3.4997 in
Lower Idler Gear Bore Inside Diameter 88.962 mm MIN 3.5024 in

88.988 mm MAX 3.5035 in
Adjustable Idler Gear Bore Inside Diameter 88.962 mm MIN 3.5024 in
88.988 mm MAX 3.5035 in
Shim Tolerance 0.225 mm MIN 0.009 in

0.275 mm MAX 0.011 in
Cylinder Block - Group 01 - Torque Values Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
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Cylinder Block - Group 01 - Torque Values

Bearings, Connecting Rod (001-005)
Used Connecting Rod Capscrews Tighten 1 70 6 [ 52 4 ft-
Capscrews In Numerical Sequence Nm lb ]
New Connecting Rod Capscrews Tighten 2 Rotate capscrews in numerical
Capscrews In Numerical Sequence sequence 60 5 degrees
1 40 6 [ 29 4 ft-
Nm lb ]
2 Loosen capscrews in numerical
sequence
3 70 6 [ 52 4 ft-
Nm lb ]
4 Rotate capscrews in numerical
sequence 60 5 degrees
Bearings, Main (001-006)
Old Blocks Main Bearing Cap Capscrews 1 149 Nm [ 110 ft-lb ]
2 Rotate 180 degrees.
Block Main Bearing Capscrews 1 149 Nm [ 110 ft-lb ]

2 Rotate 180 degrees.
Connecting Rod (001-014)

Used Connecting Rod Capscrews Tighten 1 70 6 [ 52 4 ft-
Capscrews In Numerical Sequence Nm lb ]
New Connecting Rod Capscrews Tighten 2 Rotate capscrews in numerical
Capscrews In Numerical Sequence sequence 60 5 degrees
1 40 6 [ 29 4 ft-
Nm lb ]
2 Loosen capscrews in numerical
sequence
3 70 6 [ 52 4 ft-
Nm lb ]
4 Rotate capscrews in numerical
sequence 60 5 degrees
Crankshaft Adapter (001-017)
13.6 Nm [ 120 in-lb ]
13.6 Nm [ 120 in-lb ]

Ref.No./
Steps
.
Crankshaft Pulley (001-022)

Crankshaft Pulley Mounting Capscrews - 175 Nm [ 130 ft-lb ]
Automotive
Crankshaft Pulley Mounting Capscrews - 175 Nm [ 130 ft-lb ]

Industrial And Power Generation
Crankshaft Pulley Mounting Capscrews 175 Nm [ 130 ft-lb ]

With Crank Driven Fan
Crankshaft Seal, Front (001-023)

Crankshaft Seal Replacer Plate Capscrews 20 Nm [ 177 in-lb ]
Front Crankshaft Seal Capscrews 8 Nm [ 71 in-lb ]
Lower Gear Cover Mounting Capscrews 28 Nm [ 248 in-lb ]
Crankshaft Seal, Rear (001-024)

Rear Crankshaft Seal Replacer Plate 16 Nm [ 142 in-lb ]
Capscrews
Ref.No./
Steps
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Gear Housing, Front (001-033)

Front Gear Housing Capscrews All 1 20 Nm [ 15 ft-lb ]
Capscrews Except (1) 2 72 Nm [ 53 ft-lb ]
Front Gear Housing Capscrews Capscrew 1 20 Nm [ 15 ft-lb ]
(1) 2 56 Nm [ 41 ft-lb ]
Piston Cooling Nozzle (001-046)

Piston Cooling Nozzle Capscrews 65 Nm [ 48 ft-lb ]
Vibration Damper, Viscous (001-052)

Vibration Damper Mounting Capscrew 175 Nm [ 130 ft-lb ]
Gear Cover, Upper (001-079)

Upper Gear Cover Capscrews - Automotive 28 Nm [ 21 ft-lb ]
Upper Gear Cover Capscrews - Industrial 28 Nm [ 21 ft-lb ]

And Power Generation
Gear Cover, Lower (001-080)

Lower Gear Cover Capscrews 28 Nm [ 248 in-lb ]
Bracket, Retaining Brace (001-081)

Retaining Brace Bracket To Gear Housing 45 Nm [ 33 ft-lb ]
Capscrews
Ref.No./
Steps
.
Retaining Brace Bracket To Cylinder Head 100 Nm [ 74 ft-lb ]

Capscrews
Mounting Spacer Capscrews 105 Nm [ 75 ft-lb ]
Engine Lifting Bracket Capscrews 80 Nm [ 60 ft-lb ]
Bracket, Accessory (001-082)

Accessory Bracket To Gear Housing 45 Nm [ 33 ft-lb ]
Mounting Capscrews - Automotive
Accessory Bracket To Cylinder Head 45 Nm [ 33 ft-lb ]

Mounting Capscrews - Automotive
Camshaft Position Sensor Capscrew - 25 Nm [ 221 in-lb ]

Automotive
Accessory Bracket Capscrews - Industrial 28 Nm [ 248 in-lb ]

And Power Generation
Ref.No./
Steps
.
Accessory Bracket Mounting Spacer 105 Nm [ 77 ft-lb ]

Capscrews - Industrial And Power
Generation
Camshaft Position Sensor Capscrew - 25 Nm [ 221 in-lb ]

Industrial And Power Generation
Engine Base Timing (001-088)

Lower Idler Scissor Gear Loading Screws 28 Nm [ 248 in-lb ]
Injector Camshaft Rear Cover Plate 40 Nm [ 30 ft-lb ]
Injector Camshaft Rear Cover Plate 40 Nm [ 30 ft-lb ]
Injector Camshaft Scissor Gear Loading 28 Nm [ 248 in-lb ]

Screws
Valve Camshaft Scissor Gear Retaining 148 Nm [ 109 ft-lb ]

Capscrew
Ref.No./
Steps
.
Valve Camshaft Non-Scissor Gear 148 Nm [ 109 ft-lb ]

Retaining Capscrew
Block Stiffener Plate (001-089)

Block Stiffener Plate Capscrews 137 Nm [ 102 ft-lb ]
Cylinder Head - Group 02 - Specifications Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Cylinder Head - Group 02 - Specifications

1.21 MAX 0.048
0.77 MAX 0.030
Valve to Valve Seat Vacuum 508 mm MIN 20 in Hg

Hg
685 mm MAX 25 in Hg
Hg
A to A 0.15 MAX 0.006

B to B 0.15 MAX 0.006
C to C 0.15 MAX 0.006
Valve Spring Load at 61.75 mm [2.431 in] 1511 N MIN 339.5 lbf
1604 N MAX 360.5 lbf
Valve Stem Outside Diameter 9.593 mm MIN 0.378 in

9.627 mm MAX 0.379 in
Used Valve Guide Inside Diameter (Installed) 9.663 mm MIN 0.380 in

9.713 mm MAX 0.382 in
Valve Guide Height (Installed) 44.77 mm MIN 1.763 in

45.77 mm MAX 1.802 in
Signature, ISX, and QSX15 Eng [...] Cylinder Head - Group 02
Ref.No./
Steps
.

1.21 MAX 0.048
0.77 MAX 0.030
Valve Guide Bore Inside Diameter 16.48 mm MIN 0.649 in

16.50 mm MAX 0.650 in

9.48 MAX 0.373
10.48 MAX 0.413

49.54 MAX 1.950
47.54 MAX 1.872
Valve Guide Height (Installed) 44.77 mm MIN 1.763 in

45.77 mm MAX 1.802 in
New Valve Guide Inside Diameter (Installed) 9.66 mm MIN 0.380 in

9.71 mm MAX 0.382 in

Valve Camshaft Bearing Journal Outside 64.987 mm MIN 2.5585 in
Diameter
65.013 mm MAX 2.5596 in
Cylinder Head - Group 02 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.

Injector Camshaft Bearing Journal Outside 84.987 mm MIN 3.3459 in
Diameter
85.013 mm MAX 3.3469 in
Overhead Camshaft End Clearance, Valve (002-028)

Valve Camshaft End Clearance 0.70 mm MAX 0.0276 in
Overhead Camshaft End Clearance, Injector (002-029)

Injector Camshaft End Clearance 0.70 mm MAX 0.0276 in
Signature, ISX, and QSX15 Eng [...] Cylinder Head - Group 02 - Torque Values
Ref.No./
Steps
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Cylinder Head - Group 02 - Torque Values

54 Nm [ 40 ft-lb ]
54 Nm [ 40 ft-lb ]
Valve Guide Seal, Cylinder Head (002-016)

54 Nm [ 40 ft-lb ]
54 Nm [ 40 ft-lb ]

Valve Camshaft Retainer Plate Capscrews 40 Nm [ 30 ft-lb ]

Injector Camshaft Retainer Plate 40 Nm [ 30 ft-lb ]
Capscrews
Injector Camshaft Cover Plate 40 Nm [ 30 ft-lb ]

Rocker Levers - Group 03 - Specifications Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
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Rocker Levers - Group 03 - Specifications

Brake Running Clearance 0.635 mm MIN 0.025 in
2.79 mm MAX 0.110 in
Valve Lash Specification

Intake 0.36 NOM 0.014
Exhaust 0.69 NOM 0.027
Engine Brake Rocker Lever Running 0.635 mm MIN 0.025 in

Clearance
2.790 mm MAX 0.110 in

Valve and Brake Rocker Lever Shaft Outside 34.950 mm MIN 1.3760 in
Diameter
35.000 mm MAX 1.3780 in
Injector Rocker Lever Shaft Outside 44.950 mm MIN 1.7697 in

Diameter
45.000 mm MAX 1.7717 in
Valve and Brake Rocker Lever Bushing Bore 35.037 mm MIN 1.3794 in
Inside Diameter
35.138 mm MAX 1.3834 in
Signature, ISX, and QSX15 Eng [...] Rocker Levers - Group 03
Ref.No./
Steps
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Injector Rocker Lever Bushing Bore Inside 45.037 mm MIN 1.7731 in

Diameter
45.138 mm MAX 1.7771 in
Intake and Exhaust Valve Adjusting Screw 46 mm MIN 1.81 in

Length
Rocker Lever Spacer Width 11.5 mm MIN 0.453 in

Rocker Levers - Group 03 - Torque Values Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Rocker Levers - Group 03 - Torque Values

Crankcase Breather (External) (003-001)
Crankcase Vent Hose 28 Nm [ 21 ft-lb ]
M10 47 Nm [ 35 ft-lb ]
M8 20 Nm [ 15 ft-lb ]
Crankcase Breather (Internal) (003-002)

Crankcase Breather 45 Nm [ 33 ft-lb ]
Seal Carrier 20 Nm [ 177 in-lb ]

20 Nm [ 15 ft-lb ]

Injector Lever Adjusting Screw 8 Nm [ 71 in-lb ]
Injector Lever Adjusting Screw Locknut 75 Nm [ 55 ft-lb ]
Valve Adjusting Screw 0.6 Nm [ 5 in-lb ]

Signature, ISX, and QSX15 Eng [...] Rocker Levers - Group 03
Ref.No./
Steps
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Valve Lever Adjusting Screw Locknut 45 Nm [ 33 ft-lb ]
Engine Brake Lever Adjusting Screw 20 Nm [ 177 in-lb ]

Locknut

Valve Rocker Lever Front Mounting 30 Nm [ 22 ft-lb ]
Capscrew 1 30 Nm [ 22 ft-lb ]
2 Rotate 60 degrees
Valve Rocker Lever Front Mounting 30 Nm [ 22 ft-lb ]

Capscrew 1 30 Nm [ 22 ft-lb ]
2 Rotate 60 degrees
68 Nm [ 50 ft-lb ]
1 30 Nm [ 22 ft-lb ]
2 Rotate 60 degrees
Rocker Lever Cover (003-011)

Rocker Lever Cover Capscrews 25 Nm [ 18 ft-lb ]
Fuel System - Group 05 - Torque Values Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Fuel System - Group 05 - Torque Values

Fuel Pump (005-016)
Fuel Pump Capscrews 6.5 Nm [ 50 in-lb ]
13 Nm [ 100 in-lb ]
Cooling Plate Return Line 25 Nm [ 221 in-lb ]
Fuel Pump Torx Head Screws 7 Nm [ 62 in-lb ]
Fuel Pump Pulsation Damper (005-031)

Pulsation Damper Capscrew Lower 9.5 Nm [ 84 in-lb ]
9.5 Nm [ 84 in-lb ]
Fuel Pump Pulsation Damper Screws A And 9.5 Nm [ 84 in-lb ]

B 5.5 Nm [ 48 in-lb ]
Fuel Pump Pulsation Damper Screw C
Fuel Shutoff Valve (005-043)

Fuel Shutoff Valve Coil Allen Head 3.4 Nm [ 30 in-lb ]
Capscrews
Fuel Shutoff Valve Electrical Connection 3 Nm [ 25 in-lb ]

Nut
Signature, ISX, and QSX15 Eng [...] Fuel System - Group 05
Ref.No./
Steps
.
Fuel Lift Pump (005-045)

Fuel Lift Pump Assembly Bolts 12.5 Nm [ 110 in-lb ]
18 Nm [ 159 in-lb ]
Industrial Fuel Lift Pump Mounting 25 Nm [ 212 in-lb ]

Capscrews
Industrial Fuel Lift Pump Outlet Line 27 Nm [ 239 in-lb ]
Remote Mount Lift Pump Filter Screen 23 Nm [ 204 in-lb ]

Retaining Plug
Remote Mount Fuel Lift Pump Mounting 45 Nm [ 33 ft-lb ]

Capscrews
Integrated Fuel System Module (IFSM) (005-073)

Ifsm 1724-Kpa [250-Psi] Fuel Pressure 27 Nm [ 239 in-lb ]
Regulator (Without Egr)
Fuel System - Group 05 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Ifsm 2206-Kpa [320-Psi] Fuel Pressure 27 Nm [ 239 in-lb ]

Regulator (Without Egr)
Ifsm Fuel Inlet Check Valves (Without Egr) 17 Nm [ 150 in-lb ]
Fuel Control Damper 9.5 Nm [ 84 in-lb ]
Fuel Pressure Regulators 27 Nm [ 239 in-lb ]
Fuel Pressure Sensor 23 Nm [ 204 in-lb ]
Temperature Sensor 23 Nm [ 204 in-lb ]
Compuchek Fitting 9.5 Nm [ 84 in-lb ]

Ref.No./
Steps
.
Check Valve 17 Nm [ 150 in-lb ]
Cooling Plate Supply Fitting 27 Nm [ 239 in-lb ]
Fuel Drain Fitting 45 Nm [ 33 ft-lb ]
Metering Actuator 15 Nm [ 133 in-lb ]
Timing Actuator 15 Nm [ 133 in-lb ]
Assembly To Housing 5.5 Nm [ 49 in-lb ]
Threaded Plugs 17 Nm [ 150 in-lb ]

14 Nm [ 124 in-lb ]

27 Nm [ 239 in-lb ]
Ref.No./
Steps
.
Fitting To Gear Pump 27 Nm [ 239 in-lb ]
Pump To Ifsm 11 Nm [ 97 in-lb ]
Lift Pump To Housing 18 Nm [ 159 in-lb ]
Fuel Control Damper 9.5 Nm [ 84 in-lb ]
Fuel Pressure Sensor 23 Nm [ 204 in-lb ]
Air Bleed 7.9 Nm [ 70 in-lb ]

Ref.No./
Steps
.
Compuchek Fitting 9.5 Nm [ 84 in-lb ]
Check Valve 17 Nm [ 150 in-lb ]
Cooling Plate Supply Fitting 17 Nm [ 150 in-lb ]
Filter Screen And Filter Cap 17 Nm [ 150 in-lb ]
Fuel Drain Fitting 45 Nm [ 33 ft-lb ]
Metering Actuator 15 Nm [ 133 in-lb ]
Timing Actuator 15 Nm [ 133 in-lb ]
Assembly To Housing 5.5 Nm [ 49 in-lb ]

Ref.No./
Steps
.

