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CUMMINS N14 Shop Manual

N14 series

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Summary of Contents for CUMMINS N14

  • Page 2 Foreword This manual contains complete rebuild specifications and information for the N14 model engines, and all asso- ciated components manufactured by Cummins Engine Company, Inc. A listing of accessory and component suppliers’ addresses and telephone numbers is located in Section C. Suppliers can be contacted directly for any information not covered in this manual.
  • Page 3 TABLE OF CONTENTS Page Introduction..............................Group 0 - Engine Disassembly and Assembly ................... Group 1 - Cylinder Block........................... Group 2 - Cylinder Head ........................... Group 3 - Rocker Levers........................... Group 4 - Cam Followers .......................... Group 5 - Fuel System..........................Group 6 - Injectors and Fuel Lines......................
  • Page 4: Group System Exploded Diagram

    Cummins 22-Group System Exploded Diagram...
  • Page 5 Section I - Introduction Page i-1 Section I - Introduction Section Contents Page Engine Diagrams .............................. i-13 Engine Identification ............................i-12 General Cleaning Instructions.......................... i-16 Glass or Plastic Bead Cleaning ........................i-16 Solvent and Acid Cleaning ..........................i-16 Steam Cleaning ............................. i-16 General Repair Instructions ..........................
  • Page 6 Manual Organization Section I - Introduction Page i-2 Manual Organization All references to engine components in this manual are divided into 22 specific groups. The organization is consistent with the service bulletins, service parts topics, and the parts catalogs for your convenience in updating your copy of the shop manual.
  • Page 7 Follow The Specified Disassembly and Assembly Procedures to Avoid Damage to the Components. Complete troubleshooting and repair instructions are available in the Troubleshooting and Repair Manual which can be ordered or purchased from a Cummins Authorized Repair Location. Refer to Section L, Literature, for ordering instructions.
  • Page 8: General Safety Instructions

    • Always use tools that are in good condition. Make sure you understand how to use them 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...
  • Page 9 Section I - Introduction Symbols Used in this Manual Page i-5 Symbols Used in this Manual The following group of symbols has 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. WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed.
  • Page 10 Simbolos Usados En Este Manual Section I - Introduction Page i-6 Simbolos Usados En Este Manual Los si ´ mbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuando aparece uno de estos si ´ mbolos, su significado se especifica en la parte inferior. ADVERTENCIA - Serios dan ˜...
  • Page 11 Section I - Introduction Symboles Utilises Dans Ce Manuel Page i-7 Symboles Utilises Dans Ce Manuel Les symboles suivants sont utilise ´ s dans ce manuel pour aider a ` communiquer le but des instructions. Quand l’un de ces symboles apparai ˆ t, il e ´ voque le sens de ´ fini ci-dessous: AVERTISSEMENT - De graves le ´...
  • Page 12 Symbole Section I - Introduction Page i-8 Symbole In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die Symbole haben folgende Bedeutung: WARNUNG - Wird die Warnung nicht beachtet, dann besteht erho ¨ hte Unfall- und Bescha ¨ digungsgefahr. VORSICHT - Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- und Bescha ¨...
  • Page 13 Section I - Introduction Illustrations Page i-9 Illustrations The illustrations used in this manual are intended to give an example of how to perform the action or the repair being described. Many of the illustrations are common and will not look exactly like the engine or the parts used in your application.
  • Page 14 Control Parts List; this listing identifies the specific parts that must be in- stalled on the engine to meet agency certification. Cummins Sealant: This is a one part Room Temperature Vulcanizing (RTV) silicone rubber, adhe- sive and sealant material having high heat and oil resistance, and low com- pression set.
  • Page 15 SRI, Amoco Rykon Premium No. 2, Texaco Premium RB, and Shell Dolium R. Aeroshell No. 5 is not compatible with the other greases and must not be mixed. Cummins Engine Company, Inc., uses Aeroshell No. 5 on new engines and components.
  • Page 16: Engine Identification

    The engine dataplate provides the model identification and other important information about the engine. Have the following engine data available when commu- nicating with a Cummins Authorized Repair Location. The information on the dataplate is mandatory when sourcing service parts: 1.
  • Page 17 Section I - Introduction Engine Diagrams Page i-13 Engine Diagrams The following drawings contain information about engine components, filter locations, drain points, and access locations for instrumentation and engine controls. The information and configuration of components shown in these drawings are of a general nature. Some component locations will vary depending on applications and installations.
  • Page 18 Engine Diagrams Section I - Introduction Page i-14...
  • Page 19 Section I - Introduction Engine Diagrams Page i-15...
  • Page 20: General Cleaning Instructions

    General Cleaning Instructions Solvent and Acid Cleaning Several solvent and acid-type cleaners can be used to clean the engine parts. Cummins Engine Company, Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer’s instructions. Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95 degrees Celsius [180 to 200 degrees Fahrenheit].
  • Page 21 Engine Disassembly and Assembly Page 0-1 Section 0 - Engine Disassembly and Assembly - Group 00 Section Contents Page Accessory Drive - Installation ........................0-89 Accessory Drive - Removal ..........................0-31 Accessory Drive Pulley - Installation ......................0-97 Accessory Drive Pulley - Removal ......................... 0-23 Accessory Drive Seal - Installation ........................
  • Page 22 Engine Disassembly and Assembly Page 0-2 Page CELECT™ Lubricating Oil Pressure Sensor - Removal .................. 0-29 CELECT™ Sensor Harness - Installation......................0-127 CELECT™ Sensor Harness - Removal ......................0-27 Coolant - Drainage............................0-11 Coolant Filter - Installation..........................0-147 Coolant Filter - Removal ..........................0-11 Coolant Inlet Transfer Connection - Installation...................
  • Page 23 Engine Disassembly and Assembly Page 0-3 Page Fan and Fan Spacer - Removal ........................0-13 Fan Belts - Installation and Adjustment......................0-137 Fan Belts - Removal ............................0-20 Fan Hub and Fan Hub Support Bracket - Installation................... 0-136 Fan Hub and Fan Hub Support Bracket - Removal ..................0-21 Flywheel - Installation ............................
  • Page 24 Engine Disassembly and Assembly Page 0-4 Page Lubricating Oil Transfer Tube - Installation....................0-122 Lubricating Oil Transfer Tube - Removal ...................... 0-31 Piston and Connecting Rod Assemblies - Assembly and Installation ............0-61 Piston and Connecting Rod Assemblies - Removal ..................0-40 Piston Cooling Nozzles - Installation ......................
  • Page 25: Engine Disassembly And Assembly - Service Tools

    Engine Disassembly and Assembly - Service Tools The following special tools are recommended to perform procedures in section 1. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
  • Page 26 Engine Disassembly and Assembly - Service Tools Engine Disassembly and Assembly Page 0-6 Tool No. Tool Description Tool Illustration Main Bearing Cap Puller Remove main bearings caps. ST-1178 Top Plate Included in oil seal puller/installer, Part No. ST-1259. Use to pull or install the front crankshaft oil seal.
  • Page 27 Engine Disassembly and Assembly Engine Disassembly and Assembly - Service Tools Page 0-7 Tool No. Tool Description Tool Illustration Connecting Rod Guide Pins Guide connecting rods over crankshaft during removal or in- stallation of connecting rods. 3375601 Nylon Lifting Sling Aid in removal and installation of crankshaft, flywheel, and other heavy components.
  • Page 29: Engine Disassembly And Assembly - General Information

    Engine Disassembly and Assembly - General information These procedures apply to all N14 engines. The differences between engine models due to the application, the optional equipment on an engine, and the year an engine was built are included in the instructions. Omit the steps that do not apply to the engine being rebuilt.
  • Page 30: Engine - Preparation For Cleaning

    In this case, the service rear engine lifting bracket, Part No. 3823835, will be required to remove the engine from the chassis. Refer to the N14 Troubleshooting and Repair Manual, Bulletin No. 3810456, Section 9, for further information. Install the engine on two engine support stands, Part No.
  • Page 31: Coolant - Drainage

    Engine Disassembly (00-01) Coolant - Drainage Page 0-11 NOTE: The maximum oil pan capacity is 34 liters [9.0 U.S. gallons]. Remove the drain plug and the copper washer. Check the copper washer for wear. Drain the oil. If the drain plug is installed again, tighten the plug to the specified torque.
  • Page 32: Crankcase Breather - Removal

    Crankcase Breather - Removal Engine Disassembly (00-01) Page 0-12 Crankcase Breather - Removal Loosen the hose clamp at the breather vent tube. Remove the tube support bracket capscrew and the bracket. Remove the tube and the hose from the engine. Turbocharger - Removal Remove the oil supply and the oil drain tubes from the turbocharger.
  • Page 33: Alternator Belts - Removal

    Engine Disassembly (00-01) Exhaust Manifold - Removal Page 0-13 Exhaust Manifold - Removal NOTE: Two dowels are used in each cylinder head to align the exhaust manifold assembly. Remove two capscrews, and install two guide studs. Warning: Because this assembly weighs more than 23 kg [50 lbs], two people or a hoist will be required to lift the exhaust manifold assembly to avoid personal injury.
  • Page 34: Alternator - Removal

    Alternator - Removal Engine Disassembly (00-01) Page 0-14 Alternator - Removal Remove the adjusting link capscrew and the adjusting link. Remove the alternator to alternator support bracket, nut, washer, capscrew, and the alternator. Alternator Mounting Bracket - Re- moval Remove the three alternator mounting bracket capscrews and the mounting bracket.
  • Page 35: Dipstick Tube And Housing - Removal

    Engine Disassembly (00-01) Coolant Inlet Transfer Connection - Removal Page 0-15 Warning: Because this part weighs more than 23 kg [50 lbs], two people or a hoist will be required to lift the oil cooler assembly to avoid personal injury. Remove the remaining five capscrews from the oil cooler support, and remove the cooler assembly.
  • Page 36: Water Header Covers - Removal

    Water Header Covers - Removal Engine Disassembly (00-01) Page 0-16 Water Header Covers - Removal Remove the six capscrews from each of the two water header covers. Remove the covers, and discard the gaskets. Engine - Installation on the Rebuild Stand NOTE: Use engine rebuild stand, Part No.
  • Page 37 Engine Disassembly (00-01) Engine - Installation on the Rebuild Stand Page 0-17 Install the mounting plate adapter on the rear water header. Use five 1/4-20 X 1 1/4-inch capscrews to mount the adapter. Tighten the capscrews. Torque Value: 10 N•m [7 ft-lb] Install three 1/2-13 X 3 3/8-inch capscrews through the adapter plate as shown.
  • Page 38: Flywheel - Removal

    Flywheel - Removal Engine Disassembly (00-01) Page 0-18 Adjust the position of the engine so that the remaining mounting holes in the adapter plate (1) and (2) align with the capscrew holes in the cylinder block. Use your fingers to tighten the three 1/2-13 X 3 3/8-inch capscrews (1).
  • Page 39: Flywheel Housing - Removal

    Engine Disassembly (00-01) Flywheel Housing - Removal Page 0-19 Determine the capscrew thread size, and install two ‘‘T- handles’’ in the flywheel at points (4) and (5). Remove the remaining four flywheel mounting capscrews. Warning: Because this part weighs more than 23 kg [50 lbs], two people or a hoist will be required to lift the flywheel to avoid personal injury.
  • Page 40: Rear Cover - Removal

    Rear Cover - Removal Engine Disassembly (00-01) Page 0-20 On wet-type flywheel housings, remove the o-ring from the rear cover and the 11 rectangular sealing rings from the flywheel housing. Rear Cover - Removal Remove the capscrews from the rear cover, and remove the cover from the crankshaft flange.
  • Page 41: Water Pump Belt - Removal

    Engine Disassembly (00-01) Fan Hub and Fan Hub Support Bracket - Removal Page 0-21 Fan Hub and Fan Hub Support Bracket - Removal Remove the four capscrews that attach the fan hub to the support bracket, and remove the fan hub assembly. Remove the four capscrews that attach the fan hub sup- port (1) bracket to the cylinder block and the brace (2), and remove the fan hub support bracket.
  • Page 42: Air Compressor Coolant Inlet And Outlet Tubes - Removal

    Thermostat Housing - Removal Engine Disassembly (00-01) Page 0-22 Thermostat Housing - Removal Disconnect the air compressor coolant return line from the thermostat housing. Remove the four capscrews that attach the thermostat housing to the rocker housing. Remove the thermostat housing from the water transfer tube.
  • Page 43: Accessory Drive Pulley - Removal

    Remove the water pump from the engine. Remove the water pump out and in a downward direction to clear the dowel pin. This dowel pin, used only on N14 cylinder blocks, prevents the installation of earlier model water pumps which do not incorporate an internal oil cooler coolant return passage.
  • Page 44: Stc External Oil Plumbing - Removal

    STC External Oil Plumbing - Removal Engine Disassembly (00-01) Page 0-24 STC External Oil Plumbing - Removal Disconnect the external oil manifold supply line from the rear of the external oil manifold. Plug the supply line to avoid dirt contamination. Caution: Hold the oil manifold fitting hex with a backup wrench while removing the supply line to avoid damag- ing the manifold.
  • Page 45: Stc Oil Control Valve - Removal

    Engine Disassembly (00-01) STC Oil Control Valve - Removal Page 0-25 Remove the clamp, check valve, and oil supply hose from the engine. STC Oil Control Valve - Removal Remove the two capscrews attaching the STC oil control valve to the mounting plate. Remove the valve. Remove the two capscrews attaching the mounting plate to the cylinder block and remove the mounting plate.
  • Page 46 CELECT™ Actuator Harness - Removal Engine Disassembly (00-01) Page 0-26 Disconnect the Deutsch three pin connector that contains the vehicle key switch, fan clutch, and engine brake con- trol wires from the three pin connector which is wired directly into the Deutsch nine pin connector on the sensor harness.
  • Page 47: Celect™ Sensor Harness - Removal

    Engine Disassembly (00-01) CELECT™ Sensor Harness - Removal Page 0-27 CELECT™ Sensor Harness - Removal Remove the retaining clamps for the sensor harness from the support bracket and the engine block. Although the OEM harness is shown, this will be discon- nected when the engine is out of chassis.
  • Page 48: Celect™ Ambient Air Pressure Sensor - Removal

    CELECT™ Electronic Control Module (ECM) - Removal Engine Disassembly (00-01) Page 0-28 Remove the harness retaining capscrews and disconnect the harness from the following sensors: Oil pressure sensor Oil temperature sensor Ambient air pressure* Engine position sensor Engine coolant temperature sensor *Not used on all ratings.
  • Page 49: Celect™ Lubricating Oil Pressure Sensor - Removal

    Engine Disassembly (00-01) CELECT™ Lubricating Oil Pressure Sensor - Removal Page 0-29 CELECT™ Lubricating Oil Pressure Sensor - Removal Remove the oil pressure signal line. Remove the sensor mounting capscrews. Remove the sensor from the engine. CELECT™ ECM Cooling Plate - Re- moval Remove the inlet and the outlet fuel hoses from the cool- ing plate.
  • Page 50: Stc Engines

    Air Compressor - Removal Engine Disassembly (00-01) Page 0-30 STC Engines Remove the fuel tubing and AFC air signal line: Gear pump cooling drain (1) Fuel supply line (2) Fuel rail pressure line (3) AFC air signal line (4) Tachometer cable (if equipped) (5) Fuel pressure sensing line (to STC valve) (6) Throttle switch (if equipped) (not shown) Remove the four capscrews and the fuel pump.
  • Page 51: Accessory Drive - Removal

    Engine Disassembly (00-01) Accessory Drive - Removal Page 0-31 Accessory Drive - Removal Caution: If the accessory drive dowel pin has been in- correctly installed in the accessory drive shaft, the dowel pin must be removed before attempting to remove the accessory drive to prevent damage to the accessory drive bushing.
  • Page 52: Lubricating Oil Pump - Removal

    Lubricating Oil Pump Signal Line - Removal Engine Disassembly (00-01) Page 0-32 Remove and discard the o-ring from the oil pan flange tube and the rectangular sealing ring from the lubricating oil pump mounting flange. Lubricating Oil Pump Signal Line - Removal Remove the demand flow and cooling (DFC) signal line between the cylinder block main oil rifle and the lubri-...
  • Page 53: Celect™ Intake Air Temperature Sensor - Removal

    Engine Disassembly (00-01) CELECT™ Boost Pressure Sensor - Removal Page 0-33 Remove the two mounting bracket capscrews from the pan rail. Remove the entire assembly from the engine. CELECT™ Boost Pressure Sensor - Removal Remove the sensor mounting capscrews. Remove the sensor from the engine.
  • Page 54: Rocker Housing Covers - Removal

    Rocker Housing Covers - Removal Engine Disassembly (00-01) Page 0-34 Rocker Housing Covers - Removal Remove the ten capscrews from each rocker lever cover. Remove the rocker lever covers. The rocker housing cover gaskets can be used again if they are not dam- aged.
  • Page 55: Valve Crossheads - Removal

    Engine Disassembly (00-01) Valve Crossheads - Removal Page 0-35 Valve Crossheads - Removal Remove the crossheads. Be sure to mark them appro- priately so they can be installed in the same location and orientation during the installation procedure. NOTE: Excessive crosshead wear can result if the cross- heads are not installed in their original locations.
  • Page 56: Rocker Lever Housing - Removal

    Rocker Lever Housing - Removal Engine Disassembly (00-01) Page 0-36 STC Engines Remove the injector hold down clamp capscrew and the clamp. Use injector puller, Part No. 3822697, to remove the STC injectors. Insert the threaded end of the puller into the tapped hole in the STC oil feed lock nut.
  • Page 57: Fuel Crossovers - Removal

    Engine Disassembly (00-01) Fuel Crossovers - Removal Page 0-37 Remove the rocker lever housings. Remove the gaskets. NOTE: On CELECT™ engines while handling the rocker lever housings, protect the wiring harness pass through connectors. Do not subject the pass through connectors to impact forces and do not rest the housing on the face with the pass through connectors.
  • Page 58: Cam Follower Assemblies - Removal

    Cam Follower Assemblies - Removal Engine Disassembly (00-01) Page 0-38 Cam Follower Assemblies - Removal Remove the cam follower housing assemblies as follows: 1. Remove the six capscrews and studs from each cam follower housing. NOTE: Record the position of the studs prior to removal. 2.
  • Page 59: Accessory Drive Seal - Removal

    Crankshaft Seal, Front - Removal Remove the front crankshaft seal. Accessory Drive Seal - Removal Remove the accessory drive seal. Refer to the N14 Trou- bleshooting and Repair Manual, Bulletin No. 3810456, Section 7. Camshaft - Removal Install four camshaft pilots, Part No.
  • Page 60 Piston and Connecting Rod Assemblies - Removal Engine Disassembly (00-01) Page 0-40 Use one hand to slowly rotate and pull the camshaft from the cylinder block and the other hand to balance the camshaft as it is removed. Remove the camshaft thrust washer from the camshaft. Piston and Connecting Rod Assem- blies - Removal Caution: Piston cooling nozzles must be removed prior...
  • Page 61 Engine Disassembly (00-01) Piston and Connecting Rod Assemblies - Removal Page 0-41 Install two connecting rod guide pins, Part No. 3375601. Use a ‘‘T-handle’’ piston pusher to push the rod away from the crankshaft. NOTE: Push the rod away from the crankshaft, over the crankshaft rod journal, and push the rod until the piston rings are outside of the top of the cylinder liner.
  • Page 62: Cylinder Liners - Removal

    Cylinder Liners - Removal Engine Disassembly (00-01) Page 0-42 Remove the upper rod bearing. Mark the cylinder number and the letter ‘‘U’’ in the flat surface of the bearing tang. Caution: Do not over expand the piston rings. Maximum gap at assembly is 1.63 inches. Use the piston ring expander, Part No.
  • Page 63 Engine Disassembly (00-01) Cylinder Liners - Removal Page 0-43 Turn the puller jackscrew clockwise. Use both hands to remove the liners. Remove and discard the o-rings and the crevice seals. NOTE: Do not discard the sealing rings which are located under the cylinder liner flange.
  • Page 64: Crankshaft - Removal

    Crankshaft - Removal Engine Disassembly (00-01) Page 0-44 Use a liquid metal marker to mark the cylinder number on each liner. If the sealing rings were removed, do the following: 1. Use a tag to mark the cylinder number. 2. Measure in several places and record the thickness of the sealing rings used in each cylinder.
  • Page 65 Engine Disassembly (00-01) Crankshaft - Removal Page 0-45 Use main bearing cap puller, Part No. ST-1178, to re- move the caps. The service tool must be centered on the main bearing cap. NOTE: Use a pencil or scribe to mark the bearing shells with the journal number from which they were removed if they are to be used again or if failure analysis is required.
  • Page 66: Cylinder Block - Removal From The Rebuild Stand

    Cylinder Block - Removal from the Rebuild Stand Engine Assembly (00-02) Page 0-46 Warning: Because this part weighs more than 23 kg [50 lbs], two people or a hoist will be required to lift the crankshaft to avoid personal injury. Use a hoist and a lifting sling to remove the crankshaft.
  • Page 67 Engine Assembly (00-02) Cylinder Block - Installation on the Rebuild Stand Page 0-47 Install the mounting plate adapter on the rear water header if removed during the cleaning or inspection procedure. Use five 1/4-20 X 1 1/4-inch capscrews to mount the adapter.
  • Page 68: Crankshaft - Installation

    Crankshaft - Installation Engine Assembly (00-02) Page 0-48 Adjust the position of the cylinder block so that the re- maining mounting holes in the adapter plate (2) and (3) align with the capscrew holes in the cylinder block. Use your fingers to tighten the three 1/2-13 X 3 3/8-inch capscrews (2).
  • Page 69 Engine Assembly (00-02) Crankshaft - Installation Page 0-49 Caution: The upper main bearing shells have a groove and an oil hole to provide crankshaft lubrication. The lower main bearing shells do not. Both bearings are marked on the back to indicate the location and either standard (std.) or oversize (OS).
  • Page 70 Crankshaft - Installation Engine Assembly (00-02) Page 0-50 Align the ring dowel groove in the bearings with the count- erbore in the cylinder block, and install the bearings. Both ends of the bearing will be approximately 1.50 mm [0.060-inch] below the main bearing cap mounting sur- face when installed correctly.
  • Page 71 Engine Assembly (00-02) Crankshaft - Installation Page 0-51 Use a lint free cloth to clean the thrust bearings, the main bearing shells, and the main bearing caps. NOTE: If used thrust bearings are to be installed, each must be installed in its original location in the engine. The bearing journal numbers must have been marked on the bearing during disassembly.
  • Page 72 Crankshaft - Installation Engine Assembly (00-02) Page 0-52 Install the dowel ring in the dowel ring counterbore of the cylinder block. Install the lower main bearing shells as follows: Use clean Lubriplate 105 or its equivalent to lubricate the bearing shell to the crankshaft journal mating surface. Align the dowel ring groove in the bearing with the dowel ring.
  • Page 73 Engine Assembly (00-02) Crankshaft - Installation Page 0-53 The end of the lower main bearing shell opposite the dowel ring must be engaged between the crankshaft and the cylinder block and be seated against the end of the upper bearing shell. NOTE: If installed correctly, the ends of the bearing shells (1) will meet approximately 1.50 mm [0.060-inch] below the cylinder block main bearing mounting surface.
  • Page 74 Crankshaft - Installation Engine Assembly (00-02) Page 0-54 Caution: The main bearing caps are marked for position (1) on the camshaft side and the cylinder block identi- fication (2) on the exhaust side. The cylinder block iden- tification number (3) is stamped on the pan rail on the camshaft side of the block.
  • Page 75 Engine Assembly (00-02) Crankshaft - Installation Page 0-55 Tighten the main bearing capscrews to the following torque values: 1. Tighten to 122 N•m [90 ft-lb]. 2. Tighten to 230 N•m [170 ft-lb]. 3. Tighten to 346 N•m [255 ft-lb]. 4. Loosen completely. 5.
  • Page 76 Crankshaft - Installation Engine Assembly (00-02) Page 0-56 Measure the end clearance of the crankshaft. Install a dial indicator to the rear face of the cylinder block. Put the tip of the gauge against the end of the crankshaft. Push the crankshaft toward the rear of the cylinder block. Set the dial indicator to ‘‘0.’’...
  • Page 77: Cylinder Liners - Installation