14 Nm [ 124 in-lb ]
Fitting To Gear Pump 27 Nm [ 239 in-lb ]
Pump To Ifsm 11 Nm [ 97 in-lb ]
Lift Pump To Housing 18 Nm [ 159 in-lb ]
Integrated Fuel System Module (With Egr) 45 Nm [ 33 ft-lb ]
Fuel Inlet Pre-Filter (005-096)

Inlet Pre-Filter 60 Nm [ 44 ft-lb ]
Inlet Pre-Filter 60 Nm [ 44 ft-lb ]

Ref.No./
Steps
.
Fuel Pump Screen Cap 17 Nm [ 150 in-lb ]

Injectors and Fuel Lines - Group 06 - Specifications Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Injectors and Fuel Lines - Group 06 - Specifications

Fuel Filter (Spin-On Type) (006-015)
Fuel Filter Restriction 517 kPa MAX 75 psi
Upper Location 356 MAX 14

Lower Location 305 MAX 12
Fuel Inlet Restriction (006-020)

Without remote fuel filter 76 MAX 3
With remote fuel filter 254 MAX 10
Signature, ISX, and QSX15 Eng [...] Injectors and Fuel Lines - Group 06 - Torque Values
Ref.No./
Steps
.
Injectors and Fuel Lines - Group 06 - Torque Values

ECM Cooling Plate, Fuel Cooled (006-006)
20 Nm [ 15 ft-lb ]
20 Nm [ 15 ft-lb ]
25 Nm [ 18 ft-lb ]
Fuel Drain Line Restriction (006-012)

Fuel Drain Hose 35 Nm [ 26 ft-lb ]
Injector (006-026)
Front Mounting Plate Capscrews 15.3 Nm [ 135 in-lb ]
Rear Mounting Plate Capscrews 15.3 Nm [ 135 in-lb ]
Injector Spring Retainer Capscrew 30 Nm [ 22 ft-lb ]
Injector Retaining Capscrew 80 Nm [ 59 ft-lb ]

Lubricating Oil System - Group 07 - Specifications Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Lubricating Oil System - Group 07 - Specifications

Lubricating Oil Cooler Housing Seat Depth 123.47 mm MIN 4.861 in
Lubricating Oil Filter Bypass Valve (007-014)
Lubricating Oil High Pressure Relief Valve (007-021)
High Pressure Relief Valve Spring 281.47 N MIN 63.277 lbf

(Compressed Length) Load at 45.82 mm
[1.804 in]
298.87 N MAX 67.189 lbf

Regulator Bore Depth Specification 186.95 mm MIN 7.3602 in
187.45 mm MAX 7.380 in
Lubricating Oil Pressure Regulator Spring 131.8 N MIN 29.6 lbf

Load at 70 mm [2.756 in]
135.3 N MAX 30.4 lbf
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System - Group 07
Ref.No./
Steps
.
High Pressure Relief Valve Spring 281.5 N MIN 63.3 lbf

(Compressed Length) Load at 45.82 mm
[1.804 in]
298.9 N MAX 67.2 lbf
External Idler Gear Bushing Inside Diameter 32.044 mm MIN 1.2616 in

32.069 mm MAX 1.2626 in
External Drive Gear Inside Diameter (No 24.909 mm MIN 0.9807 in

Bushing)
24.935 mm MAX 0.9817 in
Internal Idler Gear Inside Diameter 24.909 mm MIN 0.9807 in

24.935 mm MAX 0.9817 in
Internal Idler Shaft Outside Diameter 24.858 mm MIN 0.9787 in

24.871 mm MAX 0.9792 in
Internal Drive Gear Shaft Outside Diameter 24.858 mm MIN 0.9787 in

24.871 mm MAX 0.9792 in
Drive Shaft End Clearance 0.100 mm MIN 0.003 in

0.163 mm MAX 0.006 in
Lubricating Oil System - Group 07 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Oil Pump Idler Gear Backlash 0.18 mm MIN 0.008 in

0.46 mm MAX 0.018 in
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System - Group 07 - Torque Values
Ref.No./
Steps
.
Lubricating Oil System - Group 07 - Torque Values

Dual-Element Lubricating Oil Cooler (With 47 Nm [ 35 ft-lb ]
Egr)
Lubricating Oil Cooler Element (007-007)

Lubricating Oil Cooler Pressure Test Plate 20 Nm [ 15 ft-lb ]
Single-Element Lubricating Oil Cooler 20 Nm [ 15 ft-lb ]

Element Capscrew
Dual-Element Lubricating Oil Cooler 20 Nm [ 15 ft-lb ]

Element Capscrew
Lubricating Oil Dipstick Tube (007-011)

Lubricating Oil Dipstick Tube Nut 70 Nm [ 52 ft-lb ]
70 Nm [ 52 ft-lb ]
Lubricating Oil Filter Bypass Valve (007-014)

Lubricating Oil Cooler Transfer Housing 45 Nm [ 33 ft-lb ]
Retaining Plug
Lubricating Oil System - Group 07 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Lubricating Oil Filter Head Adapter (007-018)

Lubricating Oil Filter Head Adapter 450 Nm [ 332 ft-lb ]
Lubricating Oil Pan (007-025)

Lubricating Oil Pan Mounting Capscrews 55 Nm [ 41 ft-lb ]
47 Nm [ 35 ft-lb ]

Lubricating Oil Pump Cover Capcrews 29 Nm [ 21 ft-lb ]
External Idler Gear Retainer Capscrew 115 Nm [ 85 ft-lb ]
Lubricating Oil Pump Mounting Capscrews 56 Nm [ 41 ft-lb ]
Lubricating Oil Suction Tube (Block-Mounted) (007-035)

Lubricating Oil Suction Tube Capscrews 47 Nm [ 35 ft-lb ]
Lubricating Oil System (007-037)

Lubricating Oil Cooler Housing Plug 34 Nm [ 25 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System - Group 07
Ref.No./
Steps
.
Lubricating Oil Thermostat (007-039)

Lubricating Oil Thermostat Retaining Plug 100 Nm [ 74 ft-lb ]
Lubricating Oil Fill Tube (007-065)

Lubricating Oil Tube Brace Gear Cover 28 Nm [ 21 ft-lb ]
Capscrew
28 Nm [ 21 ft-lb ]
Cooling System - Group 08 - Specifications Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Cooling System - Group 08 - Specifications

Thermostat Initial Opening Temperature 81 C MIN 178 F
83 C MAX 182 F

Fan Hub End Clearance 0.08 mm MIN 0.003 in
0.25 mm MAX 0.009 in

Water Pump Housing Large Bearing Bore 71.988 mm MIN 2.834 in
Inside Diameter
72.018 mm MAX 2.835 in
Cast Iron Impeller Inside Diameter 15.850 mm MIN 0.624 in

15.875 mm MAX 0.625 in
Water Pump Shaft Diameter

Small End 25.015 MIN 0.9848
25.002 MAX 0.9843
Large End 29.015 MIN 1.1423
29.002 MAX 1.1418
Pulley Bore Inside Diameter 28.936 mm MIN 1.139 in

29.964 mm MAX 1.140 in
Water Pump Seal Installed Height 10.919 mm MIN 0.430 in

11.679 mm MAX 0.460 in
Signature, ISX, and QSX15 Eng [...] Cooling System - Group 08
Ref.No./
Steps
.
Impeller Clearance 0.29 mm MIN 0.011 in

1.24 mm MAX 0.049 in
Cooling System - Group 08 - Torque Values Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Cooling System - Group 08 - Torque Values

Coolant Filter Valve (008-009)
Coolant Filter Valve Retaining Capscrew 7 Nm [ 60 in-lb ]

Thermostat Housing Cover Capscrews 34 Nm [ 25 ft-lb ]
Thermostat Housing Cover Capscrews
Long Capscrews
Thermostat Housing Cover Plate 28 Nm [ 20 ft-lb ]

Capscrews
Upper Radiator Hose Clamp 5 Nm [ 40 in-lb ]
Coolant Thermostat Housing (008-014)

Thermostat Housing Mounting Capscrews 45 Nm [ 33 ft-lb ]
Thermostat Housing Cover 45 Nm [ 33 ft-lb ]
Thermostat Housing Capscrews 56 Nm [ 41 ft-lb ]

Ref.No./
Steps
.
Thermostat Housing Cover Capscrews 34 Nm [ 25 ft-lb ]

Thermostat Housing Cover Capscrews
Long Capscrews
Upper Radiator Hose Clamp 5 Nm [ 40 in-lb ]
Thermostat Housing Cover Plate 28 Nm [ 20 ft-lb ]

Capscrews
Cooling System (008-018)

Lower Radiator Hose Clamp 5 Nm [ 44 in-lb ]
Lower Radiator Hose Clamp 5 Nm [ 44 in-lb ]
Fan Drive Idler Pulley Assembly (008-030)

Fan Drive Idler Pulley Bracket Capscrew 18 Nm [ 159 in-lb ]
M8x60mm
Fan Drive Idler Pulley Assembly Capscrew 54 Nm [ 40 ft-lb ]

M10x80mm
Cooling System - Group 08 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.

Fan Hub Assembly Capscrew 113 Nm [ 83 ft-lb ]
Fan Hub Capscrews 90 Nm [ 66 ft-lb ]
Fan Hub Capscrews 90 Nm [ 66 ft-lb ]

Water Pump Mounting Capscrews (With 72 Nm [ 53 ft-lb ]
Egr)
Automotive Water Pump Mounting 58 Nm [ 43 ft-lb ]

Capscrews Capscrews 1, 2, And 3 72 Nm [ 53 ft-lb ]
Capscrews Capscrews 4 And 5
Automotive Water Pump Mounting
Capscrews All Capscrews, Engines Without
Belt Tensioner Bracket
Capscrews Capscrews 1, 2, And 3 72 Nm [ 53 ft-lb ]
Capscrews Capscrews 4 And 5
Automotive Water Pump Mounting
Capscrews All Capscrews, Engines Without
Belt Tensioner Bracket
Belt Idler Pulley Capscrew 30 Nm [ 25 ft-lb ]
Ref.No./
Steps
.
72 Nm [ 53 ft-lb ]
30 Nm [ 25 ft-lb ]
30 Nm [ 25 ft-lb ]
Belt Tensioner, Automatic (Water Pump) (008-080)

Belt Tensioner And Mounting Capscrew 50 Nm [ 37 ft-lb ]
Automatic Belt Tensioner Bracket Mounting 34 Nm [ 25 ft-lb ]

Capscrew 34 Nm [ 25 ft-lb ]
Industrial Low-Mount (Small Tensioner) 56 Nm [ 41 ft-lb ]

Bracket

Bracket

Cooling System - Group 08 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Water Inlet Connection (008-082)

Coolant Filter Head Mounting Capscrews 56 Nm [ 41 ft-lb ]
Fan Support (008-088)

Fan Support Capscrews 56 Nm [ 41 ft-lb ]
Belt Tensioner Support Bracket Capscrews 90 Nm [ 66 ft-lb ]
Belt Tensioner Support Bracket Capscrews 56 Nm [ 41 ft-lb ]
Fan Pulley (008-089)

Fan Pulley Capscrews 95 Nm [ 70 ft-lb ]
Water Pump Cartridge (008-102)

48 Nm [ 36 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Drive Units - Group 09 - Torque Values
Ref.No./
Steps
.
Drive Units - Group 09 - Torque Values

Refrigerant Compressor (009-051)
18 Nm [ 115 in-lb ]
36 Nm [ 27 ft-lb ]
Belt Tensioner, Refrigerant Compressor, Automatic (009-053)

45 Nm [ 33 ft-lb ]
Idler Pulley, Refrigerant Compressor (009-054)

36 Nm [ 27 ft-lb ]
Refrigerant Compressor Mounting Bracket (009-055)

Refrigerant Compressor Mounting Bracket 7 Nm [ 62 in-lb ]
Capscrew
41 Nm [ 30 ft-lb ]
Refrigerant Compressor Bracket Mounting 56 Nm [ 41 ft-lb ]

Capscrews
Drive Units - Group 09 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Alternator/Refrigerant Compressor Mounting Bracket (009-056)

Alternator/Refrigerant Compressor Bracket 18 Nm [ 14 ft-lb ]
Wire Harness Capscrews
Alternator/Refrigerant Compressor 36 Nm [ 27 ft-lb ]

Mounting Bracket Capscrews (1, 2 3 And 4) 56 Nm [ 41 ft-lb ]
Alternator/Refrigerant Compressor
Mounting Bracket Capscrews (5)

Mounting Bracket To Gear Housing
Capscrews

Mounting Bracket Capscrews (1, 2, 3, 4,
And 5)
Signature, ISX, and QSX15 Eng [...] Air Intake System - Group 10 - Specifications
Ref.No./
Steps
.
Air Intake System - Group 10 - Specifications

Charge-Air Cooler (010-027)
Charge-Air Cooler Pressure Drop 49 kPa MAX 5 psi
Charge Air Cooler Temperature Rise 11 C MAX 20 F
Charge-Air Cooler System Differential 152 mm MAX 6 in Hg

Pressure Hg
Charge-Air Cooler System Differential 21 kPa MAX 3 psi
Pressure
Turbocharger Axial Clearance 0.025 mm MIN 0.001 in
0.127 mm MAX 0.005 in
Turbocharger Radial Bearing Clearance 0.406 mm MIN 0.016 in

0.610 mm MAX 0.024 in
Turbocharger Axial Clearance 0.025 mm MIN 0.001 in

0.127 mm MAX 0.005 in
Turbocharger Wastegate Actuator (010-050)

Turbocharger Wastegate Rod Travel at 100 0.356 mm MIN 0.014 in
kPa [14.5 psi]
3.810 mm MAX 0.150 in
Air Intake System - Group 10 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Turbocharger Wastegate Rod Travel at 100 0.356 mm MIN 0.014 in

kPa [14.5 psi]
3.810 mm MAX 0.150 in
Turbocharger Wastegate Valve Body (010-055)

Wastegate Wear Measurement 25.654 mm MAX 1.010 in
Turbocharger, Variable Geometry Actuator (010-113)

Actuator Movement Range 12 mm MIN 0.472 in
Signature, ISX, and QSX15 Eng [...] Air Intake System - Group 10 - Torque Values
Ref.No./
Steps
.
Air Intake System - Group 10 - Torque Values

Air Leaks, Air Intake and Exhaust Systems (010-024)
Turbocharger-To-Charge-Air Cooler V- 9 Nm [ 80 in-lb ]
Band Clamp
Charge-Air Cooler Piping Clamp 9 Nm [ 80 in-lb ]
Turbine Housing V-Band Clamp 14 Nm [ 124 in-lb ]
Compressor Housing V-Band Clamp 9 Nm [ 80 in-lb ]
Charge Air Cooling Piping 8.5 Nm [ 75 in-lb ]
18 Nm [ 159 in-lb ]
11.3 Nm [ 100 in-lb ]
18 Nm [ 159 in-lb ]
11.3 Nm [ 100 in-lb ]
Turbocharger Mounting Nuts 61 Nm [ 45 ft-lb ]

81 Nm [ 60 ft-lb ]
Ref.No./
Steps
.
Turbocharger Discharge Elbow Clamp 9 Nm [ 80 in-lb ]
Oil Drain Tube Capscrew 25 Nm [ 221 in-lb ]
Oil Drain Tube Capscrew 25 Nm [ 221 in-lb ]
Compressor V-Bands 9 Nm [ 80 in-lb ]

12 Nm [ 106 in-lb ]
30 Nm [ 22 ft-lb ]
30 Nm [ 22 ft-lb ]
Intake And Exhaust Pipe Clamps 9 Nm [ 80 in-lb ]
102 Nm [ 75 ft-lb ]
Turbocharger Discharge Elbow Clamp 9 Nm [ 80 in-lb ]
Oil Drain Tube Capscrew 30 Nm [ 22 ft-lb ]

Signature, ISX, and QSX15 Eng [...] Air Intake System - Group 10
Ref.No./
Steps
.
Intake And Exhaust Pipe Clamps 9 Nm [ 80 in-lb ]
30 Nm [ 22 ft-lb ]
30 Nm [ 22 ft-lb ]
102 Nm [ 75 ft-lb ]
9 Nm [ 80 in-lb ]
25 Nm [ 221 in-lb ]
30 Nm [ 22 ft-lb ]
Turbocharger Coolant Hoses (010-041)

Turbocharger Coolant Supply Line 46 Nm [ 34 ft-lb ]
Turbocharger Coolant Return Line 46 Nm [ 34 ft-lb ]

Ref.No./
Steps
.
Turbocharger Tube Brace 18 Nm [ 159 in-lb ]
41 Nm [ 30 ft-lb ]
15 Nm [ 133 in-lb ]
54 Nm [ 40 ft-lb ]
46 Nm [ 34 ft-lb ]
24 Nm [ 18 ft-lb ]
16 Nm [ 142 in-lb ]
24 Nm [ 18 ft-lb ]
Turbocharger Wastegate Actuator (010-050)

Turbocharger Wastegate Actuator End-Link 8.5 Nm [ 75 in-lb ]
Locknut
Air Intake Connection (010-080)

Air Intake Connection Mounting Capscrew 45 Nm [ 33 ft-lb ]
45 Nm [ 33 ft-lb ]
Turbocharger Wastegate Controller (010-109)

Electrical Connection Post Nut 3 Nm [ 25 in-lb ]
Signature, ISX, and QSX15 Eng [...] Air Intake System - Group 10
Ref.No./
Steps
.
Coil Capscrews 3 Nm [ 25 in-lb ]
Electrical Connection Nut 3 Nm [ 25 in-lb ]
Turbocharger, Variable Geometry Actuator (010-113)

Turbocharger Actuator Capscrews 17 Nm [ 150 in-lb ]
Turbocharger Actuator Rod Capscrew 23 Nm [ 17 ft-lb ]
Turbocharger Control Shutoff Valve Filter Head (010-115)

45 Nm [ 33 ft-lb ]
Turbocharger, Variable Geometry Actuator Air Supply Line (010-120)

Turbocharger Air Supply Line To 16 Nm [ 12 ft-lb ]
Turbocharger Air Control Valve 20 Nm [ 15 ft-lb ]
16 Nm [ 12 ft-lb ]
Turbocharger, Variable Geometry Control Valve Air Supply Line (010-121)

Turbocharger Air Supply Line To 20 Nm [ 15 ft-lb ]
Turbocharger Air Control Valve 20 Nm [ 15 ft-lb ]
16 Nm [ 12 ft-lb ]
Ref.No./
Steps
.
Variable Geometry Turbocharger Actuator, Electric (010-134)

Actuator Mounting Capscrews 1 3 Nm [ 27 in-lb ]
2 11 Nm [ 97 in-lb ]
Variable Geometry Turbocharger Cross Shaft (010-137)

Vgt Yoke Retaining Capscrew 37 Nm [ 27 ft-lb ]
Diffuser Mounting Capscrews 1 4 Nm [ 35 in-lb ]

2 8 Nm [ 71 in-lb ]
Turbocharger Compressor Impeller Nut 17 Nm [ 150 in-lb ]
Turbocharger V-Band Clamp 9 Nm [ 80 in-lb ]

Signature, ISX, and QSX15 Eng [...] Exhaust System - Group 11 - Specifications
Ref.No./
Steps
.
Exhaust System - Group 11 - Specifications

Exhaust Restriction (011-009)
Without Aftertreatment 75.0 MAX 3.0
With Aftertreatment 305.0 MAX 12.0
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes

(011-047)
Minimum Loctite Anti-Seize Temperature 870 C MIN 1600 F
Range
Exhaust System - Group 11 - Torque Values Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Exhaust System - Group 11 - Torque Values

Exhaust Manifold, Dry (011-007)
Slip Joint Seal Clamp 11 Nm [ 97 in-lb ]
Exhaust Manifold Capscrews 60 Nm [ 44 ft-lb ]
Exhaust Manifold Mounting Capscrews 1 30 Nm [ 22 ft-lb ]

2 55 Nm [ 41 ft-lb ]
EGR Cooler (011-019)

17 Nm [ 150 in-lb ]
23 Nm [ 204 in-lb ]
17 Nm [ 150 in-lb ]
47 Nm [ 35 ft-lb ]
23 Nm [ 204 in-lb ]
Signature, ISX, and QSX15 Eng [...] Exhaust System - Group 11
Ref.No./
Steps
.
17 Nm [ 150 in-lb ]
20 Nm [ 177 in-lb ]
EGR Mixer (011-021)

34 Nm [ 25 ft-lb ]
EGR Valve (011-022)

17 Nm [ 150 in-lb ]
54 Nm [ 40 ft-lb ]
EGR Cooler Connection (011-024)

17 Nm [ 150 in-lb ]
EGR Connection Tubes (011-025)

27 Nm [ 239 in-lb ]
Exhaust System - Group 11 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
7 Nm [ 62 in-lb ]
47 Nm [ 35 ft-lb ]
47 Nm [ 35 ft-lb ]
47 Nm [ 35 ft-lb ]
27 Nm [ 239 in-lb ]
7 Nm [ 62 in-lb ]
EGR Differential Pressure Sensor Tubes (011-026)

26 Nm [ 230 in-lb ]
1.5 Nm [ 13 in-lb ]
Exhaust Gas Pressure Sensor Tube (011-027)

Exhaust Gas Pressure Sensor Tube Nuts 16 Nm [ 146 in-lb ]
EGR Differential Pressure Sensor Adapter (011-028)

18 Nm [ 13 ft-lb ]
Ref.No./
Steps
.
EGR Valve Coolant Lines (011-030)

10 Nm [ 88 in-lb ]
EGR Cooler Coolant Lines (011-031)

25 Nm [ 221 ft-lb ]
34 Nm [ 25 ft-lb ]
47 Nm [ 35 ft-lb ]
47 Nm [ 35 ft-lb ]
21 Nm [ 186 in-lb ]
47 Nm [ 35 ft-lb ]
Heat Shield (011-032)

23 Nm [ 17 ft-lb ]
23 Nm [ 17 ft-lb ]
Ref.No./
Steps
.
Exhaust Gas Pressure Sensor Adapter (011-033)

23 Nm [ 17 ft-lb ]
Aftertreatment Diesel Particulate Filter (011-041)

20 Nm [ 177 in-lb ]
Aftertreatment Fuel Injector (011-042)

14 Nm [ 124 in-lb ]
Aftertreatment Adapter Pipe (011-043)

11 Nm [ 97 in-lb ]
EGR Valve Mounting Bracket (011-044)

40 Nm [ 30 ft-lb ]
40 Nm [ 30 ft-lb ]
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting

Bracket (011-046)
7 Nm [ 62 in-lb ]
Ref.No./
Steps
.
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes

(011-047)
17 Nm [ 150 in-lb ]
14 Nm [ 124 in-lb ]
Aftertreatment Inlet and Outlet (011-048)

Torca Clamp 55 41 V-Band Clamp 14
124
20 Nm [ 177 in-lb ]
Aftertreatment Diesel Oxidation Catalyst (011-049)

20 Nm [ 177 in-lb ]
17 Nm [ 150 in-lb ]
Aftertreatment Injector Lines (011-051)

24 Nm [ 212 in-lb ]
24 Nm [ 212 in-lb ]
24 Nm [ 212 in-lb ]
24 Nm [ 212 in-lb ]
24 Nm [ 212 in-lb ]
24 Nm [ 212 in-lb ]
Ref.No./
Steps
.
24 Nm [ 212 in-lb ]
24 Nm [ 212 in-lb ]
24 Nm [ 212 in-lb ]
34 Nm [ 25 ft-lb ]
24 Nm [ 212 in-lb ]
24 Nm [ 212 in-lb ]
Aftertreatment Fuel Shutoff Manifold (011-052)

14 Nm [ 124 in-lb ]
14 Nm [ 124 in-lb ]
14 Nm [ 124 in-lb ]
25 Nm [ 221 in-lb ]
14 Nm [ 124 in-lb ]
14 Nm [ 124 in-lb ]
14 Nm [ 124 in-lb ]
Ref.No./
Steps
.
25 Nm [ 221 in-lb ]
Aftertreatment Fuel Injector Flow (011-054)

24 Nm [ 212 in-lb ]
24 Nm [ 212 in-lb ]
14 Nm [ 124 in-lb ]
Compressed Air System - Group 12 - Torque Values Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Compressed Air System - Group 12 - Torque Values

Air Compressor Coolant Lines (012-004)
45 Nm [ 33 ft-lb ]
45 Nm [ 33 ft-lb ]
Air Compressor (012-014)

Air Compressor Mounting Capscrews 45 Nm [ 33 ft-lb ]
Air Compressor Mounting Brace Capscrews 45 Nm [ 33 ft-lb ]
Air Compressor Air Discharge Line 60 Nm [ 44 ft-lb ]

8 Nm [ 71 in-lb ]
Signature, ISX, and QSX15 Eng [...] Electrical Equipment - Group 13 - Torque Values
Ref.No./
Steps
.
Electrical Equipment - Group 13 - Torque Values

Alternator (013-001)
Alternator Mounting Capscrews 36 Nm [ 27 ft-lb ]
Alternator Mounting Bracket Capscrews 86 Nm [ 63 ft-lb ]

56 Nm [ 41 ft-lb ]
Alternator Pulley (013-006)

Alternator Pulley Locking Nut 100 Nm [ 74 ft-lb ]
Starting Motor (013-020)

Starting Motor Mounting Capscrews 5/8-11 140 Nm [ 103 ft-lb ]
X 1.75 In Capscrew 201 Nm [ 148 ft-lb ]
Starting Motor Mounting Capscrews 5/8-11 129 Nm [ 95 ft-lb ]
X 2.00 In Capscrew 163 Nm [ 120 ft-lb ]
Starting Motor Mounting Capscrews 39 Mt
Starters (Aluminum Flywheel Housing)
Starting Motor Mounting Capscrews 39 Mt
Starters (Cast Iron Flywheel Housing)
Starter Motor Mounting With Aluminum 140 Nm [ 103 ft-lb ]
Flywheel Housing 5/8-11 X 1.75 In 201 Nm [ 148 ft-lb ]
Capscrew
Starter Motor Mounting With Aluminum
Flywheel Housing 5/8-11 X 2.00 In
Capscrew
3 Nm [ 26 in-lb ]
Starter Motor Mounting Brackets (High And 45 Nm [ 33 ft-lb ]

Low Mounted) (1) 23 Nm [ 17 ft-lb ]
Starter Motor Mounting Brackets (High And 41 Nm [ 30 ft-lb ]
Low Mounted) (2) And (3)
Starter Motor Mounting Brackets (High And
Low Mounted) (4) And (5)
Electrical Equipment - Group 13 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Belt Tensioner, Automatic (Alternator) (013-021)

Belt Tensioner Mounting Capscrew 56 Nm [ 41 ft-lb ]
Alternator Spacer (013-036)

36 Nm [ 27 ft-lb ]
Alternator Idler Pulley (013-039)

Alternator Idler Pulley Mounting Capscrew 60 Nm [ 44 ft-lb ]
Bracket, Idler Pulley and Alternator Belt Tensioner (013-040)

Idler Pulley And Alternator Belt Tensioner 56 Nm [ 41 ft-lb ]
Bracket
Idler Pulley And Alternator Belt Tensioner 90 Nm [ 66 ft-lb ]

Bracket Spacer 56 Nm [ 41 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Engine Testing - Group 14 - Specifications
Ref.No./
Steps
.
Engine Testing - Group 14 - Specifications

Engine Testing (Chassis Dynamometer) (014-002)
Fuel Inlet Temperature 7.2 C MIN 45 F
55.5 C MAX 132 F
Engine Testing (Engine Dynamometer) (014-005)

Hose Temperature 235 C MIN 500 F
Fuel Inlet Temperature 7.2 C MIN 45 F

55.5 C MAX 132 F
Mounting Adaptations - Group 16 - Specifications Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Mounting Adaptations - Group 16 - Specifications

Flywheel (016-005)
Flywheel Bore Runout 0.127 mm MAX 0.005 in

Idler Gear to Crankshaft Gear Backlash 0.15 mm MIN 0.006 in
0.28 mm MAX 0.011 in
Signature, ISX, and QSX15 Eng [...] Mounting Adaptations - Group 16 - Torque Values
Ref.No./
Steps
.
Mounting Adaptations - Group 16 - Torque Values

Engine Lifting Brackets (016-001)
Lifting Bracket Capscrews 108 Nm [ 80 ft-lb ]
Flywheel (016-005)
Flywheel Mounting Capscrews 1 125 Nm [ 92 ft-lb ]
2 250 Nm [ 184 ft-lb ]
Flywheel Housing (016-006)

Cover Plate Capscrews 11 Nm [ 97 in-lb ]
Flywheel Housing Capscrews 7 Nm [ 62 in-lb ]
Flywheel Housing Mounting Capscrews 1 100 Nm [ 74 ft-lb ]

2 197 Nm [ 145 ft-lb ]

14 Nm [ 124 in-lb ]

2 197 Nm [ 145 ft-lb ]
Mounting Adaptations - Group 16 Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Replacer Idler Shaft Capscrews 14 Nm [ 124 in-lb ]
100 Nm [ 74 ft-lb ]
100 Nm [ 74 ft-lb ]
28 Nm [ 21 ft-lb ]
28 Nm [ 21 ft-lb ]
60 Nm [ 44 ft-lb ]
20 Nm [ 177 in-lb ]
20 Nm [ 177 in-lb ]
35 Nm [ 26 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Mounting Adaptations - Group 16
Ref.No./
Steps
.
65 Nm [ 48 ft-lb ]
20 Nm [ 15 in-lb ]
65 Nm [ 48 ft-lb ]
32 Nm [ 24 ft-lb ]
32 Nm [ 24 ft-lb ]

2 197 Nm [ 145 ft-lb ]
Vehicle Braking - Group 20 - Specifications Signature, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Vehicle Braking - Group 20 - Specifications

Engine Brake Lever Running Clearance 0.635 mm MIN 0.025 in

2.790 mm MAX 0.110 in
Engine Brake Control Valve (020-017)

Signature, ISX, and QSX15 Eng [...] Vehicle Braking - Group 20 - Torque Values
Ref.No./
Steps
.
Vehicle Braking - Group 20 - Torque Values

Engine Brake Lever Adjusting Screw 20 Nm [ 177 in-lb ]
Locknut
Engine Brake Solenoid Valve (020-012)

Engine Brake Solenoid 20 Nm [ 15 ft-lb ]
Engine Brake Wiring Harness (020-015)

Deutsch Connector Retaining Clip 5 Nm [ 50 in-lb ]
23 Nm [ 18 ft-lb ]
General Engine Signature, ISX, and QSX15 Eng [...]
General Engine
Specifications
Listed below are general specifications for this engine.
Horsepower................................................................................................................Refer to the engine dataplate.
Engine Speed:
400 to 450 hp.........................................................................................................Refer to the engine dataplate.
Displacement.............................................................................................................................15 liters [912 C.I.D.]
Bore and Stroke................................................................................................137 mm [5.40 in] x 169 mm [6.65 in]
Dry Engine Weight:
Automotive................................................................................................................................1202 kg [2650 lb]
Industrial...................................................................................................................................1524 kg [3360 lb]
Power Generation.....................................................................................................................1370 kg [3020 lb]
Wet Engine Weight:
Automotive................................................................................................................................1266 kg [2790 lb]
Industrial...................................................................................................................................1628 kg [3590 lb]
Power Generation.....................................................................................................................1474 kg [3250 lb]
Firing Order..............................................................................................................................................1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine)......................................................................................Clockwise
Overhead Adjustment:
Intake Valve Adjustment..........................................................................................................0.36 mm [0.014 in]
Exhaust Valve Adjustment.......................................................................................................0.69 mm [0.027 in]
Injector Lash Adjustment Torque.................................................................................................8 Nm [70 in-lb]
Engine Brake Adjustment.............................................................................................................7.00 mm [0.276 in]
Listed below are general specifications for this engine.
Horsepower................................................................................................................Refer to the engine dataplate.
Engine Speed:
Displacement.............................................................................................................................15 liters [912 C.I.D.]
Bore and Stroke................................................................................................137 mm [5.40 in] x 169 mm [6.65 in]
Dry Engine Weight:........................................................................................................................1403 kg [3093 lb]
Wet Engine Weight........................................................................................................................1472 kg [3246 lb]
Firing Order..............................................................................................................................................1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine)......................................................................................Clockwise
Overhead Adjustment:
Intake Valve Adjustment..........................................................................................................0.36 mm [0.014 in]
Exhaust Valve Adjustment.......................................................................................................0.69 mm [0.027 in]
Injector Lash Adjustment Torque.................................................................................................8 Nm [70 in-lb]
Engine Brake Adjustment.............................................................................................................7.00 mm [0.276 in]
Signature, ISX, and QSX15 Eng [...] Fuel System
Fuel System
Specifications
Maximum Allowable Restriction to Pump With or Without Fuel Cooler:
With Clean Filter..................................................................................................................203 mm Hg [8 in Hg]
With Dirty Filter..................................................................................................................305 mm Hg [12 in Hg]
Maximum Allowable Fuel Return Line Restriction......................................................................229 mm Hg [9 in Hg]
Minimum Allowable Fuel Tank Vent Capability........................................................................... 2.0 m3/hr [70 ft3/hr]
Maximum Allowable Fuel Inlet Temperature.........................................................................................71C [160F]
Fuel Shutoff Solenoid Resistance..........................................................................................................6 to 10 ohms
Maximum Allowable Pressure Drop Across Pressure Fuel Filter.......................................................517 kPa [75 psi]
Automotive, Industrial with CM570 and Power Generation without CM570
Maximum Allowable Fuel Return Line Restriction
With Check Valve.............................................................................................................165 mm Hg [6.5 in Hg]
Without Check Valve............................................................................................................229 mm Hg [9 in Hg]
Minimum Allowable Fuel Tank Vent Capability........................................................................... 2.0 m3/hr [70 ft3/hr]
Maximum Allowable Fuel Inlet Temperature.........................................................................................71C [160F]
Fuel Shutoff Solenoid Resistance..........................................................................................................6 to 10 ohms
Maximum Allowable Inlet Restriction at the IFSM - high idle, no load:
Upper Location..................................................................................................................355 mm Hg [14 in Hg]
Lower Location..................................................................................................................305 mm Hg [12 in Hg]
Maximum Allowable Inlet Restriction at OEM Fuel Inlet:
Without Remote Mount Filter.................................................................................................76 mm Hg [3 in Hg]
With Remote Mount Filter..................................................................................................254 mm Hg [10 in Hg]
Lubricating Oil System Signature, ISX, and QSX15 Eng [...]
Lubricating Oil System