    Engine Assembly (00-02) Cylinder Liners - Installation Page 0-57 Measure the crankshaft end clearance. The end clear- ance specification for a new or reground crankshaft with new thrust bearings is 0.10 mm [0.004-inch] to 0.45 mm [0.018-inch]. NOTE: Crankshafts that have been reground on the thrust bearing surfaces are marked for oversize thrust bearings on the rear crankshaft counterweight.
  • Page 78 Cylinder Liners - Installation Engine Assembly (00-02) Page 0-58 Install the o-rings and the crevice seals as follows: 1. Install the crevice seal (1) in the top groove. 2. Install the black o-rings (2 and 3) in the center and the bottom grooves.
  • Page 79 Engine Assembly (00-02) Cylinder Liners - Installation Page 0-59 Liner installation tool, Part No. 3822953, is used to press the cylinder liner into the cylinder block. Protrusion can be checked while the liner is held down by the installation tool. Put a sealing ring into position on the counterbore ledge.
  • Page 80 5. Inspect the cylinder block liner counterbore for burrs. Remove the burrs, or replace the damaged parts. Install the liner again. Check the liner protrusion again. If protrusion is still not correct, refer to the N14 Trouble- shooting and Repair Manual, Bulletin No. 3810456, Sec- tion ‘‘Counterbore...
  • Page 81 Engine Assembly (00-02) Piston and Connecting Rod Assemblies - Assembly and Installation Page 0-61 Piston and Connecting Rod Assem- blies - Assembly and Installation Install a new snap ring in one of the snap ring grooves of the piston pin bore on each piston. Heat the pistons in boiling water for 15 minutes or in an oven for 30 minutes at 100°...
  • Page 82 Piston and Connecting Rod Assemblies - Assembly and Installation Engine Assembly (00-02) Page 0-62 The piston ring shipping package identifies the location of each piston ring by the part number. Install the rings in the sequence shown and in the proper orientation. The first and second rings have the word ‘‘TOP’’...
  • Page 83 Engine Assembly (00-02) Piston and Connecting Rod Assemblies - Assembly and Installation Page 0-63 Use clean Lubriplate 105 or its equivalent to lubricate the bearing shell. Apply a heavy film of clean 15W-40 oil to the liner. Put the piston and the ring assembly in a container of clean 15W-40 oil.
  • Page 84 Piston and Connecting Rod Assemblies - Assembly and Installation Engine Assembly (00-02) Page 0-64 Caution: To avoid piston damage, do not use a metal object to push the piston in the liner. NOTE: The tang of the connecting rod must be toward the camshaft side of the cylinder block.
  • Page 85: Rear Cover - Installation

    Engine Assembly (00-02) Rear Cover - Installation Page 0-65 Caution: The rod cap alpha-numeric characters must match the alpha-numeric characters on the connecting rod and must be installed with the characters aligned to prevent damage to the connecting rods and the crank- shaft.
  • Page 86: Crankshaft Seal, Rear - Installation

    Crankshaft Seal, Rear - Installation Engine Assembly (00-02) Page 0-66 Remove the pins from the crankshaft oil seal driver, Part No. ST-997; and use the driver to align the rear cover with the crankshaft. Install the seal drive in the crankshaft flange and in the bore of the rear cover.
  • Page 87: Flywheel Housing - Installation

    Engine Assembly (00-02) Flywheel Housing - Installation Page 0-67 Install the pins in crankshaft oil seal driver, Part No. ST-997. Use crankshaft oil seal driver, Part No. ST-997, to install the oil seal in the rear cover. Flywheel Housing - Installation Caution: If a new flywheel housing is being installed, the dowels must be removed from the cylinder block prior to installing the housing to prevent damage to the...
  • Page 88 Flywheel Housing - Installation Engine Assembly (00-02) Page 0-68 Bore Alignment - Measurement Caution: The flywheel housing bore and the surface must be in alignment with the crankshaft to prevent possible damage to the engine, the clutch, or the trans- mission.
  • Page 89 Engine Assembly (00-02) Flywheel Housing - Installation Page 0-69 Determine the total indicator runout (T.I.R.) as follows: Example: 12 o’clock 0.00 0.000 3 o’clock +0.08 +0.003 6 o’clock - 0.05 - 0.002 9 o’clock +0.08 +0.003 Equals T.I.R. 0.13 0.005 The maximum allowable total indicator runout (T.I.R.) depends on the diameter of the housing bore.
  • Page 90 Flywheel Housing - Installation Engine Assembly (00-02) Page 0-70 If the alignment is not within specifications and the bore is round, the housing can be shifted. Refer to Section 16. If the alignment is not within specifications and the bore is not round, the housing must be replaced.
  • Page 91 Engine Assembly (00-02) Flywheel Housing - Installation Page 0-71 Continue rotating the crankshaft until the dial indicator is at the 12:00 o’clock position. Check the dial indicator to make sure the needle still points to ‘‘0.’’ Determine the total indicator runout (T.I.R.) as follows: Example: 12 o’clock 0.00...
  • Page 92: Flywheel - Installation

    Flywheel - Installation Engine Assembly (00-02) Page 0-72 If the alignment is not within specifications, remove the housing. Check for nicks, burrs, or foreign material be- tween the block and the housing. Check the alignment again. If the alignment is not within specifications, the block or the housing is not machined correctly.
  • Page 93 Engine Assembly (00-02) Flywheel - Installation Page 0-73 Install two t-bolts into the flywheel clutch mounting sur- face. Install two 5/8 - 18 x 6-inch guide studs in the crankshaft flange. Warning: Because this part weighs more than 23 kg [50 lbs], two people or a hoist will be required to lift the part to avoid personal injury.
  • Page 94 Flywheel - Installation Engine Assembly (00-02) Page 0-74 Rotate the crankshaft one complete revolution. NOTE: The total indicator runout (T.I.R.) must not exceed 0.127 mm [0.0050-inch]. If the T.I.R. is greater than the specification, remove the flywheel. Inspect the flywheel mounting surface for dirt or damage. Inspect the crankshaft for dirt or damage.
  • Page 95 Engine Assembly (00-02) Flywheel - Installation Page 0-75 Install the flywheel, and inspect the bore runout again. Replace the flywheel if the runout does not meet specifications. Face Alignment - Measurement Install the contact tip of the indicator against the flywheel face, as close to the outside diameter as possible, to inspect the face (4) runout.
  • Page 96: Cylinder Heads - Installation

    Cylinder Heads - Installation Engine Assembly (00-02) Page 0-76 The total indicator runout (T.I.R.) must not exceed the following specifications: Flywheel Radius (A) Maximum (T.I.R.) of Flywheel Face 0.203 0.008 0.254 0.010 0.305 0.012 0.356 0.014 0.406 0.016 If the flywheel face runout is not within specification, remove the flywheel.
  • Page 97 Engine Assembly (00-02) Cylinder Heads - Installation Page 0-77 Install the cylinder heads over the dowel pins. If reusing original cylinder heads, install them in their original position. Use clean 15W-40 oil to lubricate the cylinder head cap- screws and both sides of the flat washers. Allow the excess oil to drain from the threads.
  • Page 98: Camshaft - Installation

    Camshaft - Installation Engine Assembly (00-02) Page 0-78 After all 12 capscrews on one head have been torqued to 298 N•m [220 ft-lb], they must be rotated in the tightening direction an additional 90 degrees. Rotate the capscrew until the mark on the cylinder head is between the next two marks joined by an arc (more than one flat and less than two flats).
  • Page 99 Engine Assembly (00-02) Camshaft - Installation Page 0-79 Align the ‘‘O’’ mark on the camshaft gear with the ‘‘O’’ mark on the crankshaft gear. After aligning the ‘‘O’’ marks, push the camshaft in the bore until the thrust washer fits against the cylinder block. Remove the camshaft installation pilots.
  • Page 100: Cam Follower Assemblies - Installation

    Cam Follower Assemblies - Installation Engine Assembly (00-02) Page 0-80 Turn the camshaft gear by hand in the opposite direction as far as it will freely move, and read the dial indicator. Backlash Between the Camshaft and the Crankshaft Gears 0.05 0.002 0.50...
  • Page 101 Engine Assembly (00-02) Injection Timing - General Information Page 0-81 The injection timing code appears on the engine dataplate. Codes are alphabetic letters that relate to a numerical specification. Specifications can be found in the Control Parts List (CPL) Manual, Bulletin No. 3379133. Advanced timing (1) means the fuel is injected earlier into the cylinder during the compression stroke.
  • Page 102: Timing Tool Installation

    Injection Timing - General Information Engine Assembly (00-02) Page 0-82 NOTE: The injection timing check is a measurement which determines the injector push rod travel in relation to the piston travel. Due to normal parts tolerances, it is necessary to check one cylinder for each cam follower housing. Timing Tool Installation Caution: Pivot the dial indicator stems away from their respective plunger rods before installing the timing fix-...
  • Page 103 Engine Assembly (00-02) Injection Timing - General Information Page 0-83 Align the plunger rod (1) and the injector push rod (3) with each other, and parallel to the plunger rod. NOTE: Tighten the clamp handle (2) after the plunger rod is aligned with the injector push rod.
  • Page 104 Injection Timing - General Information Engine Assembly (00-02) Page 0-84 NOTE: The timing tool indicator needles will both start to move in the same direction of rotation as the piston ap- proaches TDC if the cylinder is on the compression stroke. If both needles do not move in the same direction, rotate the engine one complete revolution in the same direction of rotation.
  • Page 105 Engine Assembly (00-02) Injection Timing - General Information Page 0-85 Put the push rod travel dial indicator in the center of the injector push rod plunger. Lower the indicator to within 0.63 mm [0.025-inch] of fully compressed position, and tighten the thumbscrew to hold the indicator in position. Set the dial indicator at ‘‘0’’...
  • Page 106 Injection Timing - General Information Engine Assembly (00-02) Page 0-86 Compare the reading of the injector push rod travel in- dicator to the specification listed for the timing code. NOTE: The push rod travel indicator is read in a counter- clockwise direction from ‘‘0’’...
  • Page 107 Engine Assembly (00-02) Injection Timing - General Information Page 0-87 NOTE: The injection timing can be changed by removing the cam follower housing and by increasing or decreasing the gasket thickness. Each 0.18 mm [0.007-inch] of gasket thick- ness affects injection timing by approximately 0.05 mm [0.002-inch] indicator travel.
  • Page 108 Injection Timing - General Information Engine Assembly (00-02) Page 0-88 The accompanying chart lists the different cam follower Cam Follower Housing Gaskets housing gaskets, the gasket thickness, and approximate Change in Push Rod Travel change in push rod travel at 19 degrees BTDC 0.2032- Gasket Thickness At 19°...
  • Page 109: Accessory Drive - Installation

    Engine Assembly (00-02) Accessory Drive - Installation Page 0-89 Accessory Drive - Installation Rotate the crankshaft until the accessory drive timing marks on the camshaft gear are at approximately the 1:00 o’clock position. Install a new gasket on the accessory drive assembly. Put the accessory drive shaft dowel pin at approximately the 11:30 o’clock position when facing the shaft from the pulley end.
  • Page 110 Accessory Drive - Installation Engine Assembly (00-02) Page 0-90 Use a dial indicator to check the backlash between the accessory drive gear and the camshaft gear. Install the tip of the dial indicator against a tooth on the accessory drive gear as shown. Push the accessory drive gear against the accessory drive thrust washer or thrust face.
  • Page 111: Celect™ Engine Position Sensor (Eps) - Installation

    Engine Assembly (00-02) CELECT™ Engine Position Sensor (EPS) - Installation Page 0-91 CELECT™ Engine Position Sensor (EPS) - Installation Install a new EPS in the mounting hole in the block. Make sure a new o-ring is present and in place. Use service tool, Part No.
  • Page 112: Gear Cover - Installation

    Gear Cover - Installation Engine Assembly (00-02) Page 0-92 Turn the lubricating oil pump drive gear by hand as far as it will freely move, and set the dial indicator to ‘‘0’’ (zero). Turn the lubricating oil pump drive gear by hand in the opposite direction as far as it will freely move, and read the dial indicator.
  • Page 113 Engine Assembly (00-02) Gear Cover - Installation Page 0-93 Cut off the ends of the gasket even with the cylinder block oil pan mounting flange. Mount a dial indicator on the front face of the crankshaft. Put the indicator plunger against the oil seal bore, and set the dial indicator to ‘‘0’’...
  • Page 114: Camshaft Bearing Support - Installation

    Crankshaft Seal, Front - Installation Engine Assembly (00-02) Page 0-94 Crankshaft Seal, Front - Installation NOTE: ‘‘LDL TFE’’ (Lay-down Lip, Teflon) oil seals for ser- vice replacement have an assembly tool which protects the seal lip during shipment and installation. The ‘‘LDL TFE’’ oil seal must be installed with the lip of the seal and the crank- shaft clean and dry.
  • Page 115 Engine Assembly (00-02) Camshaft Bearing Support - Installation Page 0-95 The clearance between the bearing support thrust face and the camshaft gear must be 0.20 mm to 0.33 mm [0.008- to 0.013-inch]. After measuring the space between the bearing support and the gear cover flange, add an additional 0.20 mm to 0.33 mm [0.008-inch to 0.013-inch] to that number to determine the thickness of the shims required.
  • Page 116: Accessory Drive Seal - Installation

    Accessory Drive Seal - Installation Engine Assembly (00-02) Page 0-96 Caution: Do not use lubricating oil on the o-ring. The o-ring will increase in size when in contact with lubri- cating oil. Use vegetable oil to lubricate the o-ring. Lubricate the o-ring with vegetable oil, and install the support bearing into the gear cover.
  • Page 117: Accessory Drive Pulley - Installation

    Engine Assembly (00-02) Accessory Drive Pulley - Installation Page 0-97 Accessory Drive Pulley - Installation NOTE: Make sure the pipe plug behind the pulley is installed and tightened before pulley installation. Apply a film of Lubriplate 105 or its equivalent to the accessory drive shaft.
  • Page 118: Lubricating Oil Pan - Installation

    Lubricating Oil Pan - Installation Engine Assembly (00-02) Page 0-98 Lubricating Oil Pan - Installation Install the oil pan gasket and the oil pan on the cylinder block. Use your fingers to install and tighten one of the 7/16-inch oil pan mounting capscrews on each side of the oil pan, halfway between the front and the rear of the oil pan.
  • Page 119 Engine Assembly (00-02) Rocker Lever Housing - Installation Page 0-99 Install the water tubes (A) in the front of the No. 2 and No. 3 rocker lever housings. Install the plugs (B) in the front of the No. 1 rocker lever housing and in the rear of the No. 3 rocker lever housing.
  • Page 120: Injectors - Installation

    Injectors - Installation Engine Assembly (00-02) Page 0-100 Use service tool, Part No. 3823819, to slide the two water tubes into the adjacent water manifold. Install the two water tube retainer clamps. Install and tighten the retainer clamp capscrews. Torque Value: 45 N•m [33 ft-lb] Injectors - Installation CELECT™...
  • Page 121 Engine Assembly (00-02) Injectors - Installation Page 0-101 If injector puller, Part No. 3823579, is not available, a screwdriver can be used to install the injector by putting the screwdriver on the injector body at the base of the injector solenoid and striking the screwdriver with a soft mallet.
  • Page 122: Push Tubes - Installation

    Push Tubes - Installation Engine Assembly (00-02) Page 0-102 NOTE: When installing injectors for reuse, new o-rings must be installed on the injector. Lubricate the o-rings with lubricating oil just before installation. Install the injector and hold down clamp. Use injector puller, Part No. 3822697, to install STC in- jectors.
  • Page 123: Valve Crossheads - Installation

    Engine Assembly (00-02) Valve Crossheads - Installation Page 0-103 Install the push tubes in the corresponding numbered location. On CELECT™ engines, take care to route the injector solenoid leads to avoid contact with the valve and injector push tubes. Twist the injector connector three turns to twist the lead wires.
  • Page 124: Rocker Lever Shaft Assemblies - Installation

    Rocker Lever Shaft Assemblies - Installation Engine Assembly (00-02) Page 0-104 Use a wire gauge to check the clearance between the crosshead and the valve spring retainer. The clearance must be a minimum of 0.51 mm [0.020-inch]. NOTE: The large pocket goes toward the exhaust side. Rocker Lever Shaft Assemblies - Installation Install the exhaust (1), injector (2), and intake (3) rocker...
  • Page 125: Injector And Valve Adjustment

    Engine Assembly (00-02) Injector and Valve Adjustment Page 0-105 Make sure the push rods are in the cam follower sockets, and align the push rods with the injector and valve rocker lever adjusting screws. Alternately tighten the rocker shaft capscrews in 54 N•m [40 ft-lb] increments to 156 N•m [115 ft-lb].
  • Page 126 Injector and Valve Adjustment Engine Assembly (00-02) Page 0-106 The valves and the injectors on the same cylinder are CELECT™ Engine adjusted at the same index mark on the accessory drive Injector and Valve Adjustment Sequence Bar Engine pulley. in Direction Pulley Set Cylinder One pair of valves and one injector are adjusted at each...
  • Page 127 Engine Assembly (00-02) Injector and Valve Adjustment Page 0-107 Tighten the adjusting screw on the injector rocker lever. Torque Value: 2.8 N•m [25 in-lb] Caution: After preloading the CELECT™ injector to 2.8 N•m [25 in-lb], make sure to back out the adjusting screw two flats (120 degrees) or damage to the injector will result.
  • Page 128 Injector and Valve Adjustment Engine Assembly (00-02) Page 0-108 Select a feeler gauge for the correct valve lash specification. Valve Lash Specifications Intake Exhaust 0.35 mm 0.68 mm [0.014-inch] [0.027-inch] Insert the feeler gauge between the top of the crosshead and the rocker lever pad.
  • Page 129 Engine Assembly (00-02) Injector and Valve Adjustment Page 0-109 If using the feel method, attempt to insert a feeler gauge that is 0.03 mm [0.001-inch] thicker between the cross- head and the rocker lever pad. The valve lash is not correct when a thicker feeler gauge will fit.
  • Page 130 Injector and Valve Adjustment Engine Assembly (00-02) Page 0-110 All overhead (valve and injector) adjustments must be made when the engine is cold (any stabilized coolant temperature at 60°C [140°F] or below). Each cylinder has three rocker levers: • The exhaust rocker lever (1). •...
  • Page 131 Engine Assembly (00-02) Injector and Valve Adjustment Page 0-111 Check the valve rocker levers on cylinder No. 5 to see if both the intake and exhaust valves are closed. NOTE: Both the intake and exhaust valves are closed when both rocker levers are loose and can be moved from side to side.
  • Page 132 Injector and Valve Adjustment Engine Assembly (00-02) Page 0-112 Apply thumb pressure to the tool handle to hold the tappet in the maximum upward position. Caution: An overtightened setting on the injector ad- justing screw will produce increased stress on the in- jector train and the camshaft injector lobe which can result in engine damage.
  • Page 133 Engine Assembly (00-02) Injector and Valve Adjustment Page 0-113 With the ‘‘A’’ set mark aligned with the pointer on the gear cover and both valves closed on cylinder No. 5, loosen the lock nuts on the intake and the exhaust valve adjust- ing screws.
  • Page 134 Bar Engine correctly. in Direction Pulley Set Cylinder of Rotation Position Injector Valve Install the C-Brakes again, if equipped. Refer to the N14 Start Troubleshooting and Repair Manual, Bulletin No. Advance to 3810456. Advance to Advance to Advance to Advance to...
  • Page 135: Engine Brake - Installation

    Engine Assembly (00-02) Engine Brake - Installation Page 0-115 Engine Brake - Installation Install two guide pins into each rocker lever housing. Install new C-Brake housing gaskets and the C-Brakes. Remove the guide pins. Install the C-Brake capscrews. Tighten the capscrews in the sequence shown to the torque value listed below.
  • Page 136 Set Brake Start Advance to Advance to Advance to Advance to Advance to Firing Order: 1-5-3-6-2-4 Right Hand Rotation Caution: Use of the wrong adjusting screw can result in severe engine damage. See the latest N14 parts publi- cation information.
  • Page 137 Engine Assembly (00-02) Engine Brake - Adjustment Page 0-117 Loosen the lock nut for the No. 5 slave piston adjusting screw. Install a dial indicator, Part No. 3375006, over the No. 5 slave piston adjusting screw. Use the adapter, Part No. 3823826, to mount the dial indicator fixture to the C-Brake.
  • Page 138: C-Brake - Alternate Method

    Engine Brake - Adjustment Engine Assembly (00-02) Page 0-118 Use the torque wrench adapter, Part No. ST-669, and a 1/4-inch eight point socket to tighten the lock nut. Torque Value: 24 N•m [18 ft-lb] Repeat this procedure to adjust the remaining slave pistons.
  • Page 139: Jacobs Brake

    Engine Assembly (00-02) Rocker Housing Covers - Installation Page 0-119 Tighten the slave piston adjusting screw until the slave piston contacts the feeler gauge and creates a slight drag. Use the torque wrench adapter, Part No. ST-669, to tighten the lock nut. Torque Value: 24 N•m [18 ft-lb] Repeat this procedure to adjust the remaining slave...
  • Page 140: Intake Manifold - Installation

    Intake Manifold - Installation Engine Assembly (00-02) Page 0-120 Install the covers on the rocker lever housing. Install the ten capscrews and washers in each cover. Tighten the capscrews in each cover in the sequence shown. Torque Value: 12 N•m [105 in-lb] Install the rubber grommet, breather tube, and oil filler cap into the rocker housing covers, if applicable.
  • Page 141: Celect™ Intake Air Temperature Sensor - Installation

    Engine Assembly (00-02) CELECT™ Intake Air Temperature Sensor - Installation Page 0-121 CELECT™ Intake Air Temperature Sensor - Installation Install the sensor in the engine. Tighten the sensor. Torque Value: 35 N•m [25 ft-lb] Make sure the sensor is installed with a new o-ring. CELECT™...
  • Page 142: Lubricating Oil Pump Signal Line - Installation

    Lubricating Oil Pump Signal Line - Installation Engine Assembly (00-02) Page 0-122 Connect the sensor drain line (1) to the tee fitting on the cylinder block. Torque Value: 27 N•m [20 ft-lb] Connect the pressure signal line (1) to the lubricating pump fitting (2) and the rifle pressure supply line (3) to the oil rifle fitting (4).
  • Page 143: Fuel Tubing - Installation

    Engine Assembly (00-02) Fuel Tubing - Installation Page 0-123 Install a new o-ring on the oil pan lubricating oil suction tube. Use clean vegetable oil to lubricate the o-ring. Loosely install the lubricating oil transfer tube assembly with the lubricating oil pump mounting flange, new seal- ing ring, new gasket, and the mounting capscrews to the oil pan and lubricating oil pump.
  • Page 144: Air Compressor - Installation