Specifications
Oil Pressure at Idle (minimum allowable at 93C [200F] oil temperature)........................................103 kPa [15 psi]
Oil Pressure at No-Load Governed Speed (automotive and industrial only)...................241 to 276 kPa [35 to 40 psi]
Pressure Drop Across Oil Filter (maximum allowable with 15W40 oil at operating temperature)........172 kPa [25 psi]
Oil Capacity of Standard Engine:
Combination Full-Flow/Bypass Filter Capacity............................................................................3.78 liters [1 gal]
Oil Pan Capacity: Automotive and Industrial
High....................................................................................................................................41.6 liters [11 gal]
Low.......................................................................................................................................34.1 liters [9 gal]
Oil Pan Capacity: Power Generation (for oil pan option OP1493)
High....................................................................................................................................83.3 liters [22 gal]
Low.....................................................................................................................................72.0 liters [19 gal]
Oil Change Capacity (oil pan and filter filled to capacity):
Automotive and Industrial....................................................................................................41.6 liters [11 gal]
Power Generation (for oil pan option OP1493).....................................................................87.0 liters [23 gal]
Total Lubricating Oil System Capacity Including Filter:
Automotive and Industrial.........................................................................................................45.4 liters [12 gal]
Power Generation (for oil pan option OP1493)..........................................................................90.8 liters [24 gal]
Oil Pressure Range:
Cold Engine...................................................................................................................Up to 1034 kPa [150 psi]
Warm Engine...........................................................................................................241 to 276 kPa [35 to 40 psi]
Cooling System
General Information
Cummins Inc. recommends the use of fully-formulated antifreeze or coolant containing a precharge of supplemental
coolant additive (SCA). The antifreeze or coolant must meet the specifications outlined in the Technology and
Maintenance Council (TMC) Recommended Practice (RP) 329 (ethylene glycol) or Recommended Practice (RP) 330
(propylene glycol). The use of fully-formulated antifreeze or coolant significantly simplifies cooling system
maintenance.
Copies of Technology and Maintenance Council (TMC) specifications can be obtained through Cummins Inc., or by
contacting:
Technology and Maintenance Council
American Trucking Association
2200 Mill Road
Alexandria, VA 33314-5388
Phone: (703) 838-1763
Fax (703) 836-6070
Fully-formulated antifreeze contains balanced amounts of antifreeze, SCA, and buffering compounds, but does not
contain 50 percent water. Fully-formulated coolant contains balanced amounts of antifreeze, SCA, and buffering
compounds already premixed 50/50 with deionized water.
Alternative maintenance practices for cooling systems can be found in Cummins Coolant Requirements and
Maintenance, Bulletin 3666132.
Specifications
Coolant Capacity (engine only)
With EGR...................................................................................................................................26.5 liters [28 qt]
Without EGR.................................................................................................................................24 liters [25 qt]
Standard Modulating Thermostat
Temperature Range.....................................................................................................82 to 93C [180 to 200F]
Maximum Coolant Pressure (exclusive of pressure cap - closed thermostat at the maximum no-load governed
speed)
With EGR.....................................................................................................................................434 kPa [63psi]
Without EGR...............................................................................................................................227 kPa [33 psi]
Coolant Alarm Activation Temperature
With EGR - Ratings Below 565 Horsepower...................................................................................107C [225F]
With EGR - Ratings of 565/600 Horsepower..................................................................................110C [230F]
Without EGR.................................................................................................................................110C [230F]
Maximum Allowable Top Tank Temperature
Ratings Below 565 Horsepower with EGR and without EGR Engines.............................................107C [225F]
Ratings of 565/600 Horsepower with EGR only..............................................................................110C [230F]
Minimum Recommended Top Tank Temperature
Minimum Temperature....................................................................................................................70C [160F]
Minimum Allowable Draw Down
With EGR............................................................................................................................................11 Percent
Without EGR............................................2.4 liters [2.5 qt] 10 Percent of System Capacity (whichever is greater)
Minimum Recommended Pressure Cap
With EGR....................................................................................................................................103 kPa [15 psi]
Without EGR..................................................................................................................................50 kPa [7 psi]
Preferred......................................................................................................................................69 kPa [10 psi]
Minimum Fill Rate
Without Low-Level Alarm......................................................................................................19 liters/min [5 gpm]
Maximum Deaeration Time
Maximum Time...................................................................................................................................25 minutes
Fan-on Coolant Temperature
With EGR........................................................................................................................................99C [210F]
Without EGR...................................................................................................................................99C [210F]
Fan-on Intake Air Temperature
With EGR........................................................................................................................................93C [200F]
Without EGR...................................................................................................................................88C [190F]
Shutter Opening Temperature
Coolant - with EGR..........................................................................................................................96C [205F]

Coolant - without EGR.....................................................................................................................85C [185F]
Intake Air - with EGR.....................................................................................................................104C [220F]
Intake Air - without EGR..................................................................................................................66C [150F]
Winterfronts
Air passage area.....................................................................................................................774 cm 2 [120 in 2]
Industrial and Generator Drive
Coolant Capacity
Engine Only..................................................................................................................................24 liters [25 qt]
Standard Modulating Thermostat
Temperature Range.....................................................................................................82 to 93C [180 to 200F]
Maximum Coolant Pressure
Exclusive of pressure cap - closed thermostat at the maximum no-load governed speed.............227 kPa [33 psi]
Coolant Alarm Activation Temperature
Ratings Below 565 Horsepower.....................................................................................................107C [225F]
Ratings of 565/600 Horsepower.....................................................................................................110C [230F]
Maximum Allowable Top Tank Temperature
Ratings Below 565 Horsepower.....................................................................................................107C [225F]
Ratings of 565/600 Horsepower.....................................................................................................110C [230F]
Power Generation, Standby...........................................................................................................110C [230F]
Power Generation, Prime..............................................................................................................104C [220F]
Minimum Recommended Top Tank Temperature
Minimum Temperature ...................................................................................................................70C [160F]
Minimum Allowable Draw Down.....................2.4 liters [2.5 qt] 10 Percent of System Capacity (whichever is greater)
Minimum Recommended Pressure Cap
Industrial........................................................................................................................................50 kPa [7 psi]
Power Generation.........................................................................................................................69 kPa [10 psi]
Minimum Fill Rate
Without low-level alarm........................................................................................................19 liters/min [5 gpm]
Maximum Deaeration
Time...................................................................................................................................................25 minutes
Fan-on Coolant Temperature
Temperature...................................................................................................................................95C [203F]
Fan-on Intake Air Temperature
Industrial Only.................................................................................................................................88C [190F]
Shutter Opening Temperature - Industrial Only
Coolant...........................................................................................................................................85C [185F]
Intake.............................................................................................................................................66C [150F]
Signature, ISX, and QSX15 Eng [...] Air Intake System
Air Intake System

Specifications
CAUTION
Engine intake air must be filtered to prevent dirt and debris from entering the engine. If air intake piping is
damaged or loose, unfiltered air will enter the engine and cause premature wear.
Maximum Temperature Rise between Ambient Air and Engine Air Inlet (ambient above 0C [32F])......17C [30F]
Maximum Inlet Restriction (clean filter) Normal-Duty Element..............................................250 mm H2O [10 in H2O]
Maximum Inlet Restriction (dirty filter).................................................................................635 mm H2O [25 in H2O]
Maximum Allowable Pressure Drop across Charge Air Cooler
psi..................................................................................................................................................14 kPa [2 psi]
Hg (mercury)........................................................................................................................102 mm Hg [4 in Hg]
Four-Step Wastegate Controller Solenoid Resistance..............................................................................7 to 8 ohms
Maximum Temperature Rise between Ambient Air and Engine Air Inlet (ambient above 0C [32F])
Industrial...........................................................................................................................................17C [30F]
Maximum Inlet Restriction (clean filter) Normal-Duty Element:
Industrial.......................................................................................................................250 mm H2O [10 in H2O]
Power Generation..........................................................................................................381 mm H2O [15 in H2O]
Maximum Inlet Restriction (dirty filter).................................................................................635 mm H2O [25 in H2O]
Maximum Allowable Pressure Drop across Charge Air Cooler:
Industrial
psi.............................................................................................................................................14 kPa [2 psi]
Hg (mercury)...................................................................................................................102 mm Hg [4 in Hg]
Maximum Allowable Pressure Drop from Turbocharger Outlet to Intake Manifold:
Power Generation:
psi.............................................................................................................................................14 kPa [2 psi]
Hg (mercury)...................................................................................................................102 mm Hg [4 in Hg]
Four-Step Wastegate Controller Solenoid Resistance..............................................................................7 to 8 ohms
Exhaust System Signature, ISX, and QSX15 Eng [...]
Exhaust System
Specifications
Maximum Allowable Exhaust Back Pressure Created by Piping and Silencer
Hg (mercury)..........................................................................................................................76 mm Hg [3 in Hg]
H2O (water).................................................................................................................1016 mm H2O [40 in H2O]
Exhaust Pipe Size (normally acceptable inside diameter).....................................................................127 mm [5 in]
Maximum Allowable Exhaust Back Pressure Created by Piping and Silencer:
Industrial:
Hg (mercury)....................................................................................................................76 mm Hg [3 in Hg]
H2O (water)............................................................................................................1016 mm H2O [40 in H2O]
Power Generation:
Hg (mercury)....................................................................................................................51 mm Hg [2 in Hg]
H2O (water)..............................................................................................................682 mm H2O [27 in H2O]
Exhaust Pipe Size (normally acceptable inside diameter):
Industrial........................................................................................................................................127 mm [5 in]
Power Generation...........................................................................................................................152 mm [6 in]
Automotive and Industrial:
Hg (mercury).................................................................................................................305 mm Hg [12 in Hg]
H20 (water).............................................................................................................4145 mm H20 [163 in H20]
Exhaust Pipe Size (normally acceptable inside diameter):
Automotive and Industrial...............................................................................................................127 mm [5 in]
Signature, ISX, and QSX15 Eng [...] Electrical System
Electrical System
Specifications
Minimum Recommended Battery Capacity:
System Ambient Temperatures

Voltage
-18C [0F]
Cold Reserve
Cranking Capacity*
Amperes Amperes
12 VDC
Automotive and Power Generation 1800 540
Industrial 2700 360
24 VDC**
Automotive and Power Generation 900 270
Industrial 1350 360
* The number of plates within a given battery size determines reserve capacity. Reserve capacity determines the
length of time that sustained cranking can occur.
**CCA ratings are based on two 12-VDC batteries in series.
A minimum of 6 VDC at the OEM connector is required to power up the ECM.
Minimum Battery Capacity:
12-VDC Starter......................................................400 ampere-hours to 1800 cold cranking amps @ -18C [0F]
24-VDC Starter........................................................200 ampere-hours to 900 cold cranking amps @ -18C [0F]
Maximum Starting Circuit Resistance:
12-VDC Starter................................................................................................................................0.00075 ohm
24-VDC Starter................................................................................................................................0.00200 ohm
Battery Cable Sizes - American Wire Gauge (maximum length in cranking motor circuit):
12-VDC:
No. 00..........................................................................................................................................3.7 m [12 ft]
No. 000........................................................................................................................................4.9 m [16 ft]
No. 0000 or Two No. 0*................................................................................................................6.1 m [20 ft]
Two No. 00...................................................................................................................................7.6 m [25 ft]
12-VDC High Output:
No. 00............................................................................................................................................2.1 m [7 ft]
No. 000..........................................................................................................................................2.7 m [9 ft]
No. 0000 or Two No. 0*................................................................................................................3.7 m [12 ft]
Two No. 00...................................................................................................................................4.3 m [14 ft]
24 to 32 VDC:
No. 00..........................................................................................................................................6.1 m [20 ft]
No. 000........................................................................................................................................8.2 m [27 ft]
No. 0000 or Two No. 0*..............................................................................................................10.7 m [35 ft]
Two No. 00.................................................................................................................................13.7 m [45 ft]
Minimum Ambient Air Temperature without Starting Aid..........................................................................-1C [30F]
Minimum Cranking Speed without Starting Aid.............................................................................................130 rpm
* Two strands of No. 0 cable can be used in place of one No. 0000 cable, provided that connections are carefully
made to make sure equal current flow exists in each parallel cable.
Compressed Air System Signature, ISX, and QSX15 Eng [...]
Compressed Air System