    Air Compressor - Installation Engine Assembly (00-02) Page 0-124 Air Compressor - Installation Install the splined coupling on the accessory drive. Make sure the gasket surfaces of the accessory drive and the air compressor are clean and not damaged. It is not necessary to time the air compressor on the NT engine.
  • Page 145 Engine Assembly (00-02) CELECT™ ECM Cooling Plate - Installation Page 0-125 STC Engines Install the fuel pump drive spider coupling. Use a new gasket to install the fuel pump. Install the four fuel pump mounting capscrews. Torque Value: 47 N•m [35 ft-lb] Install the AFC air signal line and fuel tubing: •...
  • Page 146: Celect™ Lubricating Oil Pressure Sensor - Installation

    CELECT™ Lubricating Oil Pressure Sensor - Installation Engine Assembly (00-02) Page 0-126 Connect and tighten the inlet and outlet fuel hoses to the cooling plate. Inspect for paint or grease on the cooling plate. CELECT™ Lubricating Oil Pressure Sensor - Installation Install the sensor on the engine.
  • Page 147 Engine Assembly (00-02) CELECT™ Sensor Harness - Installation Page 0-127 CELECT™ Sensor Harness - Installa- tion Install the sensor wiring harness on the engine. Install the sensor harness amp connector to the elec- tronic control module (ECM). Tighten the connector cap- screws to the ECM.
  • Page 148 CELECT™ Actuator Harness - Installation Engine Assembly (00-02) Page 0-128 On engines equipped with engine brakes, connect the engine brake harness to the sensor harness. Wire tie the harness to the fuel tubing at the rear of the engine. CELECT™ Actuator Harness - Installa- tion Install the actuator harness on the engine.
  • Page 149: Stc Oil Control Valve - Installation

    Engine Assembly (00-02) STC Oil Control Valve - Installation Page 0-129 Connect the actuator harness to each of the pass through connectors along the side of the rocker lever housing. Make sure the connector clicks/snaps into place. Install a new plastic wire tie, Part No. 3062329, to each of the pass through connectors to hold the actuator harness to the pass through connectors.
  • Page 150 STC External Oil Plumbing - Installation Engine Assembly (00-02) Page 0-130 STC External Oil Plumbing - Installa- tion Connect the following lines to the STC oil control valve and tighten them to the specified torque: 1. Fuel pressure sensing line - 9.5 N•m [84 in-lb] 2.
  • Page 151: Vibration Damper - Installation

    Engine Assembly (00-02) Engine Support Bracket, Front - Installation Page 0-131 Engine Support Bracket, Front - Installation Install the engine support bracket and the eight mounting capscrews. Tighten the capscrews. Torque Value: 68 N•m [50 ft-lb] Vibration Damper - Installation Install two guide pins into the end of the crankshaft.
  • Page 152 Vibration Damper - Installation Engine Assembly (00-02) Page 0-132 Install the dial indicator on the gear cover as indicated to measure damper eccentricity. Rotate the crankshaft, and record the indicator move- ment. Replace the vibration damper if the eccentricity exceeds 0.10 mm [0.004-inch] per 25.4 mm [1.0 inch] of the damper diameter.
  • Page 153: Water Pump - Installation

    Engine Assembly (00-02) Water Pump - Installation Page 0-133 Rotate the crankshaft 360 degrees, maintaining the po- sition of the crankshaft (either toward the front or the rear) in relation to the block. Record the total indicator motion. Replace the damper if wobble exceeds 0.18 mm [0.007- inch] per 25.4 mm [1.0 inch] of radius.
  • Page 154: Water Pump Belt - Installation And Adjustment

    Water Pump Belt - Installation and Adjustment Engine Assembly (00-02) Page 0-134 Water Pump Belt - Installation and Adjustment Visually inspect the pulley alignment. Pulley misalign- ment must not exceed 0.5 mm per cm [1/16-inch per foot] of distance between the pulley centers. Inspect and repair or replace the idler pulley or water pump if pulley misalignment exceeds 0.5 mm per cm [1/16-inch per foot].
  • Page 155: Air Compressor Coolant Inlet And Outlet Tubes - Installation

    Engine Assembly (00-02) Thermostat Housing - Installation Page 0-135 Thermostat Housing - Installation Install the water transfer tube with new o-rings into the water pump housing. Apply a non-petroleum based lu- bricant such as soap or vegetable oil to the o-rings on each end of the tube and to the bores in the water pump housing and the thermostat housing cover.
  • Page 156: Fan Hub And Fan Hub Support Bracket - Installation

    Fan Hub and Fan Hub Support Bracket - Installation Engine Assembly (00-02) Page 0-136 Install the coolant tubes to the air compressor and the water pump. Install the coolant tube to the thermostat housing. Fan Hub and Fan Hub Support Bracket - Installation Install the following pieces on the engine and tighten the capscrews.
  • Page 157: Fan Belts - Installation And Adjustment

    Engine Assembly (00-02) Fan Belts - Installation and Adjustment Page 0-137 Fan Belts - Installation and Adjustment Visually inspect the pulley alignment. Pulley misalign- ment must not exceed 0.5 mm per cm [1/16-inch per foot] of distance between the pulley centers. Inspect, repair, or replace the fan hub or the fan hub support bracket if pulley misalignment exceeds 0.5 mm per cm [1/16-inch per foot].
  • Page 158: Engine - Removal From The Rebuild Stand

    Engine - Removal From the Rebuild Stand Engine Assembly (00-02) Page 0-138 Refer to the Belt Tension Chart shown to select the cor- Belt Tension Specifications rect gauge and tension values for the belt width. Belt Tension New Belt Gauge Installation Used Belt A belt is considered used if it has been in operation for...
  • Page 159: Piston Cooling Nozzles - Installation

    Engine Assembly (00-02) Piston Cooling Nozzles - Installation Page 0-139 Use the hoist to move the weight of the engine off of the rebuild stand. Remove the capscrews that hold the engine to the adapter plate. Install the engine on two engine support stands, Part No. ST-163.
  • Page 160: Water Header Covers - Installation

    Torque Value: 47 N•m [35 ft-lb] NOTE: Check the dipstick calibration after the engine is installed in the vehicle chassis. Refer to N14 Troubleshoot- ing and Repair Manual, Bulletin No. 3810456. Water Header Covers - Installation Install new water header cover gaskets and the covers.
  • Page 161: Lubricating Oil Cooler Assembly - Installation

    Engine Assembly (00-02) Lubricating Oil Cooler Assembly - Installation Page 0-141 Lubricating Oil Cooler Assembly - Installation Install two guide studs in the oil cooler support mounting holes in the cylinder block. Install a new oil cooler support gasket over the guide studs.
  • Page 162: Alternator - Installation

    Alternator Mounting Bracket - Installation Engine Assembly (00-02) Page 0-142 Alternator Mounting Bracket - Installa- tion Install the alternator mounting bracket. Tighten the mount- ing capscrews. Torque Value: 47 N•m [35 ft-lb] Alternator - Installation Install the alternator, capscrew, washer, and nut to the alternator mounting bracket.
  • Page 163: Fan And Fan Spacer - Installation

    Engine Assembly (00-02) Fan and Fan Spacer - Installation Page 0-143 Adjust the belt tension to the following values: New Belt Tension Used Belt Tension 620 N [140 lbf] 490 N [110 lbf] NOTE: A belt is considered used if it has been in operation for more than 10 minutes.
  • Page 164: Starting Motor - Installation

    NOTE: The side of the gasket marked ‘‘OUT’’ must be away from the cylinder heads. Special capscrews with spacers are required for the N14 exhaust manifold. Do not use short capscrews. Warning: Because this assembly weighs more than 23 kg [50 lbs], two people or a hoist will be required to lift the exhaust manifold assembly to avoid personal injury.
  • Page 165: Turbocharger - Installation

    Engine Assembly (00-02) Turbocharger - Installation Page 0-145 Tighten the capscrews in two steps in the sequence shown. Torque Values: Step 1 47 N•m [35 ft-lb] Step 2 81 N•m [60 ft-lb] Turbocharger - Installation Apply a film of high temperature anti-seize compound, Part No.
  • Page 166 Turbocharger - Installation Engine Assembly (00-02) Page 0-146 Install a new gasket, oil drain tube, and capscrews. Tighten the capscrews. Torque Value: 44 N•m [32 ft-lb] Pour 50 to 60 cc [2.0 to 3.0 ounces] of clean engine oil in the turbocharger oil supply opening. If installing a new turbocharger, install the male union elbow.
  • Page 167: Crankcase Breather Tube - Installation

    Engine Assembly (00-02) Crankcase Breather Tube - Installation Page 0-147 Crankcase Breather Tube - Installation Install the breather vent tube on the breather tube, and tighten the hose clamps. Torque Value: 4.5 N•m [40 in-lb] Install and tighten the tube support brackets and cap- screws.
  • Page 168: Engine - Covering All Openings

    Engine - Covering All Openings Engine Assembly (00-02) Page 0-148 If the engine is to be run-in on an engine dynamometer, make sure the shutoff valve is closed. Open the valve after the run-in. Be sure the engine draincock and oil cooler draincock are closed.
  • Page 169 Cylinder Block Page 1-1 Section 1 - Cylinder Block - Group 01 Section Contents Page Camshaft - Cleaning and Inspection ......................1-63 Cleaning ............................... 1-63 Inspection ..............................1-64 Camshaft Gear - Replacement ........................1-65 Cleaning ............................... 1-66 Inspection ..............................1-66 Installation ..............................
  • Page 170: Table Of Contents

    Cylinder Block Page 1-2 Page Cylinder Block - Exploded View........................1-6 Cylinder Block - General Information ....................... 1-8 Cylinder Block - Machining ..........................1-22 Coolant Passage - Repairing ........................1-23 Cylinder Block - Deck Resurfacing ........................ 1-22 Cylinder Head Capscrew Holes - Repairing....................1-26 Cylinder Block - Service Tools..........................
  • Page 171: Cylinder Block - Service Tools

    Cylinder Block - Service Tools The following special tools are recommended to perform procedures in section 1. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
  • Page 172 Cylinder Block - Service Tools Cylinder Block Page 1-4 Tool No. Tool Description Tool Illustration Loctite Compound Use to install repair bushings. ST-1272-12 Loctite Primer T Use to clean the counterbore area and the outside diameter of the repair sleeve. ST-1272-13 Pipe Sealant Use when installing pipe plugs on engines to stop leaks.
  • Page 173 Cylinder Block Cylinder Block - Service Tools Page 1-5 Tool No. Tool Description Tool Illustration Camshaft Bushing Driver Use camshaft bushing driver set, Part No. 3376637, and driver, Part No. 3375861, to remove bushing No. 1 through No. 7. 3375861 Camshaft Bushing Driver Use to install camshaft bushings No.
  • Page 174: Cylinder Block - Exploded View

    Cylinder Block - Exploded View Cylinder Block Page 1-6 Cylinder Block - Exploded View...
  • Page 175 Cylinder Block Cylinder Block - Exploded View Page 1-7 Ref. Description Quantity Damper, Vibration Pulley, Crankshaft Bushing, Gear Cover Accessory Drive Cover, Gear Support, Camshaft Shim, Camshaft Support Seal, O-ring Gasket, Gear Cover Plug, Inspection Seal, Front Crankshaft Bearing, Camshaft Thrust Key, Woodruff Gear, Camshaft Camshaft...
  • Page 176: Cylinder Block - General Information

    2. Most of the capscrews used on the N14 engine are U.S. Customary. All fasteners have right-hand threads unless a CAUTION states that a fastener has left-hand threads.
  • Page 177: Cam Bore Rear Cup Plug - Removal

    Cylinder Block Cylinder Block - Disassembly (01-01) Page 1-9 Cylinder Block - Disassembly (01-01) Cam Bore Rear Cup Plug - Removal To remove the cup plug from the camshaft bore, use a center punch to mark the cup plug for drilling. Drill a 3.18 mm [1/8-inch] hole in the cup plug.
  • Page 178: Dowel Pin - Removal

    Cylinder Block - Disassembly (01-01) Cylinder Block Page 1-10 Remove the straight thread plug and pipe plug from the piston cooling oil passage on the exhaust side of the cylinder block. Remove pipe plugs from the coolant passage on the exhaust side of the cylinder block.
  • Page 179: Camshaft Bushings - Removal

    Cylinder Block Cylinder Block - Cleaning and Inspection (01-02) Page 1-11 Camshaft Bushings - Removal Use camshaft bushing driver set, Part No. 3376637, and driver, Part No. 3375861, to remove bushings No. 1 through No. 7. Remove the No. 1 bushing first and then the remaining six (6) bushings in order from front to rear.
  • Page 180 Cylinder Block - Cleaning and Inspection (01-02) Cylinder Block Page 1-12 Clean the following cylinder block areas: Cylinder liner counterbore ledge and press fit area. Cylinder liner packing ring bore. Cylinder head deck surface. Main bearing saddles and caps.
  • Page 181 Cylinder Block Cylinder Block - Cleaning and Inspection (01-02) Page 1-13 Camshaft bore cup plug area. All gasket surfaces. All component mounting surfaces. Clean all oil passages. Use a bottle brush with a long handle.
  • Page 182 Follow the instructions of the manufacturer of the clean- ing tank and the manufacturer of the cleaning solution. NOTE: Cummins Engine Company, Inc., does not recom- mend any specific cleaning solution. The best results can be obtained by using a cleaning solution that can be heated to 80°...
  • Page 183: Camshaft Bore - Cleaning

    Cylinder Block Cylinder Block - Cleaning and Inspection (01-02) Page 1-15 NOTE: If the cylinder block is not going to be used imme- diately, apply a coating of preservative oil to prevent rust. Cover the block to prevent dirt from sticking to the oil. Camshaft Bore - Cleaning Use a fine emery cloth to remove burrs, and clean the bushing bores.
  • Page 184 Cylinder Block - Cleaning and Inspection (01-02) Cylinder Block Page 1-16 Use two centering rings, Part No. ST-1177-39 [4.750 inches diameter]. Put the rings in the No. 2 and the No. 6 main bearing locations. Use clean 15W-40 oil to lubricate the main bearing cap- screw threads and the flat washers.
  • Page 185 Cylinder Block Cylinder Block - Cleaning and Inspection (01-02) Page 1-17 4. Hit the cap with a rubber mallet to push it into the correct position. NOTE: The main bearing caps must not have any side clearance with the block. Cylinder Block to Main Bearing Cap Press Fit 0.03 0.001...
  • Page 186 Cylinder Block - Cleaning and Inspection (01-02) Cylinder Block Page 1-18 Insert the bar through the centering rings while slowly rotating the bar. The bar must turn easily. If the bar does not turn easily, check to make sure the main bearing caps are installed correctly.
  • Page 187 Cylinder Block Cylinder Block - Cleaning and Inspection (01-02) Page 1-19 Use a 0.08 mm [0.003-inch] feeler gauge that is not more than 13 mm [0.5-inch] wide. Center the checking ring in the bore. Try to put the feeler gauge between the checking ring and the bore. Rotate the gauge in the bore at both sides of the checking ring.
  • Page 188: Cylinder Block - Inspection

    Cylinder Block - Cleaning and Inspection (01-02) Cylinder Block Page 1-20 Measure the inside diameter in the three positions shown. The inside diameter must be completely round within 0.0190 mm [0.00075-inch]. Main Bearing Bore I.D. (Capscrews Torqued to Specification) 120.599 4.7480 120.637 4.7495...
  • Page 189: Coolant Passage - Inspection

    NOTE: If the top surface of the block is machined, the ledge depth of the cylinder liner counterbore must be machined. Refer to the NH/NT Counterbore Troubleshooting and Repair Manual, Bulletin No. 3810450, or the N14 Trou- bleshooting and Repair Manual, Bulletin No. 3810456, for detailed instructions.
  • Page 190 Cylinder Block - Machining (01-03) Cylinder Block Page 1-22 Closed end thread repair inserts can be used in conjunc- tion with upper counterbore sleeves (0.020-inch oversize on the outside diameter or smaller), and coolant passage repair inserts. Cylinder blocks with vertical cracks that extend down over the counterbore ledge that can not be machined out using a 0.750-inch long sleeve can not be repaired.
  • Page 191: Coolant Passage - Repairing

    Insert Installation Tool Sealing and retaining compound is also available in a 250 ml bottle, Part No. 3823689. The coolant passage repair inserts for the N14 cylinder block are available in packages of 50, tool Part No. 3823688. NOTE: If the reamer extends too far down in the hole, it will hit the radius of the coolant jacket and deflect the drill side- ways, causing the hole to be out of round.
  • Page 192 Cylinder Block - Machining (01-03) Cylinder Block Page 1-24 Tap until the stop contacts the cylinder block head deck surface. Clean the threads with safety solvent, Part No. 3823717. Allow to dry. Clean the coolant passage insert with a safety solvent, Part No.
  • Page 193 Cylinder Block Cylinder Block - Machining (01-03) Page 1-25 Start the insert with your fingers, and install it approxi- mately half way. Liberally apply the sealing and retaining compound to the upper half of the thread, and finish installing with the installation tool.
  • Page 194: Cylinder Head Capscrew Holes - Repairing

    Cylinder Block - Machining (01-03) Cylinder Block Page 1-26 Cylinder Head Capscrew Holes - Repairing Components included in the capscrew thread repair kit, Part No. 3376208, for the N14 block are as follows: Ref. Tool No. Description 3376008 Insert 3376006...
  • Page 195 Cylinder Block Cylinder Block - Machining (01-03) Page 1-27 Ream the failed capscrew hole to the full depth of the hole. Use a chip removing unit to remove reamer chips from the capscrew hole. Set the tap stop collar to the correct height, using the insert to be installed.
  • Page 196 Cylinder Block - Machining (01-03) Cylinder Block Page 1-28 Clean and flush the newly cut threads with safety solvent, Part No. 3823717. Use a chip removing unit to clean the capscrew hole of shavings and debris, and allow to dry. Lightly spray the threads with Loctite Primer-T, Part No.
  • Page 197 Cylinder Block Cylinder Block - Machining (01-03) Page 1-29 Install and tighten the repair insert. Loosen the jam nut. Remove the cylinder head capscrew and jam nut arrangement. Correct installation will provide 0.00 mm to 0.50 mm [0.000-inch to 0.020-inch] protrusion above the cylinder block surface.
  • Page 198: Camshaft Bushings - Installation

    Com- plete counterbore repair guidelines can be found in the NH/NT Counterbore Troubleshooting and Repair Man- ual, Bulletin No. 3810450, and the N14 Troubleshooting and Repair Manual, Bulletin No. 3810456. Cylinder Block - Assembly (01-05)
  • Page 199 Cylinder Block Cylinder Block - Assembly (01-05) Page 1-31 Install the camshaft bushings in the following order: No. 7, No. 6, No. 5, No. 4, No. 3, No. 2, and No. 1. Bushing (No. 7) - Installation An alignment pointer, Part No. 3823635, is used to align the cam bearing oil holes with the oil holes in the block.
  • Page 200 Cylinder Block - Assembly (01-05) Cylinder Block Page 1-32 Bushings (No. 6 through No. 2) - Installation An alignment pointer, Part No. 3823635, is used to align the cam bearing oil holes with the oil holes in the block. To use, mount the bearing on the driver. Place the align- ment pointer against the machined side of the block at the cam follower holes with the end of the rod at the top of the bearing.
  • Page 201 Cylinder Block Cylinder Block - Assembly (01-05) Page 1-33 Use a 2.39 mm [0.094-inch] diameter rod or a 3/32-inch hexagon wrench to check the position and the location of the oil hole in the bushing and the cylinder block. The rod must pass through the oil holes in the bushing and into the oil supply drillings in the cylinder block.
  • Page 202: Dowel Pin - Installation

    Use pipe sealant, Part No. 3375066, to lubricate the pipe plug threads. Install new o-rings on the straight thread plugs. The o-ring used by Cummins Engine Company, Inc., is the only one recommended by Cummins Engine Company. Lubricate the o-ring with clean 15W-40 oil.
  • Page 203 Cylinder Block Cylinder Block - Assembly (01-05) Page 1-35 Install a 3/8-inch pipe plug in the piston cooling oil cross- over passage at the front of the cylinder block. Tighten the pipe plug. Torque Value: 27 N•m [20 ft-lb] Install a 3/4 - 16 straight thread plug in the piston cooling oil passage at the rear of the cylinder block.
  • Page 204: Cleaning

    Cylinder Liners - Cleaning and Inspection (01-06) Cylinder Block Page 1-36 Cam Bore Rear Cup Plug - Installation Caution: Do not install cup plugs in the block until the cleaning, inspection, and necessary repair procedures are completed. This will prevent dirt from being trapped in the engine.
  • Page 205 Cylinder Block Cylinder Liners - Cleaning and Inspection (01-06) Page 1-37 Caution: Do not use a hone, deglazing, or prebrushing to clean the cylinder liners. Abrasives can damage the finish and the pattern and can contaminate the liner. Warning: Wear eye protection. Make sure the wire brush is rated for the RPM being used if the brush is motor driven.
  • Page 206: Inspection

    Cylinder Liners - Cleaning and Inspection (01-06) Cylinder Block Page 1-38 Inspection Visually inspect for pitting or erosion in the crevice seal groove. Replace the liner if pitting or erosion is greater than one-half the width of the crevice seal groove. Visually inspect the outside diameter for excessive cor- rosion or pitting.
  • Page 207 Cylinder Block Cylinder Liners - Cleaning and Inspection (01-06) Page 1-39 Inspect for cracks under the flange. NOTE: Cracks can also be detected by using either mag- netic inspection or the dye method. Replace the liner if cracks are found in the flange area. Visually inspect the exterior of the liners.
  • Page 208 Cylinder Liners - Cleaning and Inspection (01-06) Cylinder Block Page 1-40 Replace the liner if: 1. a heavy polish is present over 20 percent of the piston ring travel area. 2. thirty percent (30%) of the piston ring travel area has both moderate and heavy polish, and one-half (15 percent) is heavy polish.
  • Page 209: Cleaning

    Cylinder Block Pistons - Cleaning and Inspection (01-07) Page 1-41 Cylinder Liner Flange Thickness Standard 9.01 0.355 9.04 0.356 Oversize 9.52 0.375 9.55 0.376 Pistons - Cleaning and Inspection (01-07) Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam can cause serious personal injury.
  • Page 210: Inspection

    If pistons are unacceptable for reuse, do not use the mating piston pins. Cummins recommends replacing pistons and pins in sets. Visually inspect the piston ring lands and ring grooves for wear.
  • Page 211: Cleaning

    Cylinder Block Connecting Rod Assemblies - Cleaning and Inspection (01-08) Page 1-43 Measure the piston pin bore when the piston temperature is at 21°C [70°F] in two places 90 degrees apart. Piston Pin Bore 63.504 2.500 63.530 2.5012 NOTE: Add 0.013 mm [0.0005-inch] to the bore inside di- ameter per 5°C [10°F] temperature rise up to 32°C [90°F].
  • Page 212: Inspection

    Connecting Rod Assemblies - Cleaning and Inspection (01-08) Cylinder Block Page 1-44 Inspection Visually inspect the connecting rod and the cap for fret- ting damage on the mating surfaces. The rod and the cap must be replaced as an assembly if any fretting damage is visible on either piece.
  • Page 213 Cylinder Block Connecting Rod Assemblies - Cleaning and Inspection (01-08) Page 1-45 Visually inspect the capscrew threads for damage. Visually inspect under the capscrew heads for cracks. Measure the capscrew outside diameters. Connecting Rod Capscrew O.D. 14.50 0.571 14.99 0.590 Caution: The rod cap alpha-numeric characters must match the alpha-numeric characters on the connecting rod and must be installed with the characters aligned to...
  • Page 214 Connecting Rod Assemblies - Cleaning and Inspection (01-08) Cylinder Block Page 1-46 Measure the connecting rod bearing bore inside diame- ter. Connecting Rod Crankshaft Bore I.D. 93.731 3.6902 93.769 3.6917 If any of the measurements are not within the specifica- tions, the rod must be repaired or replaced.
  • Page 215: Inspection

    Cylinder Block Connecting Rods - Bend and Twist Inspection (01-09) Page 1-47 Connecting Rod Ring Dowels - Removal Caution: Do not damage the surface or the ring dowel hole during removal of the dowel. Use pliers or locking pliers to remove the damaged ring dowels.
  • Page 216: Alignment - Inspection

    Connecting Rods - Bend and Twist Inspection (01-09) Cylinder Block Page 1-48 Install the connecting rod into the fixture. Move the dial holder to position the contact points of the indicators on the mandrel in the piston pin bore. Tighten the bracket to hold the indicators in position. Set the dial indicators to read ‘‘0.’’...
  • Page 217: Twist - Inspection

    Cylinder Block Connecting Rod Bearings - Cleaning and Inspection (01-10) Page 1-49 Measure the rod length and bend (alignment). Connecting Rod Length 304.75 11.998 304.80 12.000 Connecting Rod Alignment Bushing Removed 0.25 0.010 Bushing Installed 0.10 0.004 Twist - Inspection Using a feeler gauge, check the clearance between the mandrel and the dial indicator holding plate as shown.
  • Page 218 Connecting Rod Bearings - Cleaning and Inspection (01-10) Cylinder Block Page 1-50 NOTE: If large areas of copper lining are visible in the bear- ings before the engine has accumulated 241,000 kilometers [150,000 miles] or 3,750 hours, inspect the engine for con- tamination from fine dirt particles;...
  • Page 219: Cleaning

    Cylinder Block Crankshaft Adapter - Cleaning and Inspection (01-11) Page 1-51 Crankshaft Adapter - Cleaning and Inspection (01-11) Cleaning Warning: When performing the following procedures, wear eye protection. Also, the wire brush must be rated for the RPM being used if the brush is motor driven. Use an emery cloth or a steel wire brush.
  • Page 220 Crankshaft Pulley - Cleaning and Inspection (01-12) Cylinder Block Page 1-52 Measure the outside pilot diameter. Outside Pilot Diameter 35.013 1.3785 35.052 1.3800 Crankshaft Pulley - Cleaning and Inspection (01-12) Cleaning Warning: When performing the following procedures, wear eye protection. Also, the wire brush must be rated for the RPM being used if the brush is motor driven.
  • Page 221 Cylinder Block Vibration Damper - Cleaning and Inspection (01-13) Page 1-53 Measure the inside diameter. Spun Steel Crankshaft Pulley I.D. 35.08 1.381 35.18 1.385 Vibration Damper - Cleaning and Inspection (01-13) Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield.
  • Page 222: Crankshaft - Cleaning And Inspection

    Crankshaft - Cleaning and Inspection (01-14) Cylinder Block Page 1-54 Inspection Caution: Always wear protective gloves when handling heated parts. Personal injury can result. Apply a spray of spot check developer, type SKD-NF , or its equivalent, to the damper. Put the damper (seam side down) into an oven heated to 93°C [200°F] for 2 hours.
  • Page 223 Cylinder Block Crankshaft - Cleaning and Inspection (01-14) Page 1-55 Use a bristle brush, Part No. ST-876, and solvent to clean all the oil drillings. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam can cause serious personal injury.
  • Page 224 Crankshaft - Cleaning and Inspection (01-14) Cylinder Block Page 1-56 NOTE: A maximum of 50 percent of the threaded holes per crankshaft end can be repaired. Visually inspect the crankshaft gear for cracks and broken or chipped teeth. Where the front and the rear crankshaft seals contact the crankshaft, the maximum allowable wear is 0.13 mm [0.005 in].
  • Page 225 Cylinder Block Crankshaft - Cleaning and Inspection (01-14) Page 1-57 Measure the front oil seal area outside diameter. Crankshaft Front Oil Seal Area O.D. 92.07 3.625 92.10 3.626 Measure the rear oil seal area outside diameter. Crankshaft Rear Oil Seal Area O.D. 152.336 5.9975 152.40...
  • Page 226 Crankshaft - Cleaning and Inspection (01-14) Cylinder Block Page 1-58 Measure the main bearing journals outside diameter. Crankshaft Main Bearing Journal O.D. 114.236 4.4975 114.300 4.5000 Measure the thrust face width. Crankshaft Thrust Face Width 76.23 3.001 76.35 3.006 The crankshaft can be ground undersize if the bearing journals or the thrust distance is not within specifications.
  • Page 227 NOTE: The crankshaft gear puller kit, Part No. 3375840, contains the gear puller jaw and the bridge assemblies re- quired for all Cummins engine models. Install the puller jaw and the bridge assembly. Use engine oil to lubricate the puller jackscrew.
  • Page 228 Crankshaft Gear - Replacement (01-15) Cylinder Block Page 1-60 Visually inspect the crankshaft gear fit area for burrs or damage. Use a fine crocus cloth to remove the burrs. Inspection Visually inspect the crankshaft gear for cracks and broken or chipped teeth. Visually inspect the gear and the keyway for nicks or burrs.
  • Page 229 Cylinder Block Crankshaft Gear - Replacement (01-15) Page 1-61 Measure the crankshaft gear fit area outside diameter. Crankshaft Gear Fit Area O.D. 95.501 3.7599 95.522 3.7607 Installation Use a plastic mallet to install a new key in the crankshaft keyway. Use Lubriplate No.
  • Page 230: Main Bearings - Cleaning

    Crankshaft Bearings - Cleaning and Inspection (01-16) Cylinder Block Page 1-62 Caution: Always wear protective gloves when handling heated parts. Personal injury can result. Caution: The timing mark (1) and the part number (2) on the gear must be facing away from the crankshaft after the gear is installed.
  • Page 231: Thrust Bearings - Inspection

    Cylinder Block Camshaft - Cleaning and Inspection (01-17) Page 1-63 NOTE: Oversize bearing shells are available for crankshafts which are 0.25 mm [0.010-inch], 0.51 mm [0.020-inch], 0.76 mm [0.030-inch], or 1.02 mm [0.040-inch] undersize. Bearing shells are identified by steel stamped characters on the back of the bearings to indicate either standard or the amount of oversize.
  • Page 232 40 oil before handling. Inspection Visually inspect the valve and injector lobes for damage. NOTE: Cummins Engine Company, Inc. does not recom- mend repairing camshafts by grinding the valve or injector lobes. If the camshaft is damaged, it must be replaced.
  • Page 233 Cylinder Block Camshaft Gear - Replacement (01-18) Page 1-65 Measure the seven camshaft bushing journals. Camshaft Bushing Journal O.D. 63.37 2.495 63.42 2.497 Replace the camshaft if the journal dimensions do not meet specifications. Measure the camshaft thrust washer. Camshaft Thrust Washer Thickness 2.29 0.090 2.49...
  • Page 234 Camshaft Gear - Replacement (01-18) Cylinder Block Page 1-66 Caution: Do not use a heating torch to remove the gear. If you use a heating torch, a new gear must be installed. Push the shaft from the gear. NOTE: If the camshaft key is marked with an arrow, record the direction the arrow on the key is pointed (toward or away from the camshaft) for future reference.
  • Page 235 Cylinder Block Camshaft Gear - Replacement (01-18) Page 1-67 Measure the gear bore. Camshaft Gear Bore I.D. Flangeless 45.662 1.7977 Camshaft 45.682 1.7985 Replace the camshaft gear if it does not meet specifications. Caution: If the area of fretting is longer than a 3.175 mm [0.125-inch] wide longitudinal band, do not use the cam- shaft.
  • Page 236 Camshaft Gear - Replacement (01-18) Cylinder Block Page 1-68 Installation Camshaft Keys Change in NOTE: The accompanying chart lists different camshaft key Push Rod part numbers, the degree of offset, and the approximate 3/4 Inch Travel At injector timing change from nominal. Offset Timing 19°BTDC...
  • Page 237: Gear Cover - Cleaning And Inspection

    Cylinder Block Gear Cover - Cleaning and Inspection (01-19) Page 1-69 Caution: Wear protective gloves when handling parts that have been heated to prevent personal injury. Heat the gear in an oven at 260°C [500°F] for a minimum of 1 hour. Remove the gear from the oven.
  • Page 238 Gear Cover - Cleaning and Inspection (01-19) Cylinder Block Page 1-70 Remove the straight thread o-ring plug. Caution: The aluminum gasket surface can be easily damaged if caution is not used when removing gasket material. An oil leak will result. Use a gasket scraper to remove all gasket material.
  • Page 239: Accessory Drive Bushing - Replacement

    Cylinder Block Gear Cover - Cleaning and Inspection (01-19) Page 1-71 Measure the accessory drive seal bore. Accessory Drive Seal Bore I.D. 80.962 3.1875 81.038 3.1905 NOTE: Replace the gear cover if the accessory drive seal bore is not within specifications. Measure the crankshaft seal bore.
  • Page 240: Rear Cover - Cleaning And Inspection

    Rear Cover - Cleaning and Inspection (01-20) Cylinder Block Page 1-72 Measure the gear cover accessory drive bushing bore. Accessory Drive Bushing Bore I.D. 43.07 1.696 43.10 1.697 NOTE: Replace the gear cover if the bore is not within specifications or if the bore is cracked or damaged. Use gear cover bushing mandrel, Part No.
  • Page 241 Cylinder Block Rear Cover - Cleaning and Inspection (01-20) Page 1-73 Cleaning Remove the gasket material from the rear cover gasket sealing surface. Use solvent to clean the rear cover. Dry with compressed air. Inspection Inspect the rear cover for cracks or other damage. Measure the rear cover crankshaft seal bore.
  • Page 242: Magnetic Crack Inspection

    Magnetic Crack Inspection (01-21) Cylinder Block Page 1-74 Magnetic Crack Inspection (01-21) Refer to the Alternate Repair Manual, Bulletin No. 3379035, for procedures to magnetically check for cracks in the crankshafts, camshafts, connecting rods, gears, and capscrews.
  • Page 243 Cylinder Head Page 2-1 Section 2 - Cylinder Head - Group 02 Section Contents Page Cylinder Head - Cleaning and Inspection for Reuse ..................2-8 Cleaning ................................ 2-8 Inspection ..............................2-9 Cylinder Head - Exploded View ........................2-6 Cylinder Head - General Information ........................ 2-7 Cylinder Head - Grinding the Valves.......................
  • Page 244: Cylinder Head - Service Tools

    Cylinder Head - Service Tools The following special tools are recommended to perform procedures in Group 02. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
  • Page 245 Cylinder Head Cylinder Head - Service Tools Page 2-3 Tool No. Tool Description Tool Illustration Fuel Passage Cleaning Brush Clean the internal fuel passages in the cylinder head. ST-876 Injector Sleeve Expander Roll and seal the upper portion of the injector sleeve in the cylinder head.
  • Page 246 Cylinder Head - Service Tools Cylinder Head Page 2-4 Tool No. Tool Description Tool Illustration Injector Sleeve Holding Tool Hold the injector sleeve in place when rolling the upper portion of the sleeve and testing the cylinder head. ST-1179 Injector Sleeve Driver Drive the injector sleeve into the cylinder head.
  • Page 248: Cylinder Head - Exploded View

    Cylinder Head - Exploded View Cylinder Head Page 2-6 Cylinder Head - Exploded View Reference Reference Description Quantity Description Quantity Head Cylinder Plug, Expansion Plug, Expansion Insert, Intake Valve Seat Seal, O-ring Valve, Intake Sleeve, Injector Insert, Exhaust Valve Seat Guide, Valve Stem Valve, Exhaust Seal Stem...
  • Page 249: Cylinder Head - General Information

    Cylinder Head Cylinder Head - General Information Page 2-7 Cylinder Head - General Information The cylinder head group consists of the cylinder head, valves, valve guides, valve springs, stem seals, valve seat inserts, cylinder head capscrews, fuel crossover, collets, spring retainer, crossheads, and the injector sleeves. The exhaust valves are manufactured from a material that is capable of operating at a higher temperature than the intake valves.
  • Page 250 Cylinder Head - Cleaning and Inspection for Reuse (02-01) Cylinder Head Page 2-8 Cylinder Head - Cleaning and Inspec- tion for Reuse (02-01) Cleaning Steam clean the cylinder heads, and dry with compressed air. Blow out all capscrew holes, fuel passages, and oil passages.
  • Page 251 Cylinder Head Cylinder Head - Cleaning and Inspection for Reuse (02-01) Page 2-9 Clean with solvent, and dry with compressed air. Inspection Visually inspect the fuel drillings and the water passages for restrictions or foreign material. Remove any obstructions. Visually inspect the valves and the valve springs for cracks, bent or broken valve stems, broken valve springs, or other damage.
  • Page 252 Cylinder Head - Rebuild (02-02) Cylinder Head Page 2-10 Visually inspect the cylinder head casting for cracks or damage. NOTE: If cracks or leaks in the cylinder head are suspected, refer to Cylinder Head - Pressure Testing (02-08). Visually inspect the valves for indications of leakage or burning.
  • Page 253 Cylinder Head Cylinder Head - Rebuild (02-02) Page 2-11 Use a pencil magnet to remove the valve collets. Discard the valve collets. Slowly release the pressure on the valve spring. Remove the valve spring retainer. Remove the valve spring(s). Remove the valve stem seal. Remove the valves.
  • Page 254 Cylinder Head - Rebuild (02-02) Cylinder Head Page 2-12 Cleaning Warning: Use protective measures to prevent personal injury. Install the cylinder head and the parts in a tank of clean- ing solution. NOTE: Follow the cleaning solution manufacturer’s instruc- tions when cleaning the parts. Remove the cylinder head and parts from the cleaning tank.
  • Page 255 Cylinder Head Cylinder Head - Rebuild (02-02) Page 2-13 Use a straight edge and a 0.003-inch feeler gauge to measure the flatness of the cylinder head gasket surface. Flatness Per 25.4 mm [1.00 in] of Length 0.020 0.0008 Flatness Per Total Overall Length 0.08 0.003 NOTE: If the cylinder head is worn more than the maximum...
  • Page 256 Cylinder Head - Rebuild (02-02) Cylinder Head Page 2-14 Use valve spring tester, Part No. 3375182, to measure the valve spring load at the valve spring working height. Working Height (B) Valve Spring Part No. Limit 3070460 56.89 Nominal 2.240 Load for Working Height (C) Valve Spring Part No.
  • Page 257 Cylinder Head Cylinder Head - Rebuild (02-02) Page 2-15 Use the N14 valve head checking tool to measure the head thickness of the valves. NOTE: Install the valve on the tool with the valve head contacting the tool as shown. If the valve head is even with, or extends beyond the end of the tool, the valve can be reground.
  • Page 258 Cylinder Head - Rebuild (02-02) Cylinder Head Page 2-16 Measure the width of the valve seat area of the valve seat inserts. Valve Seat Area (Width) 1.60 0.063 3.18 0.125 NOTE: If the valve seat area is worn wider than the maximum specified, refer to ‘‘Grinding the Valve Seats’’...
  • Page 259: Grinding The Valve Seats

    Cylinder Head Cylinder Head - Rebuild (02-02) Page 2-17 Remove the injectors from the cylinder head and check the pattern of the blueing compound in the injector sleeve. The blueing pattern in the injector seating area (1) must be visible 360 degrees around the seating area. The injector bore seating width (2) must be a minimum of 1.52 mm [0.060-inch].
  • Page 260 Cylinder Head - Rebuild (02-02) Cylinder Head Page 2-18 Hold the drive unit in a vertical position, and use an up-and-down movement of 12.7 mm [0.50-inch] travel and light pressure to grind the insert. Remove the grinder unit from the arbor. Install eccentrimeter gauge (4), Part No.
  • Page 261 Cylinder Head Cylinder Head - Rebuild (02-02) Page 2-19 If the valve protrusion is out of limits, replace the old valve (A) with a new valve (B) before replacing the valve seat. If the protrusion is within limits with the new valve, pro- ceed using the new valve with the old seat.
  • Page 262 Cylinder Head - Rebuild (02-02) Cylinder Head Page 2-20 Remove the valve, and measure the valve seat width and the seat contact area as indicated by the broken lines. The pencil or Dykem marks will be worn away where the valve contacted the seat.
  • Page 263 Cylinder Head Cylinder Head - Rebuild (02-02) Page 2-21 After grinding the valve seats, use a bristle brush to clean the inside diameter of the valve guides. Use solvent to clean the cylinder head. Dry with com- pressed air. Assembly Apply cup plug sealant, Part No.
  • Page 264 Cylinder Head - Rebuild (02-02) Cylinder Head Page 2-22 Use valve spring compressor, Part No. ST-448, or its equivalent (refer to the Service Tools list) to compress the valve springs. Install the new valve spring retainer collets. NOTE: Use new valve spring retainer collets when rebuilding the cylinder head.
  • Page 265 Cylinder Head Cylinder Head - Rebuild (02-02) Page 2-23 Visually inspect the cylinder head capscrews for dam- aged threads, corroded surfaces, or a reduced diameter (due to capscrew stretching). NOTE: Do not reuse a capscrew that has damaged threads or a reduced diameter from having been stretched. Do not reuse cylinder head capscrews under the follow- ing conditions: •...
  • Page 266 Cylinder Head - Rebuild (02-02) Cylinder Head Page 2-24 The capscrews can be checked using a set of calipers if service tool, Part No. 3823546, is not available. The max- imum allowable free length (dimension ‘X’), measured from the bottom of the flange to the end of the capscrew, is 185.6 mm [7.130 in].
  • Page 267 Cylinder Head Cylinder Head - Replacing the Valve Guides (02-03) Page 2-25 Immediately after cleaning and inspecting, apply a film of clean engine lubricating oil to capscrews that are to be used again. Cylinder Head - Replacing the Valve Guides (02-03) Disassembly Use a valve guide driver, Part No.
  • Page 268 Cylinder Head - Replacing the Valve Guides (02-03) Cylinder Head Page 2-26 Assembly Measure the outside diameter of the new valve guides. Valve Guide O.D. 19.088 0.7515 19.101 0.7520 NOTE: Oversize valve guides have identification grooves on the outside diameter of the guide. The 0.25 mm [0.010-inch] oversize guide has one groove.
  • Page 269 Cylinder Head Cylinder Head - Ring Dowel Replacement (02-04) Page 2-27 Cylinder Head - Ring Dowel Replace- ment (02-04) Removal Caution: Do not damage the surface or the ring dowel hole during removal of the dowel. Use a pliers or a locking pliers to remove the damaged ring dowel.
  • Page 270 Cylinder Head - Replacing the Valve Seat Inserts (02-05) Cylinder Head Page 2-28 Inspection Visually inspect the insert bore for cracks or damage. NOTE: If cracks or damage are found, it is possible to repair the cylinder head by machining the insert bore for oversize valve seat inserts.
  • Page 271: Cylinder Head - Grinding The Valves

    Cylinder Head Cylinder Head - Grinding the Valves (02-06) Page 2-29 Use valve seat grinding machine, Part No. ST-685, and valve guide arbor set, Part No. ST-663, to grind the new valve seat inserts. Refer to ‘‘Grinding the Valve Seats’’ under Cylinder Head - Rebuild (02-02).
  • Page 272 Cylinder Head - Grinding the Valves (02-06) Cylinder Head Page 2-30 Inspection Use the N14 valve head checking tool to measure the head thickness of the valve. NOTE: If the valve head is below the end of the tool, the valve must be replaced.
  • Page 273 Cylinder Head Cylinder Head - Replacing the Injector Sleeves (02-07) Page 2-31 Cylinder Head - Replacing the Injector Sleeves (02-07) Disassembly Use an injector sleeve puller, Part No. ST-1244, to remove the injector sleeves from the cylinder head. Install the puller in the injector sleeve with the legs of the bridge against the cylinder head.
  • Page 274 Cylinder Head - Replacing the Injector Sleeves (02-07) Cylinder Head Page 2-32 If the grooves (steps) are damaged or mutilated, use a pilot, Part No. ST-884-6; holder, Part No. ST-884-1; and cutting tool, Part No. ST-788, to machine the grooves (steps) in the bottom of the injector bore.
  • Page 275 Cylinder Head Cylinder Head - Replacing the Injector Sleeves (02-07) Page 2-33 Use an injector sleeve expander, Part No. ST-880, to expand the upper section of the injector sleeve. Adjust the expander roller edge (1) and the collar (2) to the clearance specified.
  • Page 276 Cylinder Head - Replacing the Injector Sleeves (02-07) Cylinder Head Page 2-34 Caution: Support the cylinder head to prevent damage to the injector tip that protrudes from the combustion face. Apply a very light film of blueing compound to the outside diameter of the injector at the injector seat area.
  • Page 277: Cylinder Head - Pressure Testing

    Cylinder Head Cylinder Head - Pressure Testing (02-08) Page 2-35 The blueing pattern in the injector seating area (1) must be visible 360 degrees around the seating area. The injector bore seating width (2) must be a minimum of 1.52 mm [0.060-inch]. NOTE: If the injector protrusion is more than the maximum specified or if the injector sleeve blueing pattern does not meet the specifications given, the injector sleeve(s) must be...
  • Page 278 Cylinder Head - Pressure Testing (02-08) Cylinder Head Page 2-36 Tighten the injector sleeve holding tool capscrew. Torque Value: 5 N•m [45 in-lb] 10 N•m [90 in-lb] 15 N•m [130 in-lb] Install the cylinder head in a hydrostatic tester, Part No. ST-1012, and a hydrostatic tester adapter plate, Part No.
  • Page 279 Cylinder Head Cylinder Head - Magnetic Particle Checking (02-09) Page 2-37 Remove the test equipment. Dry the cylinder head with compressed air. Assemble the cylinder head. Refer to ‘‘Assembly’’ under Cylinder Head - Rebuild (02-02). A. Valve B. Valve Stem Seal C.
  • Page 280 Cylinder Head - Vacuum Testing Valve Seating for Reuse (02-10) Cylinder Head Page 2-38 Lightly spray the metal powder onto the combustion sur- face. Use compressed air regulated to 205 kPa [30 psi] to remove excess powder from the area. The powder will remain if there are any cracks and will appear as a white line.
  • Page 281 Cylinder Head Cylinder Head - Vacuum Testing Valve Seating for Reuse (02-10) Page 2-39 Install the seal ring, Part No. 3823848, and the vacuum cup, Part No. 3823847, to the vacuum hose. NOTE: The valves and the valve seats must be clean and dry when vacuum testing.
  • Page 282 Cylinder Head - Valves - Magnetic Crack Inspection (02-11) Cylinder Head Page 2-40 Use a stopwatch. 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.
  • Page 283 Cylinder Head Valve Crosshead - Cleaning and Checking for Reuse (02-12) Page 2-41 Valve Crosshead - Cleaning and Checking for Reuse (02-12) Cleaning Use solvent to clean the crosshead. Dry with compressed air. Inspection Visually inspect the rocker lever contact pad for wear, cracks, or damage.
  • Page 284 Valve Crosshead - Magnetic Crack Inspection (02-13) Cylinder Head Page 2-42 Valve Crosshead - Magnetic Crack Inspection (02-13) Refer to the Alternate Repair Manual, Bulletin No. 3379035, for procedures to magnetically check for cracks in the valve crosshead.
  • Page 285 Rocker Lever Housing Assembly Page 3-1 Section 3 - Rocker Lever Housing Assembly - Group 03 Section Contents Page Metri-Pack Pass Through Connector - Replacement ..................3-21 Installation ..............................3-22 Removal................................ 3-21 Ring and Pin Dowel - Replacement ....................... 3-20 Installation ..............................
  • Page 286: Rocker Lever Housing Assembly - Service Tools