Specifications
Cummins 18.7 CFM Model
Cylinders................................................................................................................................................................1
Compressor Swept Volume @ 1250 RPM.................................................................................6.6 L/sec. [14.0 CFM]
Piston Displacement................................................................................................................318 cc [19.405 C.I.D.]
Bore................................................................................................................................................85 mm [3.346 in]
Stroke............................................................................................................................................ 56 mm [2.204 in]
Speed.................................................................................................................................................Engine Speed
Cooling.............................................................................................................................................Engine Coolant
Lubrication.............................................................................................................................Engine Lubricating Oil
Plumbing Line Sizes:
Coolant Inlet and Outlet................................................................................................................3/4 x 16 STOR
Air Inlet............................................................................................................................25.4 mm [1 in] Nominal
Air Outlet......................................................................................................................................M27 x 2 STOR
Unloader Port................................................................................................................................M10 x 1 STOR
Governor Mounting Direct.....................................................................................................................M8 x 1.25
Height, Overall (Approximate).......................................................................................................217.4 mm [8.56 in]
Width, Overall (Approximate) ..........................................................................................................142 mm [5.59 in]
Length, Overall (Approximate).........................................................................................................216 mm [8.50 in]
Weight (Approximate).......................................................................................................................15 Kg [35.0 lbs]
Signature, ISX, and QSX15 Eng [...] Engine Testing
Engine Testing
Specifications
Maintain the following limits during the engine test and run-in procedures:
Due to variations in ratings of different engine models, refer to the specific Engine Rating Data Sheet for the particular
engine model being tested.
Charge Air Cooler Restriction (maximum)
Mercury...........................................................................................................................76.2 mm Hg [3.0 in Hg]
Pounds Force...........................................................................................................................10.3 kPa [1.5 psi]
Intake Restriction (maximum at advertised horsepower)
Clean Air Filter.........................................................................................................254.0 mm H2O [10.0 in H2O]
Dirty Air Filter..........................................................................................................635.0 mm H2O [25.0 in H2O]
Exhaust Back Pressure (maximum).......................................................................................76.2 mm Hg [3.0 in Hg]
Oil Pressure
Low Idle (minimum)...............................................................................................................103.0 kPa [15.0 psi]
Oil Pressure Range......................................................................................241.0 to 276.0 kPa [35.0 to 40.0 psi]
Cylinder Block Coolant Pressure (closed thermostat, maximum).................................................262.0 kPa [38.0 psi]
Coolant Temperature
Operating Temperature (maximum)...............................................................................................107C [225F]
Fuel Inlet Temperature (maximum).......................................................................................................71C [160F]
Fuel Inlet Maximum Restriction
Clean Fuel Filter............................................................................................................203.2 mm Hg [8.0 in Hg]
Dirty Fuel Filter..................................................................................................................304.8 mm [12.0 in Hg]
Pressure Side Fuel Filter Restriction (maximum).........................................................................517.0 kPa [75.0 psi]
Fuel Drain Line Restriction (maximum)................................................................................228.6 mm Hg [9.0 in Hg]
Blowby (maximum at advertised or torque peak rpm) with 9-mm [0.354-in] orifice
New or rebuilt engines (maximum) less than 100,000 miles.........................................305 mm H2O [12.0 in H2O]
Used Engine (maximum) greater than 100,000 miles...................................................457 mm H2O [18.0 in H2O]
Maintain the following limits during the engine test and run-in procedures:
Due to variations in ratings of different engine models, refer to the specific Engine Rating Data Sheet for the particular
engine model being tested.
Charge Air Cooler Restriction (maximum)
Mercury...........................................................................................................................76.2 mm Hg [3.0 in Hg]
Pounds Force...........................................................................................................................10.3 kPa [1.5 psi]
Intake Restriction (maximum at advertised horsepower)
Clean Air Filter.........................................................................................................254.0 mm H2O [10.0 in H2O]
Dirty Air Filter..........................................................................................................635.0 mm H2O [25.0 in H2O]
Exhaust Back Pressure (maximum)...................................................................................304.8 mm Hg [12.0 in Hg]
Oil Pressure
Low Idle (minimum)...............................................................................................................103.0 kPa [15.0 psi]
Oil Pressure Range......................................................................................241.0 to 276.0 kPa [35.0 to 40.0 psi]
Cylinder Block Coolant Pressure (closed thermostat, maximum)..................................331 kPa [48 psi] @ 1600 RPM
Coolant Temperature
Operating Temperature (maximum)...............................................................................................107C [225F]
Fuel Inlet Temperature (maximum).......................................................................................................71C [160F]
Fuel Inlet Maximum Restriction
Clean Fuel Filter............................................................................................................203.2 mm Hg [8.0 in Hg]
Dirty Fuel Filter..................................................................................................................304.8 mm [12.0 in Hg]
Pressure Side Fuel Filter Restriction (maximum).........................................................................517.0 kPa [75.0 psi]
Fuel Drain Line Restriction (maximum)................................................................................228.6 mm Hg [9.0 in Hg]
Blowby (maximum at advertised or torque peak rpm) with 9-mm [0.354-in] orifice
New or rebuilt engines (maximum) less than 100,000 miles.........................................305 mm H2O [12.0 in H2O]
Used Engine (maximum) greater than 100,000 miles...................................................457 mm H2O [18.0 in H2O]
Drive Belt Tension Signature, ISX, and QSX15 Eng [...]
Drive Belt Tension

Tension Chart
SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
Click-type Burroughs N lbf N lbf
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
31 rib - 3164750 1668 375 1330 to 1560 300 to 350
NOTE: This chart does not apply to automatic belt tensioners.
* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
Signature, ISX, and QSX15 Eng [...] Fraction, Decimal, Millimeter Conversions
Fraction, Decimal, Millimeter Conversions

Conversion Chart
Fraction inch mm Fraction inch mm
1/64 0.0156 0.397 33/64 0.5156 13.097
1/32 0.0313 0.794 17/32 0.5313 13.494
3/64 0.0469 1.191 35/64 0.5469 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.0781 1.984 37/64 0.5781 14.684
3/32 0.0938 2.381 19/32 0.5938 15.081
7/64 0.1094 2.778 39/64 0.6094 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.1406 3.572 41/64 0.6406 16.272
5/32 0.1563 3.969 21/32 0.6563 16.669
11/64 0.1719 4.366 43/64 0.6719 17.066
3/16 0.1875 4.763 11/16 0.6875 17.463
13/64 0.2031 5.159 45/64 0.7031 17.859
7/32 0.2188 5.556 23/32 0.7188 18.256
15/64 0.2344 5.953 47/64 0.7344 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.2656 6.747 49/64 0.7656 19.447
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Conversion Factor: 1 inch = 25.4 mm

Weights and Measures - Conversion Factors Signature, ISX, and QSX15 Eng [...]
Weights and Measures - Conversion Factors

Conversion Chart
From U.S. From Metric
Customary To U.S.
Quantity U.S. Customary Metric
To Metric Customary
Multiply By Multiply By
Unit Name Abbreviation Unit Name Abbreviation
sq. inch in2 sq. millimeters mm2 645.16 0.001550
Area sq. centimeters cm2 6.452 0.155
sq. foot ft2 sq. meter m2 0.0929 10.764
Fuel pounds per lb/hp-hr grams per kilowatt g/kW-hr 608.277 0.001645
Consumption horsepower hour hour
Fuel miles per gallon mpg kilometers per liter km/l 0.4251 2.352
Performance gallons per mile gpm liters per kilometer l/km 2.352 0.4251
Force pounds force lbf Newton N 4.4482 0.224809
inch in millimeters mm 25.40 0.039370
Length
foot ft millimeters mm 304.801 0.00328
Power horsepower hp kilowatt kW 0.746 1.341
pounds force per psi kilopascal kPa 6.8948 0.145037
sq. inch
inches of mercury in Hg kilopascal kPa 3.3769 0.29613
inches of water in H2O kilopascal kPa 0.2488 4.019299
inches of mercury in Hg millimeters of mm Hg 25.40 0.039370
Pressure mercury
inches of water in H2O millimeters of mm H2O 25.40 0.039370
water
bars bars kilopascals kPa 100.001 0.00999
bars bars millimeters of mm Hg 750.06 0.001333
mercury
Temperature fahrenheit F centigrade C (F-32) 1.8 (1.8 x C) +32
pound force per ft-lb Newton-meter Nm 1.35582 0.737562
foot
Torque
pound force per in-lb Newton-meter Nm 0.113 8.850756
inch
Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214
gallon (U.S.) gal. liter l 3.7853 0.264179
Volume: gallon (Imp*) gal. liter l 4.546 0.219976
liquid
displacement
cubic inch in3 liter l 0.01639 61.02545
cubic inch in3 cubic centimeter cm3 16.387 0.06102
Weight (mass) pounds (avoir.) lb kilograms kg 0.4536 2.204623
British Thermal BTU joules J 1054.5 0.000948
Unit
Work British Thermal BTU kilowatt-hour kW-hr 0.000293 3414
Unit
horsepower hours hp-hr kilowatt-hour kW-hr 0.746 1.341
Signature, ISX, and QSX15 Eng [...] Capscrew Markings and Torque Values
Capscrew Markings and Torque Values

General Information
CAUTION
When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew
being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:
Always use the torque values listed in the following tables when specific torque values are not available.
Do not use the torque values in place of those specified in other sections of this manual.
The torque values in the table are based on the use of lubricated threads.
When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
Always use the torque values listed in the following tables when specific torque values are not available.
Do not use the torque values in place of those specified in other sections of this manual.
The torque values in the table are based on the use of lubricated threads.
When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
Capscrew Markings and Torque Values - Metric
Body Torque Torque Torque

Size
Diamet Cast Iron Aluminium Cast Iron Aluminium Cast Iron Aluminium
er
mm Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb
6 9 5 7 4 13 10 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
Capscrew Markings and Torque Values Signature, ISX, and QSX15 Eng [...]
Body Torque Torque Torque

Size
Diamet Cast Iron Aluminium Cast Iron Aluminium Cast Iron Aluminium
er
mm Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb
8 23 17 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 65 50 30 25 70 50 30 25
12 80 60 55 40 115 85 55 40 125 95 55 40
14 125 90 90 65 180 133 90 65 195 145 90 65
16 195 140 140 100 280 200 140 100 290 210 140 100
18 280 200 180 135 390 285 180 135 400 290 180 135
20 400 290 550 400
Capscrew Markings and Torque Values - U.S. Customary
Capscrew Cast Iron Aluminium Cast Iron Aluminium

Body Size
Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
1/4 - 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
5/16 - 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
3/8 - 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
7/16 - 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
1/2 - 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
9/16 - 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
5/8 - 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
3/4 - 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
7/8 - 14 530 390 420 310 825 610 420 310
1-8 720 530 570 420 1100 820 570 420
1 - 14 800 590 650 480 1200 890 650 480
Signature, ISX, and QSX15 Eng [...] Newton-Meter to Foot-Pound Conversions
Newton-Meter to Foot-Pound Conversions

Conversion Chart
Nm ft-lb Nm ft-lb Nm ft-lb
1 9 in-lb 55 41 155 114
5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
11 97 in-lb 90 66 190 140
12 106 in-lb 95 70 195 144
14 124 in-lb 100 74 200 148
15 133 in-lb 105 77 205 151
16 142 in-lb 110 81 210 155
18 159 in-lb 115 85 215 159
20 15 ft-lb 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
Pipe Plug Torque Values Signature, ISX, and QSX15 Eng [...]
Pipe Plug Torque Values

Torque Table
Size Torque Torque
Thread Actual Thread O.D. In Aluminum Components In Cast Iron or
Steel Components
in in Nm ft-lb Nm ft-lb
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100
Signature, ISX, and QSX15 Eng [...] Tap-Drill Chart - U.S. Customary and Metric
Tap-Drill Chart - U.S. Customary and Metric

General Information
NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for
approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60%
range as these sizes will provide about 90% of the potential holding power. Drill sizes in the 75% range are
recommended for shallow hole tapping (less than 1 1/2 times the hole diameter) in soft metals and mild steel.
Tap-Drill Chart - U.S. Customary and Metric Signature, ISX, and QSX15 Eng [...]
Notes
Index
Page X-1
About the Manual ..........................................................................................i-1 Preparatory Steps.................................................................................11-120

General Information.....................................................................................i-1 Remove................................................................................................11-120
Acronyms and Abbreviations ......................................................................i-15 Aftertreatment Testing .............................................................................14-42
General Information...................................................................................i-15 Finishing Steps.......................................................................................14-48
Additional Service Literature .......................................................................L-1 General Information................................................................................14-42
General Information....................................................................................L-1 Preparatory Steps...................................................................................14-45
Aftertreatment Adapter Pipe ....................................................................11-93 Setup......................................................................................................14-46
Clean and Inspect for Reuse...................................................................11-95 Test........................................................................................................14-46
Finishing Steps.......................................................................................11-96 Air Compressor ..........................................................................................12-9
Install......................................................................................................11-96 Clean and Inspect for Reuse...................................................................12-10
Preparatory Steps...................................................................................11-93 Finishing Steps.......................................................................................12-12
Remove..................................................................................................11-94 Install......................................................................................................12-10
Aftertreatment Diesel Oxidation Catalyst ..............................................11-113 Preparatory Steps.....................................................................................12-9
Clean and Inspect for Reuse.................................................................11-115 Remove....................................................................................................12-9
Finishing Steps.....................................................................................11-119 Air Compressor Carbon Buildup ................................................................12-1
General Information...............................................................................11-113 Clean........................................................................................................12-2
Install....................................................................................................11-118 Initial Check..............................................................................................12-1
Preparatory Steps.................................................................................11-113 Air Compressor Coolant Lines ...................................................................12-3
Remove................................................................................................11-114 Finishing Steps.........................................................................................12-6
Aftertreatment Diesel Particulate Filter ...................................................11-82 Initial Check..............................................................................................12-3
Adjust.....................................................................................................11-87 Inspect for Reuse......................................................................................12-4
Finishing Steps.......................................................................................11-88 Install........................................................................................................12-4
General Information................................................................................11-82 Preparatory Steps.....................................................................................12-3
Inspect for Reuse....................................................................................11-84 Remove....................................................................................................12-4
Install......................................................................................................11-87 Air Compressor Cylinder Head, Single Cylinder .......................................12-6
Maintenance Check................................................................................11-86 Finishing Steps.........................................................................................12-8
Preparatory Steps...................................................................................11-83 Initial Check..............................................................................................12-6
Remove..................................................................................................11-83 Install........................................................................................................12-7
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Preparatory Steps.....................................................................................12-7
Mounting Bracket .....................................................................................11-99 Remove....................................................................................................12-7
Clean and Inspect for Reuse.................................................................11-101 Air Compressor Unloader and Valve Assembly ........................................12-8
Finishing Steps.....................................................................................11-103 Preparatory Steps.....................................................................................12-8
General Information................................................................................11-99 Air Governor (Air Compressor Pumps Continuously) .............................12-13
Install....................................................................................................11-102 Initial Check............................................................................................12-13
Preparatory Steps.................................................................................11-100 Air Governor (Air Compressor Will Not Pump) ........................................12-12
Remove................................................................................................11-100 Inspect for Reuse....................................................................................12-12
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes Remove..................................................................................................12-12
.................................................................................................................11-103 Air in Fuel .....................................................................................................6-2
Clean and Inspect for Reuse.................................................................11-104 Initial Check................................................................................................6-2
General Information...............................................................................11-103 Air Intake Connection ...............................................................................10-59
Install....................................................................................................11-106 Clean and Inspect for Reuse...................................................................10-61
Remove................................................................................................11-104 All Applications...................................................................................10-61
Aftertreatment Fuel Injector .....................................................................11-89 Finishing Steps.......................................................................................10-62
Clean and Inspect for Reuse...................................................................11-90 Automotive, Industrial with CM570 and Power Generation without CM570....
Finishing Steps.......................................................................................11-93 10-62
Install......................................................................................................11-92 Automotive with CM870......................................................................10-63
Preparatory Steps...................................................................................11-89 Automotive With CM871......................................................................10-63
Remove..................................................................................................11-89 Install......................................................................................................10-61
Aftertreatment Fuel Injector Coolant Test .............................................11-152 Automotive, Industrial with CM570 and Power Generation without CM570....
Finishing Steps.....................................................................................11-154 10-61
Preparatory Steps.................................................................................11-152 Automotive with CM870......................................................................10-62
Setup....................................................................................................11-153 Automotive With CM871......................................................................10-62
Test......................................................................................................11-153 Preparatory Steps...................................................................................10-59
Aftertreatment Fuel Injector Flow ..........................................................11-140 Automotive, Industrial with CM570 and Power Generation without CM570....
Finishing Steps.....................................................................................11-145 10-59
Flow Test..............................................................................................11-143 Automotive with CM870......................................................................10-59
Initial Check..........................................................................................11-140 Automotive With CM871......................................................................10-59
Leak Test..............................................................................................11-144 Remove..................................................................................................10-60
Setup....................................................................................................11-140 Automotive with CM870......................................................................10-60
Aftertreatment Fuel Shutoff Manifold ....................................................11-134 Automotive With CM871......................................................................10-60
Clean and Inspect for Reuse.................................................................11-136 Automotive, Industrial with CM570 and Power Generation without CM570....
Finishing Steps.....................................................................................11-139 10-60
Install....................................................................................................11-138 Air Intake Restriction ...............................................................................10-14
Preparatory Steps.................................................................................11-134 Measure..................................................................................................10-14
Remove................................................................................................11-134 Air Intake System .......................................................................................V-77
Aftertreatment Injector Lines .................................................................11-123 Specifications...........................................................................................V-77
Clean and Inspect for Reuse.................................................................11-127 Air Leaks, Air Intake and Exhaust Systems ..............................................10-3
Finishing Steps.....................................................................................11-133 Initial Check..............................................................................................10-3
Install....................................................................................................11-130 Automotive With CM871........................................................................10-5
Preparatory Steps.................................................................................11-123 Air Leaks, Compressed Air System .........................................................12-14
Remove................................................................................................11-124 Initial Check............................................................................................12-14
Aftertreatment Inlet and Outlet ..............................................................11-107 Air Pressure Relief Valve .........................................................................12-15
Assemble..............................................................................................11-110 Initial Check............................................................................................12-15
Clean and Inspect for Reuse.................................................................11-110 Alternator ....................................................................................................13-2
Disassemble.........................................................................................11-109 Clean and Inspect for Reuse.....................................................................13-5
Finishing Steps.....................................................................................11-112 Driven by Cooling Fan Drive Belt...........................................................13-5
General Information...............................................................................11-107 Finishing Steps.........................................................................................13-6
Install....................................................................................................11-111 Driven by Cooling Fan Drive Belt...........................................................13-6
Preparatory Steps.................................................................................11-108 Automotive with CM870........................................................................13-6
Remove................................................................................................11-109 Initial Check..............................................................................................13-2
Aftertreatment System ...........................................................................11-119 Alternator Wiring Test...........................................................................13-2
Assemble..............................................................................................11-122 Alternator Voltage Output Check...........................................................13-2
Clean and Inspect for Reuse.................................................................11-121 Alternator Current Output Test..............................................................13-3
Disassemble.........................................................................................11-121 Install........................................................................................................13-6
Finishing Steps.....................................................................................11-123 Driven by Cooling Fan Drive Belt...........................................................13-6
General Information...............................................................................11-119 Automotive with CM870........................................................................13-6
Install....................................................................................................11-122 Preparatory Steps.....................................................................................13-4
Index
Page X-2
Driven by Cooling Fan Drive Belt...........................................................13-4 Automotive Applications......................................................................13-25