    Rocker Lever Housing Assembly - Service Tools The following special tools are recommended to perform procedures in section 3. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
  • Page 288 Rocker Lever Housing Assembly - Exploded View Rocker Lever Housing Assembly Page 3-4 Rocker Lever Housing Assembly - Exploded View...
  • Page 289 Rocker Lever Housing Assembly Rocker Lever Housing Assembly - Exploded View Page 3-5 Rocker Lever Housing Assembly - Exploded View Reference No. Description Qty. Capscrew, Twelve Point Washer, Plain Capscrew, Hexagon Head Gasket, Rocker Lever Housing Dowel, Pin Capscrew, Twelve Point Washer, Plain Dowel, Ring Shaft, Rocker Lever...
  • Page 291: Rocker Lever Housing Assembly - General Information

    Rocker Lever Housing Assembly Rocker Lever Housing Assembly - General Information Page 3-7 Rocker Lever Housing Assembly - General Information The rocker lever housing assembly group consists of the rocker lever assembly, the step timing control (STC) oil manifold connector, external oil manifold, internal oil tube, and the rocker housing cover. The rocker levers contain replaceable bushings.
  • Page 292 Rocker Lever - Cleaning and Inspection for Reuse (03-01) Rocker Lever Housing Assembly Page 3-8 Rocker Lever - Cleaning and Inspec- tion for Reuse (03-01) Disassembly Loosen the valve and injector adjusting screw lock nuts on each rocker lever. Turn the adjusting screws counterclockwise until the rocker levers are loose.
  • Page 293 Rocker Lever Housing Assembly Rocker Lever - Cleaning and Inspection for Reuse (03-01) Page 3-9 Visually inspect the shaft for cracks or damage. Light fretting is typically found on the underside of the shaft and is not harmful, provided it meets the dimen- sional specifications.
  • Page 294 Rocker Lever - Cleaning and Inspection for Reuse (03-01) Rocker Lever Housing Assembly Page 3-10 Measure the rocker lever bushing bore inside diameter. Rocker Lever Bushing I.D. (Installed) 34.89 1.3735 34.99 1.3775 NOTE: Replace the rocker lever bushings which are worn beyond the maximum limit.
  • Page 295 Rocker Lever Housing Assembly Rocker Lever - Cleaning and Inspection for Reuse (03-01) Page 3-11 Assembly Use clean 15W-40 oil to lubricate the threads of the ad- justing screws. Install the adjusting screw and lock nut in each rocker lever. Do not tighten the lock nuts. Install the exhaust (1), injector (2), and intake (3) rocker levers onto the shaft.
  • Page 296: Rocker Lever Bushing - Replacement

    Alternately tighten the rocker shaft capscrews in 54 N•m [40 ft-lb] increments to 156 N•m [115 ft-lb]. Adjust the valves and injectors. Refer to Procedure 7-04 in the N14 Troubleshooting and Repair Manual, Bulletin No. 3810456. Rocker Lever Bushing - Replacement...
  • Page 297 Rocker Lever Housing Assembly Rocker Lever Bushing - Replacement (03-02) Page 3-13 Use a 240 grit, or finer, emery cloth to remove any rough edges or burrs from the bore of the rocker lever. Use solvent to clean the rocker levers. Dry with com- pressed air.
  • Page 298 Cleaning Remove the crankcase breather element, if used, and the oil filler cap. Refer to Procedure 2-05 in the Trouble- shooting and Repair Manual N14 Engines, Bulletin No. 3810456. Remove the gaskets. Steam clean the covers, and dry with compressed air.
  • Page 299 Rocker Lever Housing AssemblyRocker Lever Housing Assembly - Cleaning and Inspection for Reuse (03-05) Page 3-15 Steam clean the reusable gaskets. Dry with compressed air, and check for cuts or deformations in the silicone bead. Replace the gasket if there are any cuts, abrasions, or deformations in the silicone bead.
  • Page 300 Visually inspect the o-ring plugs and water tubes for cracks, pitting, corrosion, or other damage. Replace if necessary. On CELECT™ engines, remove the pass through con- nectors. Refer to the N14 Troubleshooting and Repair Manual CELECT™ System, Bulletin No. 3810469.
  • Page 301 Page 3-17 Visually inspect the pass through connectors for cracks, bent contacts, or other damage. Replace if necessary. Refer to the N14 Troubleshooting and Repair Manual CELECT™ System, Bulletin No. 3810469. On STC engines, remove the oil manifold. NOTE: When removing the oil manifold connector from the rocker lever housing, use a wide flat pry bar.
  • Page 302 Rocker Lever Housing Assembly - Cleaning and Inspection for Reuse (03-05)Rocker Lever Housing Assembly Page 3-18 Visually inspect the rocker lever shaft dowel rings (1), the dowel pins (2), and the brass cup plug (3). Replace if necessary. Use service tool, Part No. 3823821, to remove the dowel pins and dowel rings.
  • Page 303 Rocker Lever Housing Assembly STC Oil Plumbing - Cleaning and Inspection for Reuse (03-06) Page 3-19 STC Oil Plumbing - Cleaning and Inspection for Reuse (03-06) Remove the o-rings and discard. Clean the oil manifold connector, external oil manifold, and internal oil tube. Inspect the oil manifold connector for cracks, damage, or restrictions.
  • Page 304: Ring And Pin Dowel - Replacement

    Ring and Pin Dowel - Replacement (03-07) Rocker Lever Housing Assembly Page 3-20 Ring and Pin Dowel - Replacement (03-07) Removal Select the proper size ring dowel remover and insert the threaded end into the ring dowel to be removed. Tighten the hexagon nut until snug.
  • Page 305 Rocker Lever Housing Assembly Metri-Pack Pass Through Connector - Replacement (03-08) Page 3-21 Tighten the hexagon nut to grip the dowel. Mount the slide hammer on the 1/4-inch dowel remover and pull the dowel. Installation Caution: Do not use a hammer or damage to the dowel will result.
  • Page 306 Metri-Pack Pass Through Connector - Replacement (03-08) Rocker Lever Housing Assembly Page 3-22 Disconnect the actuator harness from the pass through connector. Remove the capscrew. Cut and remove the plastic wire tie that holds the actuator harness to the pass through connector.
  • Page 307 Cam Follower Assembly Page 4-1 Section 4 - Cam Follower Assembly - Group 04 Section Contents Page Cam Follower Assembly - Cleaning and Inspection for Reuse ............... 4-5 Cleaning ................................ 4-5 Inspection ..............................4-5 Cam Follower Assembly - Exploded View ......................4-3 Cam Follower Assembly - General Information....................
  • Page 308: Cam Follower Assembly - Service Tools

    Cam Follower Assembly - Service Tools The following special tools are recommended to perform procedures in section 4. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
  • Page 309: Cam Follower Assembly - Exploded View

    Cam Follower Assembly Cam Follower Assembly - Exploded View Page 4-3 Cam Follower Assembly - Exploded View Reference No. Description Qty. Reference No. Description Qty. Capscrew, Hexagon Head Roller, Cam Follower Capscrew, Hexagon Head Pin, Cam Follower Roller Gasket, Cam Follower Hous- Socket, Cam Follower Plug, Ball Screw, Lock...
  • Page 310: Cam Follower Assembly - General Information

    The cam follower group consists of the injector cam followers, valve cam followers, cam follower shafts, cam follower housing, and the valve and injector push rods. The N14 uses the crowned roller design cam follower. This design has been used since November, 1982.
  • Page 312: Cam Follower Assembly - Cleaning And Inspection For Reuse

    Cam Follower Assembly - Cleaning and Inspection for Reuse (04-01) Cam Follower Assembly Page 4-6 Measure the cam follower roller side clearance. Roller Side Clearance 0.23 0.009 0.61 0.024 NOTE: If the roller side clearance is not within these spec- ifications, the roller must be replaced.
  • Page 313: Cam Follower Assembly - Rebuild

    Cam Follower Assembly Cam Follower Assembly - Rebuild (04-02) Page 4-7 Use clean 15W-40 oil to check the oil flow through the cam followers. Cam Follower Assembly - Rebuild (04-02) Disassembly Remove the two locking screws. NOTE: Each cam follower housing assembly consists of two shaft assemblies secured in a common center support with two locking screws.
  • Page 315 Cam Follower Assembly Cam Follower Assembly - Rebuild (04-02) Page 4-9 Use a dial indicator to measure the cam follower to roller pin clearance. Roller to Pin Clearance 0.08 0.003 0.20 0.008 NOTE: If the roller to pin clearance is not within these spec- ifications, the roller and the pin must be replaced.
  • Page 316 Cam Follower Assembly - Rebuild (04-02) Cam Follower Assembly Page 4-10 Use clean 15W-40 oil to check the oil flow through the cam followers. Clean the cam follower shafts with solvent. Dry with com- pressed air. Make sure the oil drillings are not restricted or plugged. Visually inspect the cam follower shafts for scoring or damage.
  • Page 317 Cam Follower Assembly Cam Follower Assembly - Rebuild (04-02) Page 4-11 Steam clean the cam follower housings. Dry with com- pressed air. Visually inspect the cam follower housings for cracks or damage. Visually inspect the locking screw holes for damaged or distorted threads.
  • Page 318: Cam Follower Lever - Roller Replacement

    Cam Follower Lever - Roller Replacement (04-03) Cam Follower Assembly Page 4-12 Install the levers and the shafts in the housings. NOTE: To prevent increased wear, install the cam follower levers and the shafts back in their original location in the housing.
  • Page 319: Cleaning

    Cam Follower Assembly Cam Follower Lever - Roller Replacement (04-03) Page 4-13 Install the cam follower lever into an arbor press. Caution: Use the largest feeler gauge that will fit be- tween the roller and the lever to prevent leg deflection when removing the roller pin.
  • Page 320 Cam Follower Lever - Roller Replacement (04-03) Cam Follower Assembly Page 4-14 Measure the inside diameter of the new cam follower lever roller bore. Valve Lever Roller Bore I.D. 12.776 0.5030 12.801 0.5040 Injector Lever Roller Bore I.D. 19.151 0.7540 19.177 0.7550 Measure the outside diameter of the new cam follower...
  • Page 321 Cam Follower Assembly Cam Follower Lever - Roller Replacement (04-03) Page 4-15 Assembly NOTE: The roller pin must be installed correctly to make sure the cam follower roller and the roller pin are supplied with oil. Inspect the new roller pin as shown to determine the oil feed pass (1) and the alignment hole (2) locations.
  • Page 322 Cam Follower Lever - Roller Replacement (04-03) Cam Follower Assembly Page 4-16 Caution: The cam follower roller pin must be installed with the oil feed hole (1) positioned towards the top of the cam follower lever (2). NOTE: Freezing the roller pin will simplify its installation. Use clean 15W-40 oil to lubricate the roller pin.
  • Page 323: Cam Follower Socket - Replacement

    NOTE: The roller must be removed to allow access to the socket removal hole. Refer to Cam Follower Lever - Roller Replacement (04-03). The N14 valve and injector cam follower socket has an identification groove around the outside diameter and two marks 180 degrees apart on top of the socket.
  • Page 324: Push Rod - Cleaning And Inspection For Reuse

    Push Rod - Cleaning and Inspection for Reuse (04-05) Cam Follower Assembly Page 4-18 Caution: Support as shown to prevent cracks in the cam follower. An old roller can be used to support the lever. Use a brass drift or a used push rod end (2). Use an arbor press.
  • Page 325 Cam Follower Assembly Push Rod - Cleaning and Inspection for Reuse (04-05) Page 4-19 Visually inspect the socket end of the push rod for uneven wear, scratches, or separation of the insert from the tube. If a worn push rod is found, the mating adjusting screw must also be replaced.
  • Page 326 Fuel System Page 5-1 Section 5 - Fuel System - Group 05 Section Contents Page Fuel Pump - Calibration ........................... 5-7 Fuel Pump - Cleaning and Inspection for Reuse ..................... 5-3 Cleaning - CELECT™ Fuel Pump ........................5-4 Cleaning - PT Fuel Pump ..........................5-3 Inspection - CELECT™...
  • Page 327: Fuel Pump - General Information

    NOTE: Warranty repairs are not to be made to the fuel pump unless the work is performed in a shop meeting all requirements established by Cummins Engine Company, Inc. to accurately calibrate, test, and repair the fuel systems on Cummins engines.
  • Page 328: Fuel Pump - Cleaning And Inspection For Reuse

    Fuel System Fuel Pump - Cleaning and Inspection for Reuse (05-01) Page 5-3 Fuel Pump - Cleaning and Inspection for Reuse (05-01) When removing the fuel pump from step timing control (STC) engines, check to make sure the same Control Parts List (CPL) number is on both the fuel pump dataplate and the engine dataplate.
  • Page 329: Cleaning - Celect™ Fuel Pump

    Fuel Pump - Cleaning and Inspection for Reuse (05-01) Fuel System Page 5-4 Cleaning - CELECT™ Fuel Pump Install plastic cup plugs or tape on all openings of the fuel pump to prevent dirt or cleaning solvent from entering the pump.
  • Page 330 Fuel System Fuel Pump - Cleaning and Inspection for Reuse (05-01) Page 5-5 Visually inspect the drive coupling spider for cracks or other damage. Visually inspect the front cover pilot to make sure the pilot is continuous without cracks or gaps. Use clean 15W-40 oil to lubricate the tachometer drive gear.
  • Page 332: Fuel Pump - Rebuild

    The disassembly, inspection, repair, assembly, and test- ing procedures for the CELECT™ fuel pump are covered in the Troubleshooting and Repair Manual - CELECT™ System N14 Engines, Bulletin No. 3810469. Fuel Pump - Calibration (05-03) The fuel pump calibration instructions for the PT fuel pump are covered in the Fuel Pump Rebuild Manual, Bulletin No.
  • Page 333 Fuel Pump - Calibration (05-03) Fuel System Page 5-8 The Control Parts List (CPL) Manual, Bulletin No. 3379133, is a listing of basic engine parts and timing specifications which are necessary to produce a given engine performance. By using the CPL number stamped on the engine dataplate and this manual, parts within the engine can be identified.
  • Page 334 Injectors and Fuel Lines Section Contents Page 6-1 Section 6 - Injectors and Fuel Lines - Group 06 Section Contents Page Fuel Tubes, Fittings, and Mounting Parts - Cleaning and Inspection for Reuse ........... 6-9 Cleaning ................................ 6-9 Inspection ..............................6-9 Injector - CELECT™...
  • Page 336 Injectors and Fuel Lines Injector - PT (type D) Step Timing Control - Exploded View Page 6-3 Reference No. Description Quantity Ball, Check Gasket, Injector Retainer, Screen Retainer, Cup Seal, O-ring Pin, Roll Screen, Filter Washer, Plain Spring, Compression Cup, Injector Adapter, Injector Screw, Stop Retainer, Spring...
  • Page 337: Injector - Celect™ - Exploded View

    Injector - CELECT™ - Exploded View Injectors and Fuel Lines Page 6-4 Injector - CELECT™ - Exploded View Reference No. Description Quantity Reference No. Description Quantity Link, Top Plunger, Metering Retainer, Link Body, Injector Retainer, Spring Harness, Wiring Spring, Compression Retainer, Top Stop Assembly Shim, Top Stop...
  • Page 338: Injectors - Pt (Type D) Step Timing Control (Stc) - General Information

    STC allows the engine to operate with normal injection timing under heavy load conditions. The injectors used in N14 engines equipped with STC are PT (type D) STC full top stop style injectors. The injector top stop plunger travel and total travel must be adjusted with a top stop injector setting fixture before installing them into an engine.
  • Page 339: Cleaning - Stc

    Injectors - Cleaning the Exterior and Inspection for Reuse (06-01) Injectors and Fuel Lines Page 6-6 Injectors - Cleaning the Exterior and Inspection for Reuse (06-01) Remove and discard the three injector o-rings. Cleaning - STC Use a clean, lint-free cloth to clean the exterior of the injectors.
  • Page 340: Inspection - Celect

    Injectors and Fuel Lines Injectors - Cleaning the Exterior and Inspection for Reuse (06-01) Page 6-7 Visually inspect the injector for carbon deposits on the injector cup and cup retainer. Visually inspect the o-ring grooves for damage. Visually inspect the injector body and cup retainer for cracks or other damage.
  • Page 341: Stc Oil Control Valve - Cleaning

    Injectors - Rebuild (06-02) Injectors and Fuel Lines Page 6-8 Injectors - Rebuild (06-02) The disassembly, inspection, repair, and calibration pro- cedure for STC injectors are covered in Shop Manual PT (type D) Step Timing Control Injector, Bulletin No. 3810313. NOTE: CELECT™...
  • Page 342 Injectors and Fuel Lines Fuel Tubes, Fittings, and Mounting Parts - Cleaning and Inspection for Reuse (06-05) Page 6-9 Fuel Tubes, Fittings, and Mounting Parts - Cleaning and Inspection for Reuse (06-05) Cleaning Use solvent to clean the fuel tubes, fittings, and parts. Dry with compressed air.
  • Page 343 Lubricating Oil System Page 7-1 Section 7 - Lubricating Oil System - Group 07 Section Contents Page Lubricating Oil Cooler - Exploded View......................7-5 Lubricating Oil Cooler Assembly - Rebuild ....................7-28 Assembly ..............................7-35 Cleaning ............................... 7-31 Disassembly..............................7-28 Inspection ..............................
  • Page 344: Lubricating Oil System - Service Tools

    Lubricating Oil System - Service Tools The following special tools are recommended to perform procedures in Group 07. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
  • Page 345: Lubricating Oil System - Exploded View

    Lubricating Oil System Lubricating Oil System - Exploded View Page 7-3 Lubricating Oil System - Exploded View Reference Description Quantity Dipstick Tube, Oil Gauge Cover, Hand Hole Gasket, Hand Hole Cover Pan, Oil Gasket, Oil Pan Tube, Oil Suction Tube Assembly, Oil Transfer Filter and Cooler, Lubricating Oil Pump, Lubricating Oil...
  • Page 346: Lubricating Oil Pump Assembly - Exploded View

    Lubricating Oil Pump Assembly - Exploded View Lubricating Oil System Page 7-4 Lubricating Oil Pump Assembly - Exploded View Reference Reference Description Quantity Description Quantity Gasket, Lubricating Oil Pump Plunger, Pressure Regulator Gear, Lubricating Oil Pump Spring, Pressure Regulator Bushing Seal, O-ring Tube, Pressure Sensing Plug, Retainer...
  • Page 348 Lubricating Oil Cooler - Exploded View Lubricating Oil System Page 7-6 Ref. No. Description Quantity Hose, Flexible Elbow, Male Union Washer, Plain Screw, Captive Washer Cap Screw, Captive Washer Cap Screw, Captive Washer Cap Gasket, Oil Cooler Support Screw, Captive Washer Cap Bracket, Oil Cooler Seal, O-ring Plug, Threaded...
  • Page 349: Lubricating Oil System - General Information

    Lubricating Oil System Lubricating Oil System - General Information Page 7-7 Lubricating Oil System - General Information The lubricating oil system group consists of the oil pan, the oil suction tube, the oil transfer tube assembly, the oil dipstick and oil gauge tube, the oil filter and cooler assembly, and the lubricating oil pump. Service replacement dipsticks do not have the high and low level marks indicated on the dipstick.
  • Page 350 Lubricating Oil Pan - Cleaning and Inspection for Reuse (07-01) Lubricating Oil System Page 7-8 Lubricating Oil Pan - Cleaning and Inspection for Reuse (07-01) Cleaning Remove all gasket material from the oil pan gasket seal- ing surface. Warning: When using a steam cleaner, wear protec- tive clothing and safety glasses or a face shield.
  • Page 351: Lubricating Oil Dipstick - Calibration

    Lubricating Oil System Lubricating Oil Transfer Tube - Cleaning and Inspection for Reuse (07-02) Page 7-9 Lubricating Oil Transfer Tube - Clean- ing and Inspection for Reuse (07-02) Cleaning Use solvent to clean the lubricating oil transfer tube and the mounting flanges. Dry with compressed air. Inspection Visually inspect the tube and the flanges for cracks, cor- rosion, or other damage.
  • Page 352 Lubricating Oil Pump - Cleaning and Inspection for Reuse (07-05) Lubricating Oil System Page 7-10 Remove the dipstick and scribe a mark across the dipstick. Mark the ‘‘LOW’’ level with an ‘‘L.’’ NOTE: The dipstick will break if the scribe mark is too deep. NOTE: Cut the new dipstick off approximately 38 mm [1.5 inches] below the ‘‘LOW’’...
  • Page 353 Lubricating Oil System Lubricating Oil Pump - Rebuild (07-06) Page 7-11 Inspection Turn the main drive gear by hand to check the internal gears for freedom of rotation. Visually inspect the gears for cracked or broken teeth. Visually inspect the bushings for excessive wear or dis- coloration due to overheating or seizure of the shafts.
  • Page 354 Lubricating Oil Pump - Rebuild (07-06) Lubricating Oil System Page 7-12 Remove the oil pump cover. Remove and discard the cover gasket. Remove the 7/16-20 straight thread o-ring adapter from the oil pump cover. Remove the high oil pressure relief valve as follows: 1.
  • Page 355 Lubricating Oil System Lubricating Oil Pump - Rebuild (07-06) Page 7-13 Cleaning Clean the gasket material from the lubricating oil pump body and the cover. Use solvent to clean the lubricating oil pump parts. Dry with compressed air. Use an acetylene torch tip cleaner or its equivalent that is 1.02 mm [0.040-inch] or less in diameter to clean the orifice in the cover.
  • Page 356 Lubricating Oil Pump - Rebuild (07-06) Lubricating Oil System Page 7-14 Visually inspect the bushings in the oil pump body and the cover for damage. Measure the inside diameter of the bushings in the oil pump body and cover. Bushing I.D. 22.263 0.8765 22.314...
  • Page 357 Lubricating Oil System Lubricating Oil Pump - Rebuild (07-06) Page 7-15 Measure the outside diameter of the drive and the driven shafts in the bushing contact area. Shaft O.D. 22.20 0.8745 22.22 0.8750 NOTE: Shafts that are damaged or worn smaller than the minimum given must be replaced.
  • Page 358 Lubricating Oil Pump - Rebuild (07-06) Lubricating Oil System Page 7-16 Use valve spring tester, Part No. 3375182, to determine if the spring is defective. NOTE: Compress the spring to a height of 46.23 mm [1.820 inches]. The force required must be: •...
  • Page 359 Lubricating Oil System Lubricating Oil Pump - Rebuild (07-06) Page 7-17 Install the oil pump body and the drive shaft assembly in an arbor press. Support the end of the drive shaft, and press the main drive gear onto the shaft. NOTE: At this stage of assembly, there must not be more than 0.30 mm [0.012-inch] end clearance between the main drive gear and the oil pump body.
  • Page 360 Lubricating Oil Pump - Rebuild (07-06) Lubricating Oil System Page 7-18 Install the spring (4), the washer (3), the valve disc (2), and the retainer plug (1) into the bore of the locating plate. NOTE: Make sure the prongs on the disc are down (toward the washer) and that the cup side of the retainer plug is up (toward the mandrel).
  • Page 361 Lubricating Oil System Lubricating Oil Pump Body and Cover Bushing - Replacement (07-07) Page 7-19 Install new o-rings on the main oil pressure regulator plunger retainer plug. Lubricate the o-rings with vegeta- ble oil. Install the plunger (4), the spring (3), the retainer plug (2), and the capscrew (1).
  • Page 362 Lubricating Oil Pump Body and Cover Bushing - Replacement (07-07) Lubricating Oil System Page 7-20 Assembly Use bushing mandrel, Part No. ST-1158, to push the new bushings into the oil pump body and cover. NOTE: The bushings must be installed level with or no more than 0.51 mm [0.020-inch] below the surface of the oil pump body or cover.
  • Page 363 Lubricating Oil System Lubricating Oil Pump Body and Cover Bushing - Replacement (07-07) Page 7-21 Turn the adjusting knob clockwise to push the tool bit against the indicator tip. NOTE: Adjust the tool bit until the indicator is set to the same size as the setting standard.
  • Page 364 Lubricating Oil Pump Body and Cover Bushing - Replacement (07-07) Lubricating Oil System Page 7-22 Use a cutting oil, and cut the bore in both bushings in the oil pump body. NOTE: Do not push down on the drill motor. The feed mechanism in the boring tool will move the boring bar.
  • Page 365 Lubricating Oil System Lubricating Oil Pump Body and Cover Bushing - Replacement (07-07) Page 7-23 Install the boring bar through the guide bushing. NOTE: The tool bit must go through the slot in the guide bushing. Do not allow the tool bit to hit against the guide bushing.
  • Page 366 Lubricating Oil Pump Body and Cover Bushing - Replacement (07-07) Lubricating Oil System Page 7-24 Use a cutting oil to lubricate and cool the bit while cutting the bore in the bushing. Stop the drill motor when the stop collar on the drive shaft is against the body of the boring tool.
  • Page 367 Lubricating Oil System Lubricating Oil Pump Driven Gear Bushing - Replacement (07-08) Page 7-25 Measure the inside diameter of the bushings in the oil pump body and the cover. Bushing I.D. (New) 22.28 0.877 22.30 0.878 NOTE: Bushings that do not meet the specifications given must be replaced.
  • Page 368 Lubricating Oil Pump Drive Gear or Shaft - Replacement (07-09) Lubricating Oil System Page 7-26 Measure the inside diameter of the new bushings in the driven gear. Bushing I.D. (New) 22.28 0.877 22.30 0.878 NOTE: The bushings used in the driven gear are finished bushings and do not require cutting.
  • Page 369 Lubricating Oil System Lubricating Oil Pump Driven Shaft - Replacement (07-10) Page 7-27 Assembly Use clean 15W-40 oil to lubricate the drive shaft. Use spacer mandrel, Part No. ST-1157, and an arbor press to push the drive gear onto the drive shaft. If the spacer mandrel is not available, install the gear onto the shaft to the following dimension as measured from the end of the shaft.
  • Page 370 Lubricating Oil Cooler Assembly - Rebuild (07-11) Lubricating Oil System Page 7-28 Assembly Use gear and spacer mandrel, Part No. ST-1157, to install the driven shaft into the oil pump body as follows: 1. Lubricate the large outside diameter of the driven shaft with clean 15W-40 oil.
  • Page 371 Lubricating Oil System Lubricating Oil Cooler Assembly - Rebuild (07-11) Page 7-29 Remove the oil cooler core hold down capscrews. Remove the oil cooler core from the oil cooler transfer connection (housing) by pulling the oil cooler water trans- fer tubes out of the o-ring adapters. Remove the four adapter plate capscrews and the o-ring adapters.
  • Page 372 Lubricating Oil Cooler Assembly - Rebuild (07-11) Lubricating Oil System Page 7-30 Remove the oil cooler bypass valve and the spacer plate. Loosen the lubricating oil filter bypass valve retaining plug with a 5/16-inch hexagon allen wrench. Remove the retaining plug (1), the plunger (2), spring (3), and the poppet valve (4) from the lubricating oil cooler transfer housing (5).
  • Page 373 Lubricating Oil System Lubricating Oil Cooler Assembly - Rebuild (07-11) Page 7-31 Remove Compuchek fittings and straight thread o-ring plugs from the transfer housing and support. Remove the transfer housing support bracket. Cleaning Clean the gasket material from the oil cooler core, trans- fer housing, support, spacer plate and filter head.
  • Page 374 Lubricating Oil Cooler Assembly - Rebuild (07-11) Lubricating Oil System Page 7-32 Visually inspect the oil cooler support, housing, spacer plate, filter head, and support bracket for cracks or damage. Visually inspect the oil cooler bypass valve for damage. Any damage to the front face of the valve will allow oil to bypass the oil cooler.
  • Page 375: Testing - Oil Cooler Core

    Lubricating Oil System Lubricating Oil Cooler Assembly - Rebuild (07-11) Page 7-33 Inspect the o-ring on the retaining plug for cuts or tears. Replace the o-ring if damaged. Inspect the teflon o-ring on the poppet valve for wear, cuts, or tears. Replace the complete poppet valve if there is any damage.
  • Page 376: Testing - Oil Cooler Bypass Valve

    Lubricating Oil Cooler Assembly - Rebuild (07-11) Lubricating Oil System Page 7-34 Attach a regulated air pressure hose to the other water transfer tube and apply 81 kPa [60 psi] air pressure. Caution: Conduct this test with extreme caution. Pres- surization of the oil cooler assembly while submerged in a hot water bath poses a condition where one must exercise care to avoid burns and water splash.
  • Page 377: Testing - Lubricating Oil Filter Bypass Valve Poppet Valve Spring

    Lubricating Oil System Lubricating Oil Cooler Assembly - Rebuild (07-11) Page 7-35 Suspend the valve and a 116°C [250°F] thermometer in a container of new lubricating oil. Do not allow the valve or the thermometer to touch the sides or bottom of the container.
  • Page 378: Installation - Oil Cooler Core

    Lubricating Oil Cooler Assembly - Rebuild (07-11) Lubricating Oil System Page 7-36 Install the oil cooler bypass valve into the transfer housing. Place the spacer plate and a new spacer gasket on the oil cooler support. Use two of the connection retainer capscrews to keep the gasket and plate loosely aligned on the support.
  • Page 379 Lubricating Oil System Lubricating Oil Cooler Assembly - Rebuild (07-11) Page 7-37 Install the oil cooler core on the oil cooler transfer con- nection (housing) by inserting the transfer tubes into the o-ring adapters. NOTE: Make sure the o-ring adapters move freely when the transfer tubes are inserted as this will allow tubes to be centered in the adapters.
  • Page 380: Installation - Lubricating Oil Filter Bypass Valve

    Lubricating Oil Cooler Assembly - Rebuild (07-11) Lubricating Oil System Page 7-38 Lubricate the o-ring with Lubriplate 105 or equivalent, and install the shutoff valve in the filter head. Install the retaining capscrew and washer. Torque Value: 20 N•m [15 ft-lb] Turn the valve to the ‘‘ON’’...
  • Page 381 Cooling System - Service Tools........................8-2 Fan - Cleaning and Inspection ........................8-23 Cleaning ..............................8-23 Inspection ..............................8-23 N14 Water Pump and Idler Assembly - Exploded View .................. 8-4 Thermostat Housing - Cleaning and Inspection .................... 8-19 Assembly ..............................8-22 Cleaning ..............................8-20 Disassembly ..............................
  • Page 382 Cooling System - Service Tools The following special tools are recommended to perform procedures in section 8. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description...
  • Page 383 Cooling System Cooling System - Service Tools Page 8-3 Tool No. Tool Description Tool Illustration Medium Duty Puller Kit Use to remove the radiator thermostat seat from the thermostat housing bore. 3375779 O-ring Pick Use to install and remove o-rings. 3376399 Depth Gauge Use to measure the bypass thermostat seat counterbore depth.
  • Page 384 N14 Water Pump and Idler Assembly - Exploded View Cooling System Page 8-4 N14 Water Pump and Idler Assembly - Exploded View Reference No. Description Quantity Reference No. Description Quantity Pulley, Water Pump Impeller Seal, Outer Oil Gasket Ring, Retaining...
  • Page 385 The bearing is greased during assembly and a press-on cover and o-ring are used to seal the unit from dirt. The N14 water pump is different from past NT engine water pumps in that it incorporates an internal coolant return passage from the oil cooler.
  • Page 386: Inspection

    Water Pump Assembly - Cleaning and Inspection (08-01) Cooling System Page 8-6 Water Pump Assembly - Cleaning and Inspection (08-01) Cleaning Before cleaning the water pump, inspect the weephole for large amounts of chemical fallout. A small amount is normal, but rebuild or replace the pump if a large amount is caked around the weephole.
  • Page 387: Water Pump Assembly - Rebuild

    Cooling System Water Pump Assembly - Rebuild (08-02) Page 8-7 Water Pump Assembly - Rebuild (08-02) Disassembly Remove the pulley with puller, Part No. 3375257. Remove the impeller with puller, Part No. 3823040. Remove the retaining ring that holds the bearing assem- bly and shaft in the body.
  • Page 388: Cleaning

    Water Pump Assembly - Rebuild (08-02) Cooling System Page 8-8 Use the disassembly fixture to support the inner bearing. Push the shaft from the bearing. Discard the bearing. Cleaning Use a gasket scraper to remove the gasket material from the gasket sealing surfaces. Use Scotch-Brite 7448, Part No.
  • Page 389: Inspection

    Cooling System Water Pump Assembly - Rebuild (08-02) Page 8-9 Inspection Visually inspect the water pump body for cracks, porosity, or excessive corrosion. NOTE: If the part being inspected does not meet the spec- ification given or if it is damaged or no alternative is given, the part must be replaced.
  • Page 390 Water Pump Assembly - Rebuild (08-02) Cooling System Page 8-10 Measure the water pump impeller bore inside diameter. Impeller Bore I.D. 15.85 0.624 15.88 0.625 Visually inspect the water pump drive pulley for cracks or damage. Visually inspect the pulley grooves and the oil seal wear sleeve for wear or damage.
  • Page 391 Cooling System Water Pump Assembly - Rebuild (08-02) Page 8-11 Shaft Journal O.D. Point 19.121 0.7528 19.128 0.7531 25.011 0.9847 25.022 0.9851 15.905 0.6262 15.918 0.6267 Visually inspect the bearing retaining ring for nicks or cracks. Discard damaged parts. Assembly Use clean 15W-40 oil to lubricate the water pump shaft.
  • Page 392 Water Pump Assembly - Rebuild (08-02) Cooling System Page 8-12 Use water pump bearing mandrel, Part No. ST-658, to support a new outer bearing. Install the shaft and the spacer into the bearing. NOTE: Push the shaft through the bearing until the bearing is against the spacer.
  • Page 393 Cooling System Water Pump Assembly - Rebuild (08-02) Page 8-13 Install a new outside oil seal, using a mandrel to press the seal in flush with the housing. Apply a thin film of pipe sealant, Part No. 3375066, to the outside diameter of the new water pump seal.
  • Page 394: Cleaning

    Water Pump Idler Assembly - Cleaning and Inspection (08-03) Cooling System Page 8-14 Prepare the drive pulley bore surface with Locktite Primer T, Part No. ST-1272-13. Apply a light film of Locktite 609, Part No. 3823718, to the bore in the drive pulley. Support the water pump pulley in an arbor press.
  • Page 395: Inspection

    Cooling System Water Pump Idler Assembly - Rebuild (08-04) Page 8-15 Inspection Visually inspect the idler assembly for cracked, chipped, or broken pulley grooves. Turn the idler pulley by hand to inspect the shaft and the bearing for freedom of rotation. NOTE: If damaged parts are found or the idler assembly does not rotate freely, the idler assembly must be replaced or rebuilt.
  • Page 396: Cleaning

    Water Pump Idler Assembly - Rebuild (08-04) Cooling System Page 8-16 Remove the capscrew and the washer. Press the shaft out of the bearing. Discard the bearing. Cleaning Use solvent to clean the idler assembly parts. Dry with compressed air. Inspection Visually inspect the idler pulley for cracks or damage.
  • Page 397 Cooling System Water Pump Idler Assembly - Rebuild (08-04) Page 8-17 Visually inspect the idler shaft for grooves, nicks, or dam- age. Inspect the adjusting screw and the mounting nut threads for wear or distortion. Measure the outside diameter (1) of the bearing press fit area of the idler shaft.
  • Page 398 Water Pump Idler Assembly - Rebuild (08-04) Cooling System Page 8-18 Support the idler pulley in an arbor press. Use bearing installation tool, Part No. ST-658, to press the bearing into the pulley until the bearing is against the bottom of the bearing bore.
  • Page 399 Cooling System Thermostat Housing - Cleaning and Inspection (08-05) Page 8-19 Install the oil seal with the lip toward the bearing. Use seal expander, Part No. 3823885, to guide the seal onto the shaft. Use a tube mandrel to press the seal in flush with the pulley.
  • Page 400: Cleaning

    Thermostat Housing - Cleaning and Inspection (08-05) Cooling System Page 8-20 Carefully remove the thermostat seal to avoid damaging the thermostat cover. Cleaning Use a gasket scraper to remove the gasket material from the mating surfaces of the housing and the cover. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield.
  • Page 401 Cooling System Thermostat Housing - Cleaning and Inspection (08-05) Page 8-21 Inspect the thermostat seal and the thermostat cover gasket surface for cracks, corrosion, or damage. Replace the thermostat cover if necessary. The thermostat seal can not be reused. The seal must be replaced if it is removed from the cover.
  • Page 402 Thermostat Housing - Cleaning and Inspection (08-05) Cooling System Page 8-22 Measure the inside diameter of the thermostat seal count- erbore in the thermostat housing. Thermostat Seal Bore I.D. 67.39 2.653 67.46 2.656 Use a depth micrometer or a depth gauge, Part No. 3823495, to measure the depth of the seal counterbore in the thermostat housing.
  • Page 403 Cooling System Coolant Filter Head Insert (08-06) Page 8-23 Coolant Filter Head Insert (08-06) Refer to Lubricating Oil Cooler Assembly - Rebuild in Section 7 for removal, cleaning, inspection, and instal- lation of the coolant filter head insert. Coolant Filter Shutoff Valve (08-07) Refer to Lubricating Oil Cooler Assembly - Rebuild in Section 7 for removal, inspection, and installation of the coolant filter shutoff valve.
  • Page 404 Page 8-24 Warning: Do not straighten a bent fan blade or continue to use a damaged fan. Replace the original equipment fan with a fan of the identical part number. Cummins Engine Company, Inc. must approve any other fan changes.
  • Page 405 Drive Units Page 9-1 Section 9 - Drive Units - Group 09 Section Contents Page Accessory Drive - Cleaning and Inspection for Reuse ................... 9-5 Cleaning ................................ 9-5 Inspection ............................... 9-5 Accessory Drive - Exploded View ........................9-3 Accessory Drive - Rebuild ..........................9-5 Assembly ...............................
  • Page 406: Drive Units - Service Tools

    Drive Units - Service Tools The following special tools are recommended to perform procedures in section 9. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description...
  • Page 407: Accessory Drive - Exploded View

    Drive Units Accessory Drive - Exploded View Page 9-3 Accessory Drive - Exploded View Reference No. Description Quantity Reference No. Description Quantity Hub, Spline Coupling Gear, Accessory Drive Washer, Plain Pin, Groove Capscrew, Special Shaft, Accessory Drive Sleeve, Spline Coupling Housing, Accessory Drive Plug, 5/16-inch Straight Washer, Plain...
  • Page 408: Drive Units - General Information

    Drive Units - General Information Drive Units Page 9-4 Drive Units - General Information Accessory Drive The accessory drive housings are available in two designs--with and without hardware for mounting an air compressor. The fuel pump drive assembly has hardware for a hub or spider-type coupling. The compressor drive assembly has hardware for a splined sleeve-type coupling.
  • Page 409: Cleaning

    Drive Units Accessory Drive - Cleaning and Inspection for Reuse (09-01) Page 9-5 Accessory Drive - Cleaning and Inspection for Reuse (09-01) Cleaning Remove all gasket material from surfaces (1) and (2). Clean the exterior of the drive with solvent. Dry with com- pressed air.
  • Page 410 Accessory Drive - Rebuild (09-02) Drive Units Page 9-6 Use coupling puller, Part No. 3376663, to remove the splined coupling. Use a three-jaw puller to remove the hub-type coupling. Remove the capscrew. Remove the clamping washer. Remove the gear and shaft assembly. Remove the straight thread o-ring plugs from the housing.
  • Page 411 Drive Units Accessory Drive - Rebuild (09-02) Page 9-7 Visually inspect the shaft bore in the housing for scoring or damage. Measure the inside diameter of the shaft bore in the drive housing. Drive Shaft Bore I.D. 33.426 1.3160 33.515 1.3195 Measure the drive shaft outside diameter.
  • Page 412: Assembly

    Accessory Drive - Rebuild (09-02) Drive Units Page 9-8 Measure the inside diameter of the drive pulley bore. Drive Pulley Bore I.D. 34.930 1.3752 34.950 1.3760 Assembly Use clean 15W-40 oil to lubricate the housing shaft bore. Use Lubriplate 105 or its equivalent to lubricate the front thrust face on the housing.
  • Page 413 Drive Units Accessory Drive - Rebuild (09-02) Page 9-9 With the gear/shaft assembly supported in an arbor press, use a mandrel to install the coupling. Push the coupling until it touches the clamping washer. NOTE: The splined-type coupling must be installed with the relieved area facing the clamping washer.
  • Page 414: Cleaning

    Accessory Drive Gear - Replacement (09-03) Drive Units Page 9-10 If the end clearance is not within specifications, make sure the coupling is positioned tightly against the clamp- ing washer. Accessory Drive Gear - Replacement (09-03) Disassembly Install the shaft and gear assembly in an arbor press with the part number side of the gear facing upwards.
  • Page 415: Assembly

    Drive Units Accessory Drive Gear - Replacement (09-03) Page 9-11 Visually inspect the shaft in the gear fit area for fretting or burrs. NOTE: If fretting or burrs can not be removed with a fine crocus cloth, replace the shaft. Measure the inside diameter of the drive gear.
  • Page 416 Accessory Drive Gear - Replacement (09-03) Drive Units Page 9-12 Caution: The jaws of the vise must have copper plates to prevent damage to the shaft. Clamp the accessory drive shaft in a vise. Apply Lubriplate 105 or its equivalent to the gear fit area before installing the gear.
  • Page 417: Cleaning

    Drive Units Accessory Drive Pulley - Cleaning and Inspection for Reuse (09-04) Page 9-13 Accessory Drive Pulley - Cleaning and Inspection for Reuse (09-04) Cleaning Clean the accessory drive pulley with solvent. Dry with compressed air. Inspection Visually inspect the pulley for cracks, wear in the belt grooves, or other damage.
  • Page 418 Accessory Drive Pulley Wear Sleeve - Replacement (09-05) Drive Units Page 9-14 Grind a 1.57 mm [0.062-inch] radius on the cutting edge of a 19.05 mm [0.75-inch] chisel. Place the chisel point against the wear sleeve. Use mod- erate blows with a hammer to strike the chisel at four points on the outside diameter of the wear sleeve to relieve the press fit.
  • Page 419: Accessory Drive

    Drive Units Accessory Drive Pulley Wear Sleeve - Replacement (09-05) Page 9-15 Use a fine grit emergy cloth dipped in clean lubricating oil to remove minor defects. Use a crocus cloth for final polishing operation and to remove any remaining deposits on the pulley wear sleeve mounting boss.
  • Page 420 Intake Air System Page 10-1 Section 10 - Intake Air System - Group 10 Section Contents Page Intake Air Piping - Elbows ..........................10-8 Inspection ..............................10-8 Intake Air System - Exploded View......................... 10-3 Intake Air System - General Information ....................... 10-4 Intake Air System - Service Tools ........................
  • Page 421: Intake Air System - Service Tools

    Intake Air System - Service Tools The following special tools are recommended to perform procedures in section 10. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
  • Page 422: Intake Air System - Exploded View

    Intake Air System Intake Air System - Exploded View Page 10-3 Intake Air System - Exploded View Ref. No. Description Qty. Ref. No. Description Qty. Connection, Intake Manifold Seal, O-ring Seal, Rectangular Ring Plate Cover Manifold, Intake Cover Gasket, Intake Manifold Screw, Self-Tapping Elbow Capscrew...
  • Page 423: Intake Air System - General Information

    Intake Air System - General Information Intake Air System Page 10-4 Intake Air System - General Informa- tion The intake air system consists of intake air piping, turbo- charger, charge air cooler (CAC) piping, and CAC. The turbocharger uses exhaust gas energy to turn the turbine wheel.
  • Page 424: Inspection

    Intake Air System Turbocharger - Cleaning and Inspection (10-01) Page 10-5 Turbocharger - Cleaning and Inspec- tion (10-01) Cleaning Remove all carbon deposits and gasket material from the gasket mating surfaces. NOTE: Tape or plug all openings to prevent solvent or steam from entering the oil cavities in the turbocharger.
  • Page 425 Turbocharger - Cleaning and Inspection (10-01) Intake Air System Page 10-6 Cracks on the turbocharger mounting flange must not reach the mounting holes. Two cracks on the turbocharger mounting flange must be separated by 6.4 mm [0.25-inch]. Through cracks at the dividing wall are acceptable and can be any length.
  • Page 426 Intake Air System Turbocharger Shaft Axial Clearance - Checking (10-02) Page 10-7 Turbocharger Shaft Axial Clearance - Checking (10-02) Measure the axial clearance (end to end), using dial depth gauge, Part No. ST-537. Push the rotor assembly away from the gauge. Set the gauge on zero (0).
  • Page 427: Cleaning

    Intake Air Piping - Elbows (10-04) Intake Air System Page 10-8 Intake Air Piping - Elbows (10-04) Inspection Visually inspect the turbocharger compressor V-band out- let and the discharge elbow V-band connection for dents or fretting. Replace the turbocharger compressor housing or dis- charge elbow if damaged so that the compressed air will not leak.
  • Page 428 Exhaust System Page 11-1 Section 11 - Exhaust System - Group 11 Section Contents Page Exhaust Manifold - Cleaning and Inspection for Reuse ................11-4 Assembly ..............................11-4 Cleaning ..............................11-4 Disassembly ..............................11-4 Inspection ..............................11-4 Exhaust Manifold Turbocharger Mounting Stud - Replacement ..............11-5 Mounting Hole Threads - Inspection ......................
  • Page 429: Exhaust System - Exploded View

    Exhaust System - Exploded View Exhaust System Page 11-2 Exhaust System - Exploded View Reference No. Description Quantity Manifold, Exhaust (Center) Manifold, Exhaust (End) Manifold, Exhaust (End) Pin, Groove Gasket, Exhaust Manifold Spacer Capscrew...
  • Page 430: Exhaust System - General Information

    The exhaust manifold utilizes a wear coating on the sealing surfaces of the manifold sections for improved sealing characteristics and greater reliability. As a running change on the 88NT model engines, the N14 will also incorporate the towerless capscrew mounting boss design exhaust manifolds. The capscrew mounting boss ‘‘towers’’ have been removed from the manifold castings and replaced with spacers.
  • Page 431 Exhaust Manifold - Cleaning and Inspection for Reuse (11-01) Exhaust System Page 11-4 Exhaust Manifold - Cleaning and Inspection for Reuse (11-01) Disassembly Use a mallet to remove the exhaust manifold sections. Cleaning Use a wire brush to remove carbon from the gasket seal- ing surfaces.
  • Page 432: Mounting Hole Threads - Inspection