Automotive with CM870........................................................................13-4 Industrial and Power Generation.........................................................13-26
Remove....................................................................................................13-5 Remove..................................................................................................13-26
Driven by Cooling Fan Drive Belt...........................................................13-5 Automotive Applications......................................................................13-26
Automotive with CM870........................................................................13-5 Industrial and Power Generation.........................................................13-26
Alternator Idler Pulley ..............................................................................13-24 Capscrew Markings and Torque Values ....................................................V-85
Clean......................................................................................................13-24 Capscrew Markings and Torque Values - Metric........................................V-85
Inspect for Reuse....................................................................................13-25 Capscrew Markings and Torque Values - U.S. Customary.........................V-86
Install......................................................................................................13-25 General Information..................................................................................V-85
Remove..................................................................................................13-24 Centinel System .......................................................................................7-58
Alternator Pulley ........................................................................................13-8 General Information..................................................................................7-58
Clean........................................................................................................13-9 Charge-Air Cooler .......................................................................................10-9
Inspect for Reuse......................................................................................13-9 Clean........................................................................................................10-9
Install........................................................................................................13-9 Inspect for Reuse......................................................................................10-9
Remove....................................................................................................13-8 Leak Test................................................................................................10-10
Alternator Spacer .....................................................................................13-22 Pressure Differential Test........................................................................10-12
Clean and Inspect for Reuse...................................................................13-23 Temperature Differential Test..................................................................10-11
Finishing Steps.......................................................................................13-24 Compressed Air System ............................................................................V-80
Install......................................................................................................13-23 Specifications...........................................................................................V-80
Preparatory Steps...................................................................................13-22 Cummins 18.7 CFM Model...................................................................V-80
Remove..................................................................................................13-22 Coolant Filter ................................................................................................8-5
Alternator/Refrigerant Compressor Mounting Bracket .............................9-13 General Information....................................................................................8-5
Finishing Steps.........................................................................................9-16 Install..........................................................................................................8-6
Automotive with CM870........................................................................9-16 Remove......................................................................................................8-6
Automotive with CM570........................................................................9-16 Coolant Filter Valve ......................................................................................8-7
Inspect for Reuse......................................................................................9-14 Clean..........................................................................................................8-8
Automotive with CM870........................................................................9-14 Inspect for Reuse........................................................................................8-8
Automotive with CM570........................................................................9-14 Install..........................................................................................................8-8
Install........................................................................................................9-15 Remove......................................................................................................8-7
Automotive with CM870........................................................................9-15 Coolant Thermostat .....................................................................................8-9
Automotive with CM570........................................................................9-15 Finishing Steps.........................................................................................8-14
Preparatory Steps.....................................................................................9-13 Inspect for Reuse......................................................................................8-12
Automotive with CM870........................................................................9-13 Out-of-Chassis Opening Temperature Test............................................8-12
Automotive with CM570........................................................................9-13 Install........................................................................................................8-13
Remove....................................................................................................9-13 Leak Test....................................................................................................8-9
Automotive with CM870........................................................................9-13 In-Chassis Opening Temperature Test..................................................8-11
Automotive with CM570........................................................................9-14 Preparatory Steps.....................................................................................8-11
Batteries ...................................................................................................13-10 Remove....................................................................................................8-11
Initial Check............................................................................................13-10 Coolant Thermostat Housing .....................................................................8-15
Battery Cables and Connections .............................................................13-11 Finishing Steps.........................................................................................8-21
Initial Check............................................................................................13-11 Inspect for Reuse......................................................................................8-18
Belt Tensioner, Automatic (Alternator) ....................................................13-20 Install........................................................................................................8-18
Clean......................................................................................................13-20 Single Thermostat.................................................................................8-18
Inspect for Reuse....................................................................................13-20 Dual Thermostat...................................................................................8-19
Install......................................................................................................13-21 Preparatory Steps.....................................................................................8-15
Automotive Applications......................................................................13-21 Remove....................................................................................................8-16
Remove..................................................................................................13-20 Single Thermostat.................................................................................8-16
Automotive Applications......................................................................13-20 Dual Thermostat...................................................................................8-16
Belt Tensioner, Automatic (Water Pump) ..................................................8-68 Coolant Thermostat Seal ...........................................................................8-21
Clean and Inspect for Reuse.....................................................................8-71 Inspect for Reuse......................................................................................8-22
All Applications.....................................................................................8-71 Install........................................................................................................8-22
CM570..................................................................................................8-72 Single Seal...........................................................................................8-22
Finishing Steps.........................................................................................8-74 Dual Seal..............................................................................................8-22
Drives Alternator...................................................................................8-74 Remove....................................................................................................8-21
Initial Check..............................................................................................8-68 Single Seal...........................................................................................8-21
All Applications.....................................................................................8-68 Dual Seal..............................................................................................8-22
Install........................................................................................................8-72 Coolant Vent Lines .....................................................................................8-23
Drives Alternator...................................................................................8-72 Initial Check..............................................................................................8-23
Automotive Applications........................................................................8-72 Cooling System ..........................................................................................8-23
Industrial and Power Generation...........................................................8-73 Drain.........................................................................................................8-23
Preparatory Steps.....................................................................................8-69 Fill............................................................................................................8-26
Drives Alternator...................................................................................8-69 Flush........................................................................................................8-24
Remove....................................................................................................8-69 Pressure Test...........................................................................................8-31
Drives Alternator...................................................................................8-69 Cooling System ..........................................................................................V-75
Automotive Applications........................................................................8-69 General Information..................................................................................V-75
Industrial and Power Generation...........................................................8-70 Specifications...........................................................................................V-75
Belt Tensioner, Refrigerant Compressor, Automatic ..................................9-5 Automotive Applications.......................................................................V-75
Finishing Steps...........................................................................................9-6 Industrial and Generator Drive..............................................................V-76
With Water Pump and Refrigerant Compressor Belt Routing...................9-6 Cooling System - Air or Combustion Gas Test .........................................8-32
Initial Check................................................................................................9-5 Initial Check..............................................................................................8-32
With Water Pump and Refrigerant Compressor Belt Routing...................9-5 Air in Cooling System............................................................................8-32
Install..........................................................................................................9-6 Leak Test..................................................................................................8-34
With Water Pump and Refrigerant Compressor Belt Routing...................9-6 Fan, Shutter, or Heater Air Control Valve..............................................8-34
Preparatory Steps.......................................................................................9-6 Air Compressor.....................................................................................8-34
With Water Pump and Refrigerant Compressor Belt Routing...................9-6 Combustion Gas Leak...........................................................................8-35
Remove......................................................................................................9-6 Overflow Method...................................................................................8-38
With Water Pump and Refrigerant Compressor Belt Routing...................9-6 Crankcase Blowby, Measure ....................................................................14-30
Bracket, Idler Pulley and Alternator Belt Tensioner ...............................13-25 General Information................................................................................14-30
Clean......................................................................................................13-26 Initial Check............................................................................................14-34
Finishing Steps.......................................................................................13-28 Measure..................................................................................................14-35
Automotive Applications......................................................................13-28 Crankcase Breather (External) .....................................................................3-2
Industrial and Power Generation.........................................................13-28 Assemble....................................................................................................3-4
Inspect for Reuse....................................................................................13-27 Automotive With CM871.........................................................................3-4
Install......................................................................................................13-27 Clean and Inspect for Reuse.......................................................................3-3
Automotive Applications......................................................................13-27 Automotive with CM870..........................................................................3-3
Industrial and Power Generation.........................................................13-27 Automotive With CM871.........................................................................3-4
Preparatory Steps...................................................................................13-25 Disassemble...............................................................................................3-3
Index
Page X-3
Automotive With CM871.........................................................................3-3 Remove..................................................................................................11-21

Install..........................................................................................................3-4 EGR Cooler Connection ...........................................................................11-48
Automotive with CM870..........................................................................3-4 Clean and Inspect for Reuse...................................................................11-48
Automotive With CM871.........................................................................3-5 Finishing Steps.......................................................................................11-50
Remove......................................................................................................3-2 Install......................................................................................................11-50
Automotive with CM870..........................................................................3-2 Preparatory Steps...................................................................................11-48
Automotive With CM871.........................................................................3-2 Remove..................................................................................................11-48
Crankcase Breather (Internal) ......................................................................3-5 EGR Cooler Coolant Lines .......................................................................11-70
Clean and Inspect for Reuse.......................................................................3-6 Clean and Inspect for Reuse...................................................................11-73
Finishing Steps...........................................................................................3-8 Finishing Steps.......................................................................................11-77
Install..........................................................................................................3-7 Install......................................................................................................11-75
Preparatory Steps.......................................................................................3-5 Preparatory Steps...................................................................................11-70
Remove......................................................................................................3-6 Remove..................................................................................................11-71
Crankcase Breather Element .....................................................................3-32 EGR Differential Pressure Sensor Adapter ..............................................11-67
Install........................................................................................................3-33 Clean and Inspect for Reuse...................................................................11-67
Remove....................................................................................................3-32 Finishing Steps.......................................................................................11-68
Cummins Customized Parts Catalog ...........................................................L-3 Install......................................................................................................11-68
General Information....................................................................................L-3 Preparatory Steps...................................................................................11-67
Ordering the Customized Parts Catalog......................................................L-3 Remove..................................................................................................11-67
Ordering by Telephone...........................................................................L-3 EGR Differential Pressure Sensor Tubes ................................................11-61
Ordering On-Line....................................................................................L-3 Clean and Inspect for Reuse...................................................................11-61
Cylinder Head ...............................................................................................2-5 Automotive with CM870......................................................................11-61
Assemble..................................................................................................2-32 Automotive With CM871......................................................................11-62
Clean........................................................................................................2-10 Finishing Steps.......................................................................................11-65
Clean and Inspect for Reuse.....................................................................2-21 Automotive with CM870......................................................................11-65
Disassemble.............................................................................................2-17 Automotive With CM871......................................................................11-65
Finishing Steps.........................................................................................2-38 Install......................................................................................................11-64
General Information....................................................................................2-5 Automotive with CM870......................................................................11-64
Initial Check................................................................................................2-6 Automotive With CM871......................................................................11-64
Inspect for Reuse........................................................................................2-9 Preparatory Steps...................................................................................11-61
Install........................................................................................................2-37 Automotive With CM871......................................................................11-61
Leak Test..................................................................................................2-11 Remove..................................................................................................11-61
Magnetic Crack Inspect.............................................................................2-30 Automotive with CM870......................................................................11-61
Measure...................................................................................................2-27 Automotive With CM871......................................................................11-61
Preparatory Steps.......................................................................................2-7 EGR Mixer .................................................................................................11-37
Remove......................................................................................................2-8 Clean and Inspect for Reuse...................................................................11-38
Vacuum Test.............................................................................................2-15 Finishing Steps.......................................................................................11-39
Drive Belt Tension .....................................................................................V-82 Install......................................................................................................11-39
Tension Chart...........................................................................................V-82 Preparatory Steps...................................................................................11-37
Drive Belt, Alternator .................................................................................13-7 Remove..................................................................................................11-38
Adjust.......................................................................................................13-8 EGR Valve .................................................................................................11-40
Inspect for Reuse......................................................................................13-7 Assemble................................................................................................11-45
Install........................................................................................................13-7 Clean and Inspect for Reuse...................................................................11-42
Remove....................................................................................................13-7 Disassemble...........................................................................................11-42
Drive Belt, Cooling Fan ................................................................................8-3 Finishing Steps.......................................................................................11-47
Clean and Inspect for Reuse.......................................................................8-3 Install......................................................................................................11-45
Drives Alternator.....................................................................................8-3 Preparatory Steps...................................................................................11-40
Install..........................................................................................................8-3 Remove..................................................................................................11-41
Drives Alternator.....................................................................................8-3 EGR Valve Coolant Lines .........................................................................11-68
Remove......................................................................................................8-3 Clean and Inspect for Reuse...................................................................11-69
Drives Alternator.....................................................................................8-3 Finishing Steps.......................................................................................11-70
Drive Belt, Refrigerant Compressor ............................................................9-3 Install......................................................................................................11-69
Clean and Inspect for Reuse.......................................................................9-3 Preparatory Steps...................................................................................11-68
With Water Pump and Refrigerant Compressor Belt Routing...................9-3 Remove..................................................................................................11-69
Finishing Steps...........................................................................................9-4 EGR Valve Mounting Bracket ...................................................................11-96
With Water Pump and Refrigerant Compressor Belt Routing...................9-4 Clean and Inspect for Reuse...................................................................11-97
Install..........................................................................................................9-4 Finishing Steps.......................................................................................11-98
With Water Pump and Refrigerant Compressor Belt Routing...................9-4 Install......................................................................................................11-98
Preparatory Steps.......................................................................................9-3 Preparatory Steps...................................................................................11-96
With Water Pump and Refrigerant Compressor Belt Routing...................9-3 Automotive With CM871......................................................................11-96
Remove......................................................................................................9-3 Remove..................................................................................................11-97
With Water Pump and Refrigerant Compressor Belt Routing...................9-3 Electrical System .......................................................................................V-79
Drive Belt, Water Pump ...............................................................................8-4 Specifications...........................................................................................V-79
Adjust.........................................................................................................8-5 Engine Brake Assembly .............................................................................20-1
Inspect for Reuse........................................................................................8-4 Adjust.......................................................................................................20-4
Install..........................................................................................................8-5 Initial Check..............................................................................................20-2
Remove......................................................................................................8-4 Engine Brake Solenoid..........................................................................20-2
Dynamometer Worksheet ...........................................................................14-4 Engine Brake Rocker Lever..................................................................20-3
Worksheet................................................................................................14-4 Resistance Check.....................................................................................20-1
ECM Cooling Plate, Fuel Cooled ..................................................................6-2 Voltage Check..........................................................................................20-1
Clean and Inspect for Reuse.......................................................................6-3 Engine Brake Control Valve .....................................................................20-13
Finishing Steps...........................................................................................6-5 Inspect for Reuse....................................................................................20-14
Install..........................................................................................................6-5 Install......................................................................................................20-14
Preparatory Steps.......................................................................................6-2 Remove..................................................................................................20-13
Remove......................................................................................................6-3 Engine Brake Piston .................................................................................20-15
EGR Connection Tubes ............................................................................11-51 Inspect for Reuse....................................................................................20-16
Clean and Inspect for Reuse...................................................................11-55 Install......................................................................................................20-16
Finishing Steps.......................................................................................11-60 Remove..................................................................................................20-15
Install......................................................................................................11-57 Engine Brake Solenoid Valve ...................................................................20-10
Preparatory Steps...................................................................................11-51 Finishing Steps.......................................................................................20-11
Remove..................................................................................................11-52 Inspect for Reuse....................................................................................20-10
EGR Cooler ...............................................................................................11-19 Install......................................................................................................20-11
Clean and Inspect for Reuse...................................................................11-22 Preparatory Steps...................................................................................20-10
Finishing Steps.......................................................................................11-36 Remove..................................................................................................20-10
Install......................................................................................................11-33 Engine Brake Wiring Harness ..................................................................20-11
Preparatory Steps...................................................................................11-19 Inspect for Reuse....................................................................................20-12
Pressure Test..........................................................................................11-29 Install......................................................................................................20-13
Index
Page X-4
Threaded Brake Pass-Through............................................................20-13 Automotive, Industrial with CM570 and Power Generation without CM570....
Non-Threaded Brake Pass-Through....................................................20-13 11-6
Remove..................................................................................................20-11 Automotive With CM871........................................................................11-7
Threaded Brake Pass-Through............................................................20-11 Remove....................................................................................................11-7
Non-Threaded Brake Pass-Through....................................................20-12 Repair.......................................................................................................11-4
Engine Lifting Brackets ..............................................................................16-2 Automotive with CM870........................................................................11-4
Clean and Inspect for Reuse.....................................................................16-3 Exhaust Restriction ..................................................................................11-17
Finishing Steps.........................................................................................16-4 Initial Check............................................................................................11-17
Install........................................................................................................16-3 Exhaust System .........................................................................................V-78
Preparatory Steps.....................................................................................16-2 Specifications...........................................................................................V-78
Remove....................................................................................................16-2 Automotive Applications.......................................................................V-78
Engine Mounts ..........................................................................................16-41 Industrial and Generator Drive..............................................................V-78
General Information................................................................................16-41 Automotive With CM871.......................................................................V-78
Inspect for Reuse....................................................................................16-43 Exhaust System Diagnostics ..................................................................11-145
Install......................................................................................................16-44 General Information...............................................................................11-145
Remove..................................................................................................16-43 Fan Clutch, On-Off .....................................................................................8-39
Engine Run-in (Chassis Dynamometer) ...................................................14-12 Initial Check..............................................................................................8-39
Run-In Instructions..................................................................................14-12 With Low Temperature Fan-On Control.................................................8-39
Engine Run-in (Engine Dynamometer) .....................................................14-25 With High Temperature Fan On............................................................8-40
Run-In Instructions..................................................................................14-25 Fan Drive Idler Pulley Assembly ................................................................8-42
Engine Run-in (Without Dynamometer) ...................................................14-16 Finishing Steps.........................................................................................8-43
Run-In Instructions..................................................................................14-16 Install........................................................................................................8-42
Engine Support Bracket, Front ..................................................................16-4 Preparatory Steps.....................................................................................8-42
Clean and Inspect for Reuse.....................................................................16-5 Remove....................................................................................................8-42
Finishing Steps.........................................................................................16-6 Fan Hub, Belt Driven ..................................................................................8-43
Install........................................................................................................16-6 Clean and Inspect for Reuse.....................................................................8-44
Preparatory Steps.....................................................................................16-4 Automotive with CM870........................................................................8-44
Remove....................................................................................................16-4 Automotive, Industrial with CM570 and Power Generation without CM570....
Engine Testing ...........................................................................................V-81 8-45
Specifications...........................................................................................V-81 Finishing Steps.........................................................................................8-46
Engine Testing (Chassis Dynamometer) ...................................................14-6 Automotive with CM870........................................................................8-46
Setup........................................................................................................14-6 Automotive with CM570........................................................................8-47
Test..........................................................................................................14-9 Industrial CM570 and Power Generation without CM570.......................8-47
Engine Testing (Engine Dynamometer) ...................................................14-17 Install........................................................................................................8-45
Setup......................................................................................................14-17 Automotive with CM870........................................................................8-45
Test........................................................................................................14-22 Automotive with CM570........................................................................8-46
Engine Testing (In Chassis) .....................................................................14-29 Industrial CM570 and Power Generation without CM570.......................8-46
Setup......................................................................................................14-29 Preparatory Steps.....................................................................................8-43
Engine Testing (Portable Dynamometer or Load Bank) ..........................14-29 Automotive with CM870........................................................................8-43
General Information................................................................................14-29 Automotive with CM570........................................................................8-43
Exhaust Gas Pressure Sensor Adapter ...................................................11-80 Industrial CM570 and Power Generation without CM570.......................8-43
Finishing Steps.......................................................................................11-81 Remove....................................................................................................8-44
Automotive with CM870......................................................................11-81 Automotive with CM870........................................................................8-44
Inspect for Reuse....................................................................................11-80 Automotive with CM570........................................................................8-44
All Applications...................................................................................11-80 Industrial CM570 and Power Generation without CM570.......................8-44
Install......................................................................................................11-81 Fan Pulley ...................................................................................................8-78
All Applications...................................................................................11-81 Inspect for Reuse......................................................................................8-79
Preparatory Steps...................................................................................11-80 Install........................................................................................................8-79
Automotive with CM870......................................................................11-80 Industrial and Power Generation...........................................................8-79
Remove..................................................................................................11-80 Remove....................................................................................................8-78
All Applications...................................................................................11-80 Industrial and Power Generation...........................................................8-78
Exhaust Gas Pressure Sensor Tube ........................................................11-65 Fan Shroud Assembly ................................................................................8-47
Clean and Inspect for Reuse...................................................................11-66 Initial Check..............................................................................................8-47
Finishing Steps.......................................................................................11-66 Fan Support ................................................................................................8-75
Install......................................................................................................11-66 Finishing Steps.........................................................................................8-78
Preparatory Steps...................................................................................11-65 Industrial and Power Generation...........................................................8-78
Remove..................................................................................................11-65 Install........................................................................................................8-76
Exhaust Manifold, Dry ................................................................................11-4 Industrial and Power Generation...........................................................8-76
Assemble................................................................................................11-12 Preparatory Steps.....................................................................................8-75
Automotive with CM870......................................................................11-12 Industrial and Power Generation...........................................................8-75
Automotive, Industrial with CM570 and Power Generation without CM570.... Remove....................................................................................................8-76
11-12 Industrial and Power Generation...........................................................8-76
Automotive With CM871......................................................................11-13 Fan, Cooling ...............................................................................................8-48
Clean and Inspect for Reuse.....................................................................11-8 Inspect for Reuse......................................................................................8-48
Automotive, Industrial with CM570 and Power Generation without CM570.... Install........................................................................................................8-49
11-8 Remove....................................................................................................8-48
Automotive with CM870 and CM871......................................................11-9 Flywheel .....................................................................................................16-7
Disassemble.............................................................................................11-7 Clean and Inspect for Reuse...................................................................16-10
Automotive with CM870........................................................................11-7 Finishing Steps.......................................................................................16-13
Automotive, Industrial with CM570 and Power Generation without CM570.... Initial Check..............................................................................................16-7
11-8 Bore Runout.........................................................................................16-7
Automotive With CM871........................................................................11-8 Face Runout.........................................................................................16-8
Finishing Steps.......................................................................................11-16 Install......................................................................................................16-12
Automotive with CM870......................................................................11-16 Preparatory Steps.....................................................................................16-9
Automotive, Industrial with CM570 and Power Generation without CM570.... Remove..................................................................................................16-10
11-16 Flywheel Housing .....................................................................................16-14
Automotive With CM871......................................................................11-17 Clean and Inspect for Reuse...................................................................16-16
Initial Check..............................................................................................11-4 Finishing Steps.......................................................................................16-23
Automotive with CM870........................................................................11-4 Install......................................................................................................16-17
Automotive With CM871........................................................................11-4 Measure..................................................................................................16-18
Install......................................................................................................11-13 Bore Alignment...................................................................................16-18
Automotive with CM870 and CM871....................................................11-13 Face Alignment...................................................................................16-21
Automotive, Industrial with CM570 and Power Generation without CM570.... Preparatory Steps...................................................................................16-14
11-14 Remove..................................................................................................16-14
Preparatory Steps.....................................................................................11-6 Flywheel Housing, REPTO .......................................................................16-24
Automotive with CM870........................................................................11-6 Clean and Inspect for Reuse...................................................................16-27
Finishing Steps.......................................................................................16-40
Index
Page X-5
Install......................................................................................................16-29 Automotive With CM871.......................................................................V-72