    Exhaust System Exhaust Manifold Turbocharger Mounting Stud - Replacement (11-02) Page 11-5 Exhaust Manifold Turbocharger Mounting Stud - Replacement (11-02) Apply penetrating oil to the base of the turbocharger mounting stud to be removed. Use a standard stud extractor to remove the turbocharger mounting stud(s) from the center section.
  • Page 433 Air Equipment Page 12-1 Section 12 - Air Equipment - Group 12 Section Contents Page Air Compressor Cleaning and Inspection for Reuse........................ 12-3 Cleaning ..............................12-3 Inspection ..............................12-3 Air Equipment..............................12-2 General Information ............................12-2 Air Compressor ............................12-2...
  • Page 434: Air Compressor

    • Single cylinder air compressor - Air Equipment Rebuild Manual, Bulletin No. 3810242 • Two-cylinder air compressor - Air Equipment Rebuild Manual, Bulletin No. 3810257 Instructions for testing and repairing air cranking motors and air compressors not manufactured by Cummins can be obtained from the original equipment manufacturers.
  • Page 435 Air Equipment Air Compressor - Cleaning and Inspection for Reuse (12-01) Page 12-3 Air Compressor - Cleaning and Inspection for Reuse (12-01) Cleaning Remove all gasket material from the sealing surfaces. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury.
  • Page 436 Air Compressor - Cleaning and Inspection for Reuse (12-01) Air Equipment Page 12-4 Visually inspect the compressor drive gear and the fuel pump hub-type drive coupling for wear or damage. Measure the single cylinder air compressor crankshaft end clearance. Crankshaft End Clearance 0.06 0.002 0.69...
  • Page 437 Electrical Equipment Page 13-1 Section 13 - Electrical Equipment - Group 13 Section Contents Page Alternator Adjusting Link Cleaning and Inspection for Reuse ........................3 Cleaning ..............................13-3 Inspection ..............................3 Alternator Bracket Cleaning and Inspection for Reuse ........................3 Cleaning ..............................
  • Page 438 Page 13-2 Electrical Equipment - General Information The electrical equipment used on the N14 engine is not manufactured by Cummins Engine Company, Inc.Complete instructions for adjusting, testing, and repairing the electrical equipment can be obtained from the equipment manufacturer. The following list contains the suppliers of the electrical equipment used on Cummins engines:...
  • Page 439: Alternator Adjusting Link

    Alternator Bracket - Cleaning and Inspection for Reuse (13-01) Page 13-3 Wiring Diagrams A complete collection of electrical wiring diagrams, as applied to all Cummins engines, is contained in Wiring Diagrams, Bulletin No. 3379099. Alternator Bracket - Cleaning and Inspection for Reuse (13-01) Cleaning Use solvent to clean the bracket.
  • Page 440: Cleaning And Inspection For Reuse

    Starting Motor - Cleaning and Inspection for Reuse (13-03) Electrical Equipment Page 13-4 Inspection Visually inspect the gear (1) for cracked or broken teeth. Visually inspect the drive bushing (2) and the gear shaft (3) for excessive wear or damage. Visually inspect the terminal posts (4) for loose or broken connections.
  • Page 441 Engine Testing Page 14-1 Section 14 - Engine Testing - Group 14 Section Contents Page Chassis Dynamometer Operation........................14-29 Definition of Terms On Engine Performance Curve..................14-3 Dynamometer Worksheet ..........................14-28 Engine Dynamometer - Install Engine ......................14-9 Electronic Hookup - CELECT™ Engines Only ....................14-14 Engine Speed (RPM) With a Verified Tachometer ..................
  • Page 442: General Information

    However, light load/high rpm operation must be avoided during the run-in period. The following in-chassis run-in guidelines are recommended for N14 engines after a repair involving replacement of one or more of the piston ring sets, cylinder liners or cylinder kits where engine or chassis dynamometer or load bank run-in can not be performed.
  • Page 443: Definition Of Terms On Engine Performance Curve

    Engine Testing Definition of Terms On Engine Performance Curve Page 14-3 Definition of Terms On Engine Performance Curve Cummins 1991 N14 Heavy Duty Engine Operating Curve Definitions: 1. Peak Torque (N•m [ft-lb]) - Maximum torque that the engine will produce. Also, sometimes referred to as COMMAND TORQUE.
  • Page 444: General Run-In Procedures

    General Run-In Procedures Engine Testing Page 14-4 General Run-In Procedures Caution: Refer to General Engine Test Specifications before operating the engine to avoid internal component damage. Caution: The lubricating oil system must be pressurized before operating the engine to avoid internal component damage.
  • Page 445 Engine Testing General Run-In Procedures Page 14-5 Caution: Do not shut off the engine immediately after the run-in is completed. Allow the engine to cool by operating at low idle for a minimum of 3 minutes to avoid internal component damage.
  • Page 446: General Engine Test/Run-In Specifications

    General Engine Test/Run-In Specifications Engine Testing Page 14-6 General Engine Test/Run-In Specifications Maintain the following limits during the engine test/run-in procedures: Due to variations in ratings of different engine models, refer to the specific ‘‘Engine Data Sheet’’ for the particular engine model being tested.
  • Page 447: Engine Testing - Service Tools

    Engine Testing - Service Tools The following special tools are recommended to perform procedures in Section 14. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
  • Page 448 Part No. ST-435-1 is the hose 3375932 and Part No. ST-435-6 is the pressure gauge. Fuel Measuring Device Measure the rate of fuel consumption of a Cummins diesel engine. 3376375 Digital Optical Tachometer Used to measure engine speed (RPM).
  • Page 449: Engine Dynamometer - Install Engine

    Engine Testing Engine Dynamometer - Install Engine (14-01) Page 14-9 Engine Dynamometer - Install Engine (14-01) NOTE: Be sure the dynamometer capacity is sufficient to permit testing at 100 percent of the engine rated horse- power. If the capacity is not enough, the testing procedure must be modified to the restrictions of the dynamometer.
  • Page 450 Engine Dynamometer - Install Engine (14-01) Engine Testing Page 14-10 Visually inspect the engine for coolant leaks. Repair all leaks found. The intake air piping must be plumbed through an af- tercooler to control the temperature of the intake air dur- ing the run-in procedure.
  • Page 451 Engine Testing Engine Dynamometer - Install Engine (14-01) Page 14-11 Remove the straight thread fitting in the accessory drive and install the lubricating oil temperature sensor. Remove the pipe plug from the main oil rifle drilling in the cylinder block. Install the lubricating oil pressure sensor.
  • Page 452 Engine Dynamometer - Install Engine (14-01) Engine Testing Page 14-12 Fuel Rate The Part No. 3376375, Fuel Measuring instrument, is used during the performance check to measure fuel con- sumption. Install the fuel measuring device as follows: • The fuel return hose from the engine to the fuel measuring device (A).
  • Page 453: Fuel Pressure

    NOTE: The gauge will not measure the correct pressure if the gauge is not held at the same level as the connection. NOTE: All air compressors manufactured by Cummins En- gine Company, Inc. must be operating during the engine run-in. During the performance check, all air compressors must be in the unload or non-operating mode.
  • Page 454: Electronic Hookup - Celect™ Engines Only

    CELECT™ ECM while the engine run-in or performance test is in process. The engine dynamometer OEM harness for both the N14 and L10 engines are the same. The CELECT™ dyna- mometer test OEM wiring harness, Service Tool Part No.
  • Page 455 Engine Testing Engine Dynamometer - Install Engine (14-01) Page 14-15 Connect the dynamometer test OEM wiring harness AMP connector to the ECM. Tighten the connector capscrews to the ECM. Torque Value: 2.0 N•m [18 in-lb] Connect the dynamometer test OEM wiring harness 3-pin connector to the actuator harness power connector (shroud).
  • Page 456 Engine Dynamometer - Install Engine (14-01) Engine Testing Page 14-16 Connect the dynamometer test OEM wiring harness start- ing motor solenoid lead (yellow) to the starting motor solenoid. Connect the ground lead (black) to the starting motor or battery negative or ground side. Connect the +12 volt DC power lead (red) to either the starting motor or battery positive (+12 volt DC) side.
  • Page 457 Engine Testing Engine Dynamometer - Install Engine (14-01) Page 14-17 Select the ‘‘Feature Selection’’ from the menu options by depressing the number ‘‘1’’ on the keypad. The next screen will show if the ‘‘Progressive Shift Fea- ture’’ is turned ‘‘ON’’ or ‘‘OFF’’. Check the ‘‘Progressive Shift Feature’’.
  • Page 458: Lubricating Oil System Priming

    Priming the Lubricating Oil and Fuel Systems (14-02) Engine Testing Page 14-18 If the parameter is to be bypassed with the Compulink™, refer to the following instructions. Select ‘‘Troubleshooting’’, key (1), from the ‘‘Main Menu Option’’ screen. Select ‘‘Special Functions’’, key (4), from the ‘‘Trouble- shooting Menu’’.
  • Page 459 On CELECT™ engines, remove the lubricating oil tem- perature sensor from the lubricating oil pump cover. Lubricating oil pumps on N14 STC engines are equipped with a 9/16-18 UNF Compuchek coupling nipple. Use the coupler, Part No. 3376859, to connect the priming pump to the coupling.
  • Page 460 Priming the Lubricating Oil and Fuel Systems (14-02) Engine Testing Page 14-20 NOTE: If an external pressure pump is not available, prime the lubricating system as follows: Use the dipstick to measure the lubricating oil level. Fill the oil pan to the ‘‘high’’ level mark on the dipstick. Disconnect the turbocharger lubricating oil supply line.
  • Page 461 Engine Testing Priming the Lubricating Oil and Fuel Systems (14-02) Page 14-21 Disconnect the electrical wire that supplies power to the fuel pump solenoid. NOTE: The manual override screw must be turned coun- terclockwise until it stops. Caution: Do not crank the starting motor for more than 30 seconds.
  • Page 462: Fuel System Priming - Pt System

    Priming the Lubricating Oil and Fuel Systems (14-02) Engine Testing Page 14-22 Install the filter on the filter head and tighten the filter until the gasket contacts the filter head surface. Tighten the filter an additional one-half to three-fourths (1/2 to 3/4) turn. Fuel System Priming - PT System To reduce engine cranking time, prime the fuel pump.
  • Page 463: Fuel System Priming - Celect™ System

    Engine Testing Priming the Lubricating Oil and Fuel Systems (14-02) Page 14-23 Install the electrical wire that supplies power to the so- lenoid. NOTE: The manual override screw on the solenoid must be turned counterclockwise until it stops to allow the solenoid to open and close.
  • Page 464 Engine Run-In Procedure - Engine Dynamometer (14-03) Engine Testing Page 14-24 If the filter cap opening can not be used, remove the fuel supply hose to the gear pump. Lubricate the gear pump gears with clean engine lubri- cating oil. Install the fuel supply hose to the gear pump.
  • Page 465 2. Injector Parts Flow and Cross Reference, Bulletin No. 3379664. 3. Engine Data Sheets. 4. N14 Troubleshooting and Repair Manual, Bulletin No. 3810456. If a sudden increase in blowby occurs, or if blowby ex- ceeds the maximum allowable limit during any run-in step, return to the previous step and continue the run-in.
  • Page 466 Engine Run-In Procedure - Engine Dynamometer (14-03) Engine Testing Page 14-26 Open the throttle to obtain speed at which maximum horsepower is developed and adjust the dynamometer load to achieve 75 percent of rated fuel pressure or 75 percent fuel rate on CELECT™ engines. Operate the en- gine at this speed and load level for 3 minutes.
  • Page 467 Engine Testing Engine Run-In Procedure - Engine Dynamometer (14-03) Page 14-27 Caution: Shutting off the engine immediately after op- erating at full load will damage the turbocharger and internal components. Always allow the engine to cool before shutting it off. Remove the dynamometer load completely, and operate the engine at 700 to 900 RPM for 3 to 5 minutes.
  • Page 468: Dynamometer Worksheet

    Dynamometer Worksheet Engine Testing Page 14-28 Dynamometer Worksheet Date Repair Order No. Operator Fuel Pump Code Complaint SC Code (CELECT™) PARAMETER CODE SPECIFICATIONS ACTUAL READING Fuel Pressure (psi @ RPM) Fuel Rate (pph) Check Point 1 (psi @ RPM) (Reference Only) Intake Mfd.
  • Page 469: Chassis Dynamometer Operation

    Engine Testing Chassis Dynamometer Operation (14-04) Page 14-29 Chassis Dynamometer Operation (14-04) 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 ap- proximately: •...
  • Page 470 Chassis Dynamometer Operation (14-04) Engine Testing Page 14-30 • Make sure the tires are inflated to the manufactur- er’s specifications. • Remove all rocks or other material from the tread of all tires that will be rotating on the dynamometer rollers.
  • Page 471 Engine Testing General Test Procedure - Chassis Dynamometer (14-05) Page 14-31 • Make sure there is proper overhead clearance for exhaust stacks, air deflectors, or other attachments above the cab. General Test Procedure - Chassis Dynamometer (14-05) Check the engine coolant level to be sure it is filled to the proper level.
  • Page 472: Fuel Pressure (Stc Engines Only)

    General Test Procedure - Chassis Dynamometer (14-05) Engine Testing Page 14-32 To properly monitor engine performance, record the fol- lowing parameters. To limit dynamometer operating time, instrument the engine to make as many checks as pos- sible. • Engine speed rpm with a verified tachometer •...
  • Page 473 Engine Testing General Test Procedure - Chassis Dynamometer (14-05) Page 14-33 Fuel Rate Use fuel measuring device, Part No. 3376375, to mea- sure the rate of fuel consumption. Install the fuel measuring device as follows: • The fuel return hose from the engine to the fuel measuring device (A).
  • Page 474: Intake Manifold Pressure

    General Test Procedure - Chassis Dynamometer (14-05) Engine Testing Page 14-34 Fuel Drain Line Restriction Use Pressure Gauge, Part No. ST-1273, to measure fuel drain line restriction. NOTE: Do not measure fuel drain line restriction with the fuel measuring device installed. This will not measure the drain line restriction of the vehicle’s return plumbing.
  • Page 475: Charge Air Cooler Restriction

    Engine Testing General Test Procedure - Chassis Dynamometer (14-05) Page 14-35 Charge Air Cooler Restriction Measure the intake pressure drop across the charge air cooler. This test can be done with a mercury manometer or two separate gauges, Part No. ST-1273. If two gauges are being used, calibrate both gauges on a common pressure source at 206 kPa [30 PSI] to ensure consistency.
  • Page 476: Exhaust Air Restriction

    General Test Procedure - Chassis Dynamometer (14-05) Engine Testing Page 14-36 Operate the engine at maximum horsepower RPM and Advertised Horsepower. Observe the reading on the gauge or manometer. NOTE: Restriction must not exceed 635 mm H 0 [25 inches Exhaust Air Restriction Measure the exhaust air restriction.
  • Page 477: Lubricating Oil Pressure

    Engine Testing General Test Procedure - Chassis Dynamometer (14-05) Page 14-37 Install a plug in the crankcase breather vent tube. Remove the ‘‘bottle stopper’’ oil filler cap and install the blowby checking tool, Part No. 3375150. Install the water manometer to the blowby checking tool. Observe the engine blowby.
  • Page 478 CPL and fuel pump codes in the following publications: 1. Fuel Pump Calibration Values, Bulletin No. 3379352. 2. Injector Parts Flow and Cross Reference, Bulletin No. 3379664. 3. Engine Data Sheets 4. N14 Troubleshooting and Repair Manual, Bulletin No. 3810456...
  • Page 479 Engine Testing Engine Run-In Procedure - Chassis Dynamometer (14-06) Page 14-39 If a sudden increase in blowby occurs, or if blowby ex- ceeds the maximum allowable limit during any run-in, return to the previous step 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.
  • Page 480 Engine Run-In Procedure - Chassis Dynamometer (14-06) Engine Testing Page 14-40 Operate the engine at nominal torque peak RPM, full load, wide open throttle, for 5 minutes. Check the gauges, and record the readings. NOTE: Refer to the engine ‘‘Data Sheet’’ for the torque peak RPM of the engine model being tested.
  • Page 481 Engine Testing Engine Run-In Procedure Without Dynamometer (14-07) Page 14-41 Engine Run-In Procedure Without Dynamometer (14-07) On-Highway Caution: Refer to General Information and General En- gine Test Specifications and Procedures before operat- ing the engine to avoid internal component damage. Operate the vehicle pulling heaviest available trailer al- lowed for the first 80 to 160 km [50 to 100 miles] after rebuild.
  • Page 482: Engine Painting

    Engine Painting (14-08) Engine Testing Page 14-42 Engine Painting (14-08) Cover the following: • Exhaust and Intake Openings • Electrical Components • Fuel Inlet and Drain Connections • Any Exposed Fittings, Threads and Electrical Wire Terminals Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield.
  • Page 483 Engine Testing Engine Storage - Short Term (14-09) Page 14-43 Engine Storage - Short Term (14-09) NOTE: This procedure describes the proper method to pre- pare an engine for short term storage (1 to 6 months). Operate the engine at ‘‘High Idle’’ speed until the coolant temperature indicator reaches: Temperature: 70°C [160°F]...
  • Page 484 Engine Storage - Short Term (14-09) Engine Testing Page 14-44 Turn the fuel pump manual shutoff valve counterclock- wise until it stops. Remove the electrical wiring from the fuel pump solenoid. Drain the cooling system. NOTE: It is not necessary to drain the coolant if it is a permanent type antifreeze with a rust inhibitor.
  • Page 485: Remove The Engine From Short Term Storage

    Engine Testing Engine Storage - Long Term (14-10) Page 14-45 Remove the Engine From Short Term Storage Remove the tape from the openings. Remove the warn- ing tag. Replace the oil, water, and fuel filters. Prime the lubricating oil system. Refer to Priming the Lubricating Oil System (14-02).
  • Page 486 Engine Storage - Long Term (14-10) Engine Testing Page 14-46 Drain the lubricating oil pan. Install the drain plug. Torque Value: 136 N•m [100 ft-lb] Fill the oil pan to the ‘‘High’’ level mark with preservative oil. NOTE: Use Shell 66202, or an equivalent preservative oil. The oil must meet Military Specification MIL-L-21260 Type R10 Grade 2 SAE 30.
  • Page 487: Remove The Engine From Long Term Storage

    Engine Testing Engine Storage - Long Term (14-10) Page 14-47 Remove the intake manifold. Remove the exhaust man- ifold. Refer to Engine Disassembly (00-01). Spray preservative oil into the intake and exhaust ports in the cylinder head and into the exhaust manifolds. Install the intake manifold.
  • Page 488 Engine Storage - Long Term (14-10) Engine Testing Page 14-48 Use clean diesel fuel to flush the preservative oil from the fuel system. Remove a plug from the main oil rifle drilling. Use a light mineral oil to flush the preservative oil from the engine. NOTE: Use the accessory drive shaft to rotate the crank- shaft three to four revolutions during the flushing procedure.
  • Page 489 Instruments and Controls Page 15-1 Section 15 - Instruments and Controls - Group 15 Section Contents Page Instruments and Controls ..........................2, 3 General Information..........................15-2, 15-3...
  • Page 490 Cold weather operating aids provide cold weather protection and better starting conditions for the engine. The instruments and controls used on the N14 engine are not manufactured by Cummins Engine Company, Inc. The following list contains the suppliers of the instrumentation used on Cummins engines:...
  • Page 491 Instruments and Controls General Information Page 15-3 Instruments and Controls - General Information (Cont’d) Oil Heaters Fleetguard, Inc. Route 8 Cookeville, TN 38501 Telephone: (615) 526-9551 Kim Hotstart Co. West 917 Broadway Spokane, WA 99210 Telephone: (509) 534-6171 Service Products Company, Inc. 635 S.
  • Page 492 Mounting Adaptations Page 16-1 Section 16 - Mounting Adaptations - Group 16 Section Contents Page Flywheel Cleaning and Inspection for Reuse ......................16-5 Cleaning ..............................16-5 Inspection ..............................16-5 Flywheel Housing Cleaning and Inspection for Reuse ......................16-6 Cleaning ..............................16-6 Inspection ..............................
  • Page 493: Mounting Adaptations - Service Tools

    Mounting Adaptations - Service Tools The following special tools are recommended to perform procedures in Group 16. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location.
  • Page 494: Mounting Adaptations - Exploded View

    Mounting Adaptations Mounting Adaptations - Exploded View Page 16-3 Mounting Adaptations - Exploded View Reference Reference Description Quantity Description Quantity Support, Front Engine Gear, Ring Cover, Access Hole Flywheel Housing, Flywheel...
  • Page 495: Mounting Adaptations - General Information

    Mounting Adaptations - General Information Mounting Adaptations Page 16-4 Mounting Adaptations - General Information The mounting adaptations group consists of the flywheel housing, flywheel, flywheel ring gear, pilot bearing, and the front engine support. The flywheel is available only as an assembly with the ring gear installed; however, the ring gear is available for service replacement.
  • Page 496 Mounting Adaptations Flywheel - Cleaning and Inspection for Reuse (16-01) Page 16-5 Flywheel - Cleaning and Inspection for Reuse (16-01) Cleaning Use a wire brush to clean the crankshaft pilot bore. Steam clean or use a solvent, and dry with compressed air.
  • Page 497: Flywheel Ring Gear - Replacement

    Flywheel Ring Gear - Replacement (16-02) Mounting Adaptations Page 16-6 Flywheel Ring Gear - Replacement (16-02) Caution: Do not use a cutting torch to heat the ring gear. The flywheel can be damaged. Heat the outside diameter of the ring gear with a heating torch.
  • Page 498 Mounting Adaptations Flywheel Housing - Redowel to Cylinder Block (16-04) Page 16-7 Inspection Visually 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.
  • Page 499 Flywheel Housing - Redowel to Cylinder Block (16-04) Mounting Adaptations Page 16-8 Measure and record the diameter of one of the dowel pins which was removed to determine the next oversize dowel to be installed after the housing is aligned. Install the flywheel housing without the dowel pins.
  • Page 500 Mounting Adaptations Flywheel Housing - Redowel to Cylinder Block (16-04) Page 16-9 If the total indicator reading exceeds the limits listed in Section 00-02 ‘‘Flywheel Housing Installation,’’ use a mallet to horizontally move the housing one-half the dis- tance of the total indicator reading. Rotate the crankshaft until the indicator is at the 12:00 o’clock position.
  • Page 501 Flywheel Housing - Redowel to Cylinder Block (16-04) Mounting Adaptations Page 16-10 Tighten the mounting capscrews in the sequence shown. Torque Value: 203 N•m [150 ft-lb] After the capscrews are torqued, check the housing bore and the surface alignment again before doweling the housing.
  • Page 502 Mounting Adaptations Flywheel Housing - Redowel to Cylinder Block (16-04) Page 16-11 The dowel must be long enough to protrude from the block one-half of the flywheel housing wall thickness but must not protrude past the housing wall. NOTE: There are three oversize dowel pins available: Oversize Dowel Pin O.D.
  • Page 503 Flywheel Housing - Redowel to Cylinder Block (16-04) Mounting Adaptations Page 16-12 After reaming one hole, turn the plate and align it with the second dowel hole. Repeat the procedure in the second hole. Remove the plate from the crankshaft. Caution: To avoid possible engine damage, make sure the dowel hole does not contain any metal chips.
  • Page 504: Front Engine Support Bracket - Cleaning And Inspection For Reuse

    Mounting Adaptations Front Engine Support Bracket - Cleaning and Inspection for Reuse (16-05) Page 16-13 Front Engine Support Bracket - Cleaning and Inspection for Reuse (16-05) Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury.
  • Page 505 Specifications Group Index NT 855 Page 18-1 Specifications - Group 18 Group Index Page Air Compressor Inspection Specifications ..........................18-66 Cam Follower Assembly Rebuild Specifications ..........................18-46 Fixed Injection Timing ..........................18-46 MVT Injection Timing ..........................18-46 Torque Values............................. 18-51 Capscrew Markings and Torque Values ......................
  • Page 506 Group Index Specifications Page 18-2 NT 855 Page Specifications General Information ............................18-8 Thermostat Housing Assembly Rebuild Specifications ..........................18-59 Thermostat (Reserve Flow Cooling) Operating Temperature ..........................18-60 Turbocharger Inspection Specifications ..........................18-66 Vehicle Braking Rebuild Specifications ..........................18-67 Water Pump Assembly Rebuild Specifications ..........................
  • Page 507 Specifications General Engine Specifications NT 855 Page 18-3 General Engine Specifications General Engine Data Metric [U.S. Customary] Horsepower (Refer to the engine dataplate) Engine speed @ Maximum Output: • Standard Rating (RPM) ........................2100 • Formula Rating (RPM) ......................1800 or 1900 Bore &...
  • Page 508 General Engine Specifications (Continued) Specifications Page 18-4 NT 855 General Engine Specifications (Continued) Cooling System Metric [U.S. Customary] Coolant Capacity (engine only) ..................21 liters [22 U.S. qt.] Standard Modulating Thermostat Range: • Conventional Aftercooling ................82 to 93°C [180 to 200°F] •...
  • Page 509: Capscrew Markings And Torque Values

    Specifications Capscrew Markings and Torque Values NT 855 Page 18-5 Capscrew Markings and Torque Values Caution: When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using incorrect capscrews can result in engine damage. SAE capscrews are graded according to the strength of the capscrew.
  • Page 510 Pipe Plug Torque Values Specifications Page 18-6 NT 855 Pipe Plug Torque Values Size Torque Torque In Cast Iron or Thread Actual Thread O.D. In Aluminum Components Steel Components N•m ft-lb N•m ft-lb 1/16 0.32 45 in-lb 10.4 0.41 13.7 0.54 17.3 0.68...
  • Page 511 Specifications Decimal and Metric Equivalents NT 855 Page 18-7 Decimal and Metric Equivalents Metric Decimal Fractions Metric Decimal Fractions 0.39688 0.015625 1/64 13.09687 0.515625 33/64 0.79375 0.03125 1/32 13.49375 0.53125 17/32 1.19062 0.046875 3/64 13.89062 0.546875 35/64 1.58750 0.0625 1/16 14.28750 0.5625 9/16...
  • Page 512 Specifications - General Information Specifications Page 18-8 NT 855 Specifications - General Information The specifications in this section are organized in the same sequence used in each group of this manual. The minimum and maximum tolerance limit specifications are listed in both metric and U.S. Customary dimensions. The assembly and rebuild specifications and torque values are provided to make sure the parts are correctly assembled, fit correctly, and are secured with the correct torque value.
  • Page 513 Specifications Engine Assembly - Specifications NT 855 Page 18-9 Part or Assembly Ref. Point Engine Assembly - Specifications Cylinder Liner Protrusion 0.10 0.004 0.18 0.007 Cylinder Liner to Lower Cylinder 0.05 0.002 Liner Bore Clearance 0.15 0.006 Cylinder Liner Out of Round 0.05 0.002 Crankshaft End Clearance...
  • Page 514 Engine Assembly - Specifications Specifications Page 18-10 NT 855 Part or Assembly Ref. Point Piston Ring Gap Piston • Top 0.43 0.017 0.68 0.027 • Second 0.51 0.020 0.76 0.030 • Third 0.48 0.019 0.74 0.029 • Oil 0.25 0.010 0.64 0.025 Note: Add 0.08 mm [0.003-inch] to the maximum limit for each 0.03 mm [0.001-inch] wear in the...
  • Page 515 Specifications Engine Assembly - Specifications NT 855 Page 18-11 Part or Assembly Ref. Point Accessory Drive Assembly Timing Position the accessory drive shaft dowel pin at the 12:00 o’clock position. Align the timing mark on the accessory drive gear with the timing mark on the camshaft gear. Backlash Between the Accessory 0.05 0.002...
  • Page 516 Engine Assembly - Specifications Specifications Page 18-12 NT 855 Part or Assembly Ref. Point PTD Top-Stop Injector Adjustment Refer to Engine Assembly, Group 00, PTD Top-Stop Injector Adjustment, Page 0-129. PTD STC Injector Adjustment Refer to Engine Assembly, Group 00, PTD STC Injector Adjustment, Page 0-133. Intake Valve Lash Specifications 0.28 0.011...
  • Page 517 Specifications Engine Assembly - Specifications NT 855 Page 18-13 Part or Assembly Ref. Point Belt Tension Ref. Point Newtons Pounds Force Water Pump Belt (Big Cam IV and New Big Cam IV) • New Belt Tension • Used Belt Tension 290-580 65-130 Belt Tension...
  • Page 518 Engine Assembly - Capscrew Torque Values Specifications Page 18-14 NT 855 Torque Values Part or Assembly Step N•m ft-lb Engine Assembly - Capscrew Torque Values Adapter Plate to Rebuild Stand Mounting Plate Adapter to Rear Water Header, if Removed Adapter Plate Mounting Capscrews •...
  • Page 519 Specifications Engine Assembly - Capscrew Torque Values NT 855 Page 18-15 Torque Values Part or Assembly Step N•m ft-lb Flywheel Housing Note: Tighten in the sequence shown. Connecting Rod Capscrews Note: Tighten the connecting rod capscrews in alternating sequence. Cylinder Head Note: Tighten in the sequence shown.
  • Page 520 Engine Assembly - Capscrew Torque Values Specifications Page 18-16 NT 855 Torque Values Part or Assembly Step N•m ft-lb Camshaft Bearing Support Accessory Drive Pulley Front Engine Support Bracket Vibration Damper Capscrew Size: 5/8-inch; SAE grade No. 8 Flywheel Note: Tighten the capscrews in a star pattern. Water Manifold Assembly Injectors (PTD-Top Stop) •...
  • Page 521 Specifications Engine Assembly - Capscrew Torque Values NT 855 Page 18-17 Torque Values Part or Assembly Step N•m ft-lb Injectors (PTD-Top Stop) • New Big Cam IV and 88 Big Cam IV Note: For New Big Cam IV and 88 Big Cam IV engines (3/8-inch - 16 capscrews), tighten the capscrews alternately and evenly, 11 N•m [8 ft-lb] torque one at a time to a final torque of 34 N•m [25 ft-lb].
  • Page 522 • With torque wrench adapter, Part No. ST-669 • Without adapter Cummins C Brake Nuts Note: Tighten the C Brake nuts in the sequence shown. Cummins C Brake Lock Nut Jacobs Hold Down Nuts Note: Tighten the nuts in the sequence shown. Jacobs Lock Nut •...
  • Page 523 Specifications Engine Assembly - Capscrew Torque Values NT 855 Page 18-19 Torque Values Part or Assembly Step N•m ft-lb Rocker Housing Covers • Big Cam IV/New Big Cam IV • 88 Big Cam IV Note: Tighten in the sequence shown. Oil Pan (7/16-inch Mounting Capscrews) Note: Tighten one of the 7/16-inch oil pan mounting capscrews on each side of the oil pan, halfway between the front and the rear of the oil pan.
  • Page 524 Engine Assembly - Capscrew Torque Values Specifications Page 18-20 NT 855 Torque Values Part or Assembly Step N•m ft-lb Fuel Pump Support Bracket to Cylinder Block Mounting Capscrews Fuel Tubing Tube Size 1/4-inch 15-20 10-15 5/16-inch 20-25 15-20 3/8-inch 25-35 20-25 1/2-inch 35-40...
  • Page 525 Specifications Engine Assembly - Capscrew Torque Values NT 855 Page 18-21 Torque Values Part or Assembly Step N•m ft-lb Water Pump (Big Cam IV and New Big Cam IV) Note: Tighten the capscrews in the sequence shown. Water Pump (88 Big Cam IV) Idler Pulley Support Bracket Note: The two capscrews which mount the idler pulley support bracket are longer than the other four water pump capscrews.
  • Page 526 Engine Assembly - Capscrew Torque Values Specifications Page 18-22 NT 855 Torque Values Part or Assembly Step N•m ft-lb Water Pump Belt (88 Big Cam IV) • New Belt Tension 620 N 140 lbf • Used Belt Tension 270-490 N 60-110 lbf Note: A belt is considered used if it has been in operation for more than 10 minutes.
  • Page 527 Specifications Engine Assembly - Capscrew Torque Values NT 855 Page 18-23 Torque Values Part or Assembly Step N•m ft-lb Hand Hole Cover Coolant Filter Head (88 Big Cam IV) Thermostat Housing (Big Cam IV and New Big Cam IV) Thermostat Housing (88 Big Cam IV) Thermostat (Reserve Flow Cooling) Big Cam IV, New Big Cam IV, 110 in-lb...
  • Page 528 Engine Assembly - Capscrew Torque Values Specifications Page 18-24 NT 855 Torque Values Part or Assembly Step N•m ft-lb Thermostat (Reserve Flow Cooling) Rear Hold Down Strap Capscrew Oil Cooler Assembly (Big Cam IV and New Big Cam IV) Cooler Brace Oil Cooler Assembly (88 Big Cam IV) Support Bracket to Cylinder Block (2) Support Bracket to Rear Oil Cooler Cover...
  • Page 529 Specifications Engine Assembly - Capscrew Torque Values NT 855 Page 18-25 Torque Values Part or Assembly Step N•m ft-lb Water Transfer Tube (Big Cam IV and New Big Cam IV) • Retaining Clip Water Transfer Housing to Thermostat Housing Water Transfer Tube (88 Big Cam IV) Hose Clamps 40 in-lb Water Fill Tube (88 Big Cam IV Only)
  • Page 530 Engine Assembly - Capscrew Torque Values Specifications Page 18-26 NT 855 Torque Values Part or Assembly Step N•m ft-lb Aftercooler Coolant Inlet and Outlet Tubes (88 Big Cam IV) • Hose Clamps (1) and (2) 40 in-lb Aftercooler Coolant Inlet and Outlet Tubes (88 Big Cam IV) •...
  • Page 531 Specifications Engine Assembly - Capscrew Torque Values NT 855 Page 18-27 Torque Values Part or Assembly Step N•m ft-lb Air Crossover Tube Support Clamp(s) Turbocharger • Capscrews • Hose Clamps 40 in-lb Turbocharger Oil Supply Hose Swivel Nuts Bypass Oil Filter Return Tube Swivel Nuts Hose Clamps 40 in-lb...
  • Page 532 Engine Assembly - Capscrew Torque Values Specifications Page 18-28 NT 855 Torque Values Part or Assembly Step N•m ft-lb Alternator Belts • New Belt Tension 620 N 140 lbf • Used Belt Tension 270-490 N 60-110 lbf Note: A belt is considered used if it has been in operation for more than 10 minutes.
  • Page 533 Specifications Cylinder Block - Rebuild Specifications NT 855 Page 18-29 Part or Assembly Ref. Point Cylinder Block - Rebuild Specifications Cylinder Block Height 421.87 16.609 422.45 16.632 Upper Press Fit Design Counterbore Diameter 6.5615 - 6.5635 • Standard 166.662 - 166.713 6.5815 - 6.5835 •...
  • Page 534 Cylinder Block - Rebuild Specifications Specifications Page 18-30 NT 855 Part or Assembly Ref. Point Cylinder Block Camshaft Bore I.D. 68.237 2.6865 68.262 2.6875 Cylinder Liner Protrusion 0.10 0.004 0.18 0.007 Counterbore Sealing Ring Thickness • Standard Lower Press Fit or Upper Press Fit Liners 0.18 0.007...
  • Page 535 Specifications Cylinder Block - Rebuild Specifications NT 855 Page 18-31 Part or Assembly Ref. Point Liner O.D. (Lower Press Fit Area) Upper Press Fit Design • Standard 159.86 6.294 159.99 6.299 • .020 Oversize 159.86 6.294 159.99 6.299 Liner O.D. (Lower Press Fit Area) Lower Press Fit Design •...
  • Page 536 Cylinder Block - Rebuild Specifications Specifications Page 18-32 NT 855 Part or Assembly Ref. Point Piston Pin Bore 50.762 1.9985 50.800 2.0000 Piston Pin O.D. 50.762 1.9985 50.775 1.9990 Note: Discard the piston pin if it is more than 0.03 mm [0.001-inch] out of round. Crankshaft Oil Seal Wear Groove 0.25 0.010...
  • Page 537 Specifications Cylinder Block - Rebuild Specifications NT 855 Page 18-33 Part or Assembly Ref. Point Crankshaft Main Bearing Journal O.D. 114.237 4.4975 114.300 4.5000 Crankshaft Thrust Face Width 76.23 3.001 76.28 3.003 Crankshaft Gear Bore I.D. 95.394 3.7557 95.415 3.7565 Crankshaft Gear Fit Area O.D.
  • Page 538 Cylinder Block - Rebuild Specifications Specifications Page 18-34 NT 855 Part or Assembly Ref. Point Main Bearing Shell Thickness (Standard) 3.086 0.1215 3.145 0.1238 Thrust Bearing Thickness 6.210 0.2445 6.286 0.2475 Connecting Rod Bearing Thickness 2.362 0.0930 (Standard) 2.405 0.0947 Connecting Rod Capscrew O.D.
  • Page 539 Specifications Cylinder Block - Rebuild Specifications NT 855 Page 18-35 Part or Assembly Ref. Point Connecting Rod - Twist: • (Without Bushing) 0.50 0.020 • (With Bushing) 0.25 0.010 The instructions for performing a magnetic crack inspection of the connecting rod is provided in Group 01.
  • Page 540 Cylinder Block - Rebuild Specifications Specifications Page 18-36 NT 855 Part or Assembly Ref. Point Crankshaft Pulley I.D. 35.05 1.380 35.10 1.382 Vibration Damper Thickness Measure the thickness in four places 90 degrees apart approximately 3.18 mm [0.125 inch] from the outside diameter. The difference between any two of the four measurements must not exceed 0.25 mm [0.010 inch].
  • Page 541 Specifications Cylinder Block - Torque Values NT 855 Page 18-37 Torque Values Part or Assembly Step N•m ft-lb Cylinder Block - Torque Values Cylinder Block Pipe Plugs • 1/4-inch • 3/8-inch Cylinder Block Pipe Plugs • 3/8-inch • 1/8-inch Cylinder Block Pipe Plugs •...
  • Page 542 Cylinder Head - Rebuild Specifications Specifications Page 18-38 NT 855 Part or Assembly Ref. Point Cylinder Head - Rebuild Specifications Cylinder Head Flatness Per 25.4 mm [1.00 in.] of Length 0.020 0.0008 Cylinder Head Flatness (Total Overall 0.08 0.003 Length) Cylinder Head Thickness 109.85 4.325...
  • Page 543 Specifications Cylinder Head - Rebuild Specifications NT 855 Page 18-39 Part or Assembly Ref. Point Valve Guide Height (Installed) 32.26 1.270 32.51 1.280 Crosshead Guide O.D. 10.975 0.4321 11.011 0.4335 Crosshead Guide Height (Installed) 47.25 1.860 47.75 1.880 Valve Seat Area Width 1.60 0.063 3.18...
  • Page 544 Cylinder Head - Rebuild Specifications Specifications Page 18-40 NT 855 Part or Assembly Ref. Point Valve Seat Width Limit 1.60 0.063 3.18 0.125 Valve Guide Bore I.D. 19.05 0.750 19.07 0.751 Valve Guide O.D. 19.088 0.7515 19.101 0.7520 Valve Guide Height (Installed) 32.26 1.270 32.51...
  • Page 545 Specifications Cylinder Head - Rebuild Specifications NT 855 Page 18-41 Part or Assembly Ref. Point Crosshead Guide Bore I.D. 10.947 0.4310 10.972 0.4320 Crosshead Guide Height (Installed) 47.25 1.860 47.75 1.880 Valve Head Thickness (at O.D.) 2.90 0.114 Injector Tip Protrusion: 1.52 0.060 1.78...
  • Page 546 Cylinder Head - Rebuild Specifications Specifications Page 18-42 NT 855 Part or Assembly Ref. Point Valve Crosshead Stem Pocket to Pad Face 9.65 0.380 10.16 0.400...
  • Page 547 Specifications Cylinder Head - Torque Values NT 855 Page 18-43 Torque Values Part or Assembly Step N•m ft-lb Cylinder Head - Torque Values Install the Injectors into the Cylinder Head Capscrew Timing Size Fixed 5/16 Fixed Note: Refer to Cylinder Head - Rebuild (02-02), page No.
  • Page 548 Rocker Lever Housing Assembly - Rebuild Specifications Specifications Page 18-44 NT 855 Part or Assembly Ref. Point Rocker Lever Housing Assembly - Rebuild Specifications Rocker Lever Bushing Bore I.D. (Installed) • Pre-88NT 28.562 1.1245 28.666 1.1286 • 88NT 34.886 1.3735 34.988 1.3775 Rocker Lever Shaft O.D.
  • Page 549 Specifications Rocker Lever Housing Assembly - Torque Values NT 855 Page 18-45 Torque Values Part or Assembly Step N•m ft-lb Rocker Lever Housing Assembly - Torque Values Rocker Lever Shaft Set Screw 100 in-lb Note: The 80-degree tilt engines use spray nozzles instead of set screws in the rocker lever housings.
  • Page 550 Cam Follower Assembly - Rebuild Specifications Specifications Page 18-46 NT 855 Part or Assembly Ref. Point Cam Follower Assembly - Rebuild Specifications Fixed Injection Timing Cam Follower Roller Side Clearance 0.23 0.009 0.61 0.024 Cam Follower Roller to Pin Clearance 0.08 0.003 0.20...
  • Page 551 Specifications Cam Follower Assembly - Rebuild Specifications NT 855 Page 18-47 Part or Assembly Ref. Point Valve Lever Bushing or Bore I.D. 19.052 0.7501 19.100 0.7520 Injector Lever Bushing I.D. 34.963 1.3765 35.011 1.3784 Injector Cam Follower Lever Eccentrics O.D. 34.900 1.3740 34.920...
  • Page 552 Cam Follower Assembly - Rebuild Specifications Specifications Page 18-48 NT 855 Part or Assembly Ref. Point Actuator Shaft Guide I.D. 19.28 0.759 19.35 0.762 Actuator Plunger O.D. 49.60 1.953 49.78 1.960 Timing Spacer Length Part No. 35.68mm [1.405in] 3021515 35.43mm [1.395in] 31.11mm [1.225in] 3024029 30.86mm [1.215in]...
  • Page 553 Specifications Cam Follower Assembly - Rebuild Specifications NT 855 Page 18-49 Part or Assembly Ref. Point Cam Follower Shaft From Housing 23.25 0.915 Extension Dimension 23.75 0.935 The Shaft End Opposite the Actuator Must Have a Depth in the Housing as Follows: Dimensions 25.30 0.996...
  • Page 554 Cam Follower Assembly - Rebuild Specifications Specifications Page 18-50 NT 855 Part or Assembly Ref. Point Valve Roller Pin O.D. 12.692 0.4997 12.700 0.5000 Injector Roller Pin O.D. 17.772 0.6997 17.780 0.7000 Cam Follower Roller Side Clearance 0.23 0.009 0.61 0.024 (1) Cam Follower Socket O.D.
  • Page 555 Specifications Cam Follower Assembly - Torque Values NT 855 Page 18-51 Torque Values Part or Assembly Step N•m ft-lb Cam Follower Assembly - Torque Values Cam Follower Shafts Locking Screws 15 in-lb Note: The heads of the locking screws must be flush or below flush with the gasket surface of the cam follower housing.
  • Page 556 Fuel Pump - Rebuild Specifications Specifications Page 18-52 NT 855 Torque Values Part or Assembly Step N•m ft-lb Spring Retainer Lock Nut Actuator Cap Fuel Pump - Rebuild Specifications The disassembly, inspection, repair, assembly and calibration procedures for the fuel pump are covered in PT Fuel Pump Rebuilding and Calibration Instructions, Bulletin No.
  • Page 557 Specifications Lubricating Oil System - Capacities NT 855 Page 18-53 U.S. Part or Assembly Ref. Point Liters Gallons Lubricating Oil System - Capacities Oil Pan Capacity: • Automotive High • Industrial 22.7 26.5 High Refer to Lubrication System Specifications, page 18-3, for additional specifications. Part or Assembly Ref.
  • Page 558 Lubricating Oil Pump - Inspection Specifications Specifications Page 18-54 NT 855 Part or Assembly Ref. Point Lubricating Oil Pump Body and 25.387 0.9995 Cover Bushing Bore I.D. 25.413 1.0005 Bushing I.D. (New) 22.28 0.877 22.30 0.878 Driven Gear Bushing Bore I.D. 25.387 0.9995 25.413...
  • Page 559 Specifications Lubricating Oil System - Torque Values NT 855 Page 18-55 Part or Assembly Ref. Point Driven Shaft Press Fit Area O.D. 22.301 0.8780 22.314 0.8785 Driven Shaft Protrusion 17.90 0.705 18.67 0.735 Torque Values Part or Assembly Step N•m ft-lb Lubricating Oil System - Torque Values Sending Unit Capscrew (Big Cam IV and...
  • Page 560 Lubricating Oil System - Torque Values Specifications Page 18-56 NT 855 Torque Values Part or Assembly Step N•m ft-lb Oil Cooler Connection (Housing) to Support Capscrews (88 Big Cam IV) Rear Cover to Oil Cooler Connection (Housing) Capscrews (88 Big Cam IV) Oil Cooler Core Holddown Clamp Nuts and Capscrews (88 Big Cam IV) Tighten the nuts and the capscrews in the...
  • Page 561 Specifications Water Pump Assembly - Rebuild Specifications NT 855 Page 18-57 Part or Assembly Ref. Point Water Pump Assembly - Rebuild Specifications Water Pump Body Bearing Bore I.D. 61.991 2.4406 62.017 2.4416 Water Pump Body Seal and Seat Assembly Bore I.D. 36.45 1.435 36.47...
  • Page 562 Fan Hub - Inspection Specifications Specifications Page 18-58 NT 855 Part or Assembly Ref. Point Water Pump Idler Pulley Bearing Bore I.D. 61.996 2.4408 (Big Cam IV and New Big Cam IV) 62.012 2.4414 Idler Shaft O.D. 24.989 0.9838 (Big Cam IV and New Big Cam IV) 25.011 0.9847 Idler Pulley Bearing Bore I.D.
  • Page 563 Specifications Thermostat Housing Assembly - Rebuild Specifications NT 855 Page 18-59 Part or Assembly Ref. Point Inner Bearing Spacer Length 50.78 1.999 50.82 2.001 Outer Bearing Spacer Length 50.67 1.995 50.75 1.998 Fan Hub End Clearance 0.08 0.003 0.25 0.010 Thermostat Housing Assembly - Rebuild Specifications Radiator Thermostat Seat Height 38.18...
  • Page 564 Thermostat (Reserve Flow Cooling) - Operating Temperature Specifications Page 18-60 NT 855 Part or Assembly Ref. Point Bypass Thermostat Seat Counterbore 2.92 0.115 Depth (Big Cam IV and New Big Cam IV) 3.17 0.125 Bypass Thermostat Seat O.D. 44.462 1.7505 (Big Cam IV and New Big Cam IV) 44.513 1.7525...
  • Page 565 Specifications Thermostat (Reserve Flow Cooling) - Operating Temperature NT 855 Page 18-61 Part or Assembly Ref. Point Thermostat Rectangular Seal Bore Depth