Measure..................................................................................................16-36 General Repair Instructions ..........................................................................i-8
Bore Alignment...................................................................................16-36 General Information.....................................................................................i-8
Face Alignment...................................................................................16-38 Welding on a Vehicle with an Electronic Controlled Fuel System..................i-9
Preparatory Steps...................................................................................16-24 General Safety Instructions ..........................................................................i-6
Remove..................................................................................................16-24 Important Safety Notice................................................................................i-6
Flywheel Ring Gear ..................................................................................16-41 Heat Shield ...............................................................................................11-78
Install......................................................................................................16-41 Clean and Inspect for Reuse...................................................................11-79
Remove..................................................................................................16-41 Finishing Steps.......................................................................................11-80
Fraction, Decimal, Millimeter Conversions ...............................................V-83 Automotive with CM870......................................................................11-80
Conversion Chart......................................................................................V-83 Install......................................................................................................11-79
Fuel Consumption ........................................................................................5-3 Automotive with CM870......................................................................11-79
Maintenance Check....................................................................................5-3 Automotive With CM871......................................................................11-79
Fuel Drain Line Restriction ..........................................................................6-6 Preparatory Steps...................................................................................11-78
Measure.....................................................................................................6-6 Automotive with CM870......................................................................11-78
Fuel Filter (Spin-On Type) ............................................................................6-6 Remove..................................................................................................11-78
Clean..........................................................................................................6-9 Automotive with CM870......................................................................11-78
Initial Check................................................................................................6-6 Automotive With CM871......................................................................11-78
Install..........................................................................................................6-9 How to Use the Manual .................................................................................i-2
Remove......................................................................................................6-8 General Information.....................................................................................i-2
Fuel Inlet Pre-Filter .....................................................................................5-47 Idler Pulley, Refrigerant Compressor ..........................................................9-7
Clean........................................................................................................5-49 Finishing Steps...........................................................................................9-8
General Information..................................................................................5-47 With Water Pump and Refrigerant Compressor Belt Routing...................9-8
Install........................................................................................................5-50 Inspect for Reuse........................................................................................9-7
Remove....................................................................................................5-48 With Water Pump and Refrigerant Compressor Belt Routing...................9-7
Fuel Inlet Restriction ..................................................................................6-11 Install..........................................................................................................9-7
Measure...................................................................................................6-11 With Water Pump and Refrigerant Compressor Belt Routing...................9-7
With Pressurized Fuel Filtering.............................................................6-11 Preparatory Steps.......................................................................................9-7
With Vacuum Fuel Filtering...................................................................6-12 With Water Pump and Refrigerant Compressor Belt Routing...................9-7
Fuel Lift Pump ............................................................................................5-14 Remove......................................................................................................9-7
Clean and Inspect for Reuse.....................................................................5-20 With Water Pump and Refrigerant Compressor Belt Routing...................9-7
Finishing Steps.........................................................................................5-24 Illustrations ....................................................................................................i-5
Initial Check..............................................................................................5-14 General Information.....................................................................................i-5
Install........................................................................................................5-22 Injector ........................................................................................................6-14
Preparatory Steps.....................................................................................5-17 Assemble..................................................................................................6-23
Pressure Test...........................................................................................5-16 Disassemble.............................................................................................6-19
Remove....................................................................................................5-17 Finishing Steps.........................................................................................6-27
Replace....................................................................................................5-21 Inspect for Reuse......................................................................................6-18
Resistance Check.....................................................................................5-14 Install........................................................................................................6-27
Test..........................................................................................................5-16 Leak Test..................................................................................................6-14
Voltage Check..........................................................................................5-15 Preparatory Steps.....................................................................................6-16
Fuel Pump ....................................................................................................5-4 Remove....................................................................................................6-17
Clean and Inspect for Reuse.......................................................................5-6 Injector Camshaft Scissor Gear .................................................................2-86
Finishing Steps...........................................................................................5-7 Install........................................................................................................2-87
Install..........................................................................................................5-6 Remove....................................................................................................2-86
Leak Test....................................................................................................5-4 Intake Manifold Pressure .........................................................................10-58
Preparatory Steps.......................................................................................5-5 Measure..................................................................................................10-58
Pressure Test.............................................................................................5-4 Integrated Fuel System Module (IFSM) .....................................................5-30
Prime..........................................................................................................5-8 Assemble..................................................................................................5-34
Remove......................................................................................................5-5 Clean and Inspect for Reuse.....................................................................5-32
Fuel Pump Pulsation Damper ......................................................................5-9 Disassemble.............................................................................................5-32
Clean and Inspect for Reuse.....................................................................5-10 Finishing Steps.........................................................................................5-46
Automotive with CM870........................................................................5-10 Install........................................................................................................5-44
Automotive, Industrial with CM570 and Power Generation without CM570.... Preparatory Steps.....................................................................................5-30
5-10 Remove....................................................................................................5-31
Finishing Steps.........................................................................................5-11 Lubricating Oil and Filter Analysis ............................................................7-58
All Applications.....................................................................................5-11 Inspect......................................................................................................7-58
Install........................................................................................................5-10 Lubricating Oil......................................................................................7-58
Automotive with CM870........................................................................5-10 Lubricating Oil Filter..............................................................................7-59
Automotive, Industrial with CM570 and Power Generation without CM570.... Lubricating Oil Cooler ..................................................................................7-4
5-11 Clean and Inspect for Reuse.......................................................................7-6
Preparatory Steps.......................................................................................5-9 All Applications.......................................................................................7-6
All Applications.......................................................................................5-9 Finishing Steps.........................................................................................7-10
Remove......................................................................................................5-9 Automotive with CM870........................................................................7-10
Automotive with CM870..........................................................................5-9 Automotive, Industrial with CM570 and Power Generation without CM570....
Automotive, Industrial with CM570 and Power Generation without CM570.... 7-11
5-10 Install........................................................................................................7-10
Fuel Shutoff Valve ......................................................................................5-11 All Applications.....................................................................................7-10
Inspect for Reuse......................................................................................5-12 Leak Test....................................................................................................7-8
Install........................................................................................................5-13 All Applications.......................................................................................7-8
Remove....................................................................................................5-11 Preparatory Steps.......................................................................................7-4
Fuel Supply Lines .......................................................................................6-13 Automotive with CM870..........................................................................7-4
Inspect for Reuse......................................................................................6-13 Automotive, Industrial with CM570 and Power Generation without CM570....
Remove....................................................................................................6-13 7-5
Fuel System ...............................................................................................V-73 Remove......................................................................................................7-5
Specifications...........................................................................................V-73 All Applications.......................................................................................7-5
General Cleaning Instructions ....................................................................i-10 Lubricating Oil Cooler Element ..................................................................7-11
Abrasive Pads and Abrasive Paper.............................................................i-10 Assemble..................................................................................................7-14
Definition of Clean......................................................................................i-10 Single-Element.....................................................................................7-14
Fuel System...............................................................................................i-13 Dual-Element........................................................................................7-14
Gasket Surfaces........................................................................................i-11 Clean and Inspect for Reuse.....................................................................7-12
Plastic Bead Cleaning................................................................................i-12 Disassemble.............................................................................................7-11
Solvent and Acid Cleaning.........................................................................i-11 Single-Element.....................................................................................7-11
Steam Cleaning.........................................................................................i-12 Dual-Element........................................................................................7-11
General Engine ...........................................................................................V-72 Finishing Steps.........................................................................................7-15
Specifications...........................................................................................V-72 Preparatory Steps.....................................................................................7-11
Automotive with CM870........................................................................V-72 Pressure Test...........................................................................................7-13
Index
Page X-6
Lubricating Oil Dipstick ..............................................................................7-15 Install........................................................................................................2-62

Calibrate...................................................................................................7-15 Remove....................................................................................................2-57
Lubricating Oil Dipstick Tube ....................................................................7-16 Overhead Camshaft End Clearance, Injector ............................................2-83
Install........................................................................................................7-16 Measure...................................................................................................2-83
Automotive with CM870........................................................................7-16 Overhead Camshaft Gear, Valve ................................................................2-86
Automotive With CM871........................................................................7-17 Install........................................................................................................2-86
Remove....................................................................................................7-16 Remove....................................................................................................2-86
Automotive with CM870........................................................................7-16 Overhead Camshaft, Injector .....................................................................2-51
Automotive With CM871........................................................................7-16 Clean and Inspect for Reuse.....................................................................2-54
Lubricating Oil Fill Tube ............................................................................7-52 Finishing Steps.........................................................................................2-55
Clean and Inspect for Reuse.....................................................................7-54 Install........................................................................................................2-55
Automotive With CM871........................................................................7-54 Remove....................................................................................................2-53
Install........................................................................................................7-55 Overhead Camshaft, Valve ........................................................................2-47
Automotive with CM870........................................................................7-55 Clean and Inspect for Reuse.....................................................................2-49
Automotive With CM871........................................................................7-56 Finishing Steps.........................................................................................2-50
Remove....................................................................................................7-52 Install........................................................................................................2-50
Automotive With CM871........................................................................7-53 Remove....................................................................................................2-48
Lubricating Oil Filter (Spin-On) ..................................................................7-17 Overhead Set ................................................................................................3-8
General Information..................................................................................7-17 Adjust.......................................................................................................3-12
Install........................................................................................................7-19 Finishing Steps.........................................................................................3-20
Measure...................................................................................................7-18 Measure.....................................................................................................3-8
Remove....................................................................................................7-19 General Information................................................................................3-8
Lubricating Oil Filter Bypass Valve ...........................................................7-20 Preparatory Steps.....................................................................................3-12
Clean........................................................................................................7-21 Pipe Plug Torque Values ...........................................................................V-88
General Information..................................................................................7-20 Torque Table............................................................................................V-88
Inspect for Reuse......................................................................................7-21 Radiator ......................................................................................................8-49
Install........................................................................................................7-22 Initial Check..............................................................................................8-49
Remove....................................................................................................7-20 Radiator Hoses ...........................................................................................8-50
Lubricating Oil Filter Head Adapter ...........................................................7-23 Inspect for Reuse......................................................................................8-50
Clean and Inspect for Reuse.....................................................................7-24 Radiator Pressure Cap ...............................................................................8-50
Finishing Steps.........................................................................................7-25 Inspect for Reuse......................................................................................8-50
Install........................................................................................................7-24 .............................................................................................................8-50
Preparatory Steps.....................................................................................7-23 Radiator Shutter Assembly ........................................................................8-51
Remove....................................................................................................7-23 General Information..................................................................................8-51
Lubricating Oil High Pressure Relief Valve ...............................................7-25 Refrigerant Compressor ...............................................................................9-1
General Information..................................................................................7-25 Clean and Inspect for Reuse.......................................................................9-2
Inspect for Reuse......................................................................................7-26 With Water Pump and Refrigerant Compressor Belt Routing...................9-2
Install........................................................................................................7-26 Climate Control Incorporated..................................................................9-2
Remove....................................................................................................7-25 Finishing Steps...........................................................................................9-3
Lubricating Oil Leaks .................................................................................7-27 With Water Pump and Refrigerant Compressor Belt Routing...................9-3
General Information..................................................................................7-27 Install..........................................................................................................9-2
Lubricating Oil Pan .....................................................................................7-29 Sanden...................................................................................................9-2
Clean and Inspect for Reuse.....................................................................7-30 Climate Control Incorporated..................................................................9-2
Finishing Steps.........................................................................................7-31 Preparatory Steps.......................................................................................9-1
Install........................................................................................................7-30 With Water Pump and Refrigerant Compressor Belt Routing...................9-1
Preparatory Steps.....................................................................................7-29 Remove......................................................................................................9-1
Remove....................................................................................................7-30 Sanden...................................................................................................9-1
Lubricating Oil Pressure Gauge .................................................................7-32 Climate Control Incorporated..................................................................9-1
Test..........................................................................................................7-32 Refrigerant Compressor Mounting Bracket .................................................9-8
Lubricating Oil Pump .................................................................................7-32 Clean and Inspect for Reuse.....................................................................9-10
Assemble..................................................................................................7-40 Automotive with CM870........................................................................9-10
Clean and Inspect for Reuse.....................................................................7-34 Automotive, Industrial with CM570 and Power Generation without CM570....
Disassemble.............................................................................................7-33 9-10
Finishing Steps.........................................................................................7-44 Finishing Steps.........................................................................................9-12
Install........................................................................................................7-42 Automotive with CM870........................................................................9-12
Preparatory Steps.....................................................................................7-32 Automotive, Industrial with CM570 and Power Generation without CM570....
Remove....................................................................................................7-32 9-12
Lubricating Oil Suction Tube (Block-Mounted) .........................................7-45 Install........................................................................................................9-11
Finishing Steps.........................................................................................7-46 Sanden.................................................................................................9-11
Inspect for Reuse......................................................................................7-45 Climate Control Incorporated................................................................9-11
Install........................................................................................................7-46 Automotive, Industrial with CM570 and Power Generation without CM570....
Preparatory Steps.....................................................................................7-45 9-11
Remove....................................................................................................7-45 Preparatory Steps.......................................................................................9-8
Lubricating Oil System ...............................................................................7-47 Automotive with CM870..........................................................................9-8
Drain.........................................................................................................7-47 Automotive, Industrial with CM570 and Power Generation without CM570....
Fill............................................................................................................7-49 9-8
Prime........................................................................................................7-47 Remove......................................................................................................9-9
Lubricating Oil System ..............................................................................V-74 Sanden...................................................................................................9-9
Specifications...........................................................................................V-74 Climate Control Incorporated..................................................................9-9
Lubricating Oil Thermostat ........................................................................7-50 Automotive, Industrial with CM570 and Power Generation without CM570....
Inspect for Reuse......................................................................................7-50 9-9
Install........................................................................................................7-51 Rocker Lever Assembly .............................................................................3-21
Remove....................................................................................................7-50 Clean and Inspect for Reuse.....................................................................3-22
Newton-Meter to Foot-Pound Conversions ...............................................V-87 Finishing Steps.........................................................................................3-30
Conversion Chart......................................................................................V-87 Install........................................................................................................3-26
Overhead Camshaft End Clearance, Valve ................................................2-81 Preparatory Steps.....................................................................................3-21
Measure...................................................................................................2-81 Remove....................................................................................................3-21
Overhead Camshaft Bushings, Injector .....................................................2-69 Rocker Lever Cover ....................................................................................3-30
Initial Check..............................................................................................2-69 Clean and Inspect for Reuse.....................................................................3-30
Inspect for Reuse......................................................................................2-74 Install........................................................................................................3-32
Install........................................................................................................2-74 Remove....................................................................................................3-30
Remove....................................................................................................2-69 Service Literature Ordering Location ..........................................................L-2
Overhead Camshaft Bushings, Valve ........................................................2-57 Contact Information....................................................................................L-2
Initial Check..............................................................................................2-57 Service Tools ...............................................................................................2-1
Inspect for Reuse......................................................................................2-62 ...................................................................................................................2-1
Index
Page X-7
Service Tools ...............................................................................................3-1 Automotive with CM870......................................................................10-46

Rocker Levers.............................................................................................3-1 Automotive With CM871......................................................................10-47
Service Tools ...............................................................................................5-1 Preparatory Steps...................................................................................10-43
Fuel System................................................................................................5-1 Automotive with CM870......................................................................10-43
Service Tools ...............................................................................................6-1 Automotive With CM871......................................................................10-43
...................................................................................................................6-1 Remove..................................................................................................10-44
Service Tools ...............................................................................................7-1 Automotive with CM870......................................................................10-44
...................................................................................................................7-1 Automotive With CM871......................................................................10-44
Service Tools ...............................................................................................8-1 Turbocharger Wastegate Actuator ..........................................................10-49
Cooling System...........................................................................................8-1 Adjust.....................................................................................................10-54
Service Tools ..............................................................................................10-1 Finishing Steps.......................................................................................10-57
.................................................................................................................10-1 Initial Check............................................................................................10-49
Service Tools ..............................................................................................11-1 Inspect....................................................................................................10-52
.................................................................................................................11-1 Inspect for Reuse....................................................................................10-53
Service Tools ..............................................................................................13-1 Install......................................................................................................10-55
Electrical Equipment.................................................................................13-1 Preparatory Steps...................................................................................10-51
Service Tools ..............................................................................................14-1 Remove..................................................................................................10-52
Engine Testing..........................................................................................14-1 Turbocharger Wastegate Controller ........................................................10-63
Service Tools ..............................................................................................16-1 Inspect for Reuse....................................................................................10-64
Mounting Adaptations...............................................................................16-1 Install......................................................................................................10-64
Stall Speed Test .........................................................................................5-25 Remove..................................................................................................10-63
Stall Speed Check....................................................................................5-25 Turbocharger Wastegate Valve Body ......................................................10-57
Stall Speed Check List..............................................................................5-28 Inspect for Reuse....................................................................................10-57
Stall Speed Too Low.............................................................................5-28 Turbocharger, Variable Geometry Actuator ............................................10-65
Stall Speed Too High............................................................................5-29 Finishing Steps.......................................................................................10-69
Time Speed Check....................................................................................5-27 Variable Geometry..............................................................................10-69
Starter Magnetic Switch ...........................................................................13-12 General Information................................................................................10-65
Current Check.........................................................................................13-12 Variable Geometry..............................................................................10-65
Starter Solenoid ........................................................................................13-15 Inspect for Reuse....................................................................................10-67
Voltage Check.........................................................................................13-15 Variable Geometry..............................................................................10-67
Starter Switch ...........................................................................................13-14 Install......................................................................................................10-68
Voltage Check.........................................................................................13-14 Variable Geometry..............................................................................10-68
Starting Motor ...........................................................................................13-17 Preparatory Steps...................................................................................10-66
Finishing Steps.......................................................................................13-19 Variable Geometry..............................................................................10-66
All Applications...................................................................................13-19 Remove..................................................................................................10-66
Install......................................................................................................13-18 Variable Geometry..............................................................................10-66
All Except 50MT With Aluminum Flywheel Housing.............................13-18 Test........................................................................................................10-68
50MT With Aluminum Flywheel Housing.............................................13-19 Variable Geometry..............................................................................10-68
Preparatory Steps...................................................................................13-17 Turbocharger, Variable Geometry Actuator Air Supply Line ..................10-73
All Applications...................................................................................13-17 Inspect for Reuse....................................................................................10-74
Remove..................................................................................................13-18 Install......................................................................................................10-74
All Except 50MT With Aluminum Flywheel Housing.............................13-18 Remove..................................................................................................10-73
50MT With Aluminum Flywheel Housing.............................................13-18 Turbocharger, Variable Geometry Control Valve Air Supply Line ..........10-75
Symbols .........................................................................................................i-4 Inspect for Reuse....................................................................................10-75
General Information.....................................................................................i-4 Install......................................................................................................10-76
Tap-Drill Chart - U.S. Customary and Metric ............................................V-89 Remove..................................................................................................10-75
General Information..................................................................................V-89 Valve Guide Seal, Cylinder Head ...............................................................2-39
Turbocharger ............................................................................................10-15 Finishing Steps.........................................................................................2-47
Assemble................................................................................................10-33 On-Engine Repair.................................................................................2-47
Clean......................................................................................................10-26 Off-Engine Repair.................................................................................2-47
Disassemble...........................................................................................10-25 General Information..................................................................................2-39
Finishing Steps.......................................................................................10-40 Install........................................................................................................2-43
Initial Check............................................................................................10-15 Preparatory Steps.....................................................................................2-39
Inspect for Reuse....................................................................................10-27 On-Engine Repair.................................................................................2-39
Install......................................................................................................10-34 Off-Engine Repair.................................................................................2-40
Leak Test................................................................................................10-18 Remove....................................................................................................2-40
Preparatory Steps...................................................................................10-19 Variable Geometry Turbocharger Actuator, Electric ...............................10-77
Remove..................................................................................................10-21 Calibrate.................................................................................................10-84
Test........................................................................................................10-17 Clean and Inspect for Reuse...................................................................10-78
Turbocharger Air Shutoff Valve Filter .....................................................10-69 Finishing Steps.......................................................................................10-84
Clean and Inspect for Reuse...................................................................10-70 General Information................................................................................10-77
Variable Geometry..............................................................................10-70 Install......................................................................................................10-80
Finishing Steps.......................................................................................10-70 Preparatory Steps...................................................................................10-77
Variable Geometry..............................................................................10-70 Remove..................................................................................................10-78
Install......................................................................................................10-70 Variable Geometry Turbocharger Cross Shaft ........................................10-85
Variable Geometry..............................................................................10-70 Assemble................................................................................................10-92
Preparatory Steps...................................................................................10-69 Clean and Inspect for Reuse...................................................................10-92
Variable Geometry..............................................................................10-69 Disassemble...........................................................................................10-86
Remove..................................................................................................10-69 Finishing Steps.......................................................................................10-99
Variable Geometry..............................................................................10-69 Initial Check............................................................................................10-85
Turbocharger Control Shutoff Valve Filter Head .....................................10-71 Preparatory Steps...................................................................................10-86
Clean and Inspect for Reuse...................................................................10-72 Steam Cleaning......................................................................................10-86
Variable Geometry..............................................................................10-72 Water Inlet Connection ..............................................................................8-74
Finishing Steps.......................................................................................10-73 Finishing Steps.........................................................................................8-75
Variable Geometry..............................................................................10-73 Install........................................................................................................8-75
Install......................................................................................................10-72 Preparatory Steps.....................................................................................8-74
Variable Geometry..............................................................................10-72 Remove....................................................................................................8-75
Preparatory Steps...................................................................................10-71 Water Pump ................................................................................................8-51
Variable Geometry..............................................................................10-71 Assemble..................................................................................................8-60
Remove..................................................................................................10-71 Clean........................................................................................................8-55
Variable Geometry..............................................................................10-71 Automotive With CM871........................................................................8-55
Turbocharger Coolant Hoses ...................................................................10-43 Clean and Inspect for Reuse.....................................................................8-57
Clean and Inspect for Reuse...................................................................10-45 Disassemble.............................................................................................8-56
Finishing Steps.......................................................................................10-48 Finishing Steps.........................................................................................8-67
Automotive with CM870......................................................................10-48 Automotive with CM870........................................................................8-67
Automotive With CM871......................................................................10-49 Automotive with CM570........................................................................8-67
Install......................................................................................................10-46 Industrial CM570 and Power Generation without CM570.......................8-67
Index
Page X-8
Automotive With CM871........................................................................8-67

Install........................................................................................................8-63
Automotive with CM870........................................................................8-63
Industrial CM570 and Power Generation without CM570.......................8-65
Measure...................................................................................................8-59
Preparatory Steps.....................................................................................8-51
Remove....................................................................................................8-53
Water Pump Cartridge ................................................................................8-80
Clean and Inspect for Reuse.....................................................................8-81
Finishing Steps.........................................................................................8-81
Install........................................................................................................8-81
Preparatory Steps.....................................................................................8-80
Remove....................................................................................................8-80
Weights and Measures - Conversion Factors ...........................................V-84
Conversion Chart......................................................................................V-84
NOTES
NOTES
Cummins Inc.
Service Manual
Service Manual Signature, ISX and QSX15 Volume 2

Box 3005
Columbus, Indiana, U.S.A., 47202 Signature, ISX and QSX15
Registered Office Volume 2
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright 2010
Cummins Inc.
Bulletin 3666239
Printed in U.S.A. 27-APRIL-2010 p41
302158_Cummins_Vol2.indd 1 5/11/10 9:37 AM

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Service Manual Signature, ISX and QSX15 Volume 2

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

Copyright 2010 Bulletin 3666239

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

This Page Left Intentionally Blank

About the Manual

How to Use the Manual

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

The illustrations are intended to show repair or

General Safety Instructions

General Repair Instructions

Follow all safety instructions noted in the procedures

Welding on a Vehicle with an Electronic Controlled Fuel System

General Cleaning Instructions

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

Acronyms and Abbreviations

psi Pounds Per Square Inch

Section 2 - Cylinder Head - Group 02

Tool No. Tool Description Tool Illustration

Four-Valve Spring Compressor

Head Bolt Stretch Gauge

Hydraulic Camshaft Bushing Installation and Removal Tool

Valve Camshaft Bushing Installation and Removal Tool

Injector Camshaft Bushing Installation and Removal Tool

Tool No. Tool Description Tool Illustration

Air Impact Wrench

Depth Gauge Assembly

Valve Seal Installation Tool

Valve Seal Puller

Valve Guide Installer

Tool No. Tool Description Tool Illustration

Exhaust Seat Installer

Exhaust Seat Puller

Intake Seat Puller

Valve Guide Removal Tool

Valve Vacuum Tester

Slide Hammer Assembly

Magnetic Crack Detector

Tool No. Tool Description Tool Illustration

Cylinder Head Fuel Passage Leak Test Kit

Cylinder Head (002-004)

There are two different designs of cylinder liners used in

Operate the engine at low idle.

Listen for a chirping sound between the cylinder head and

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

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

Remove the cylinder head gasket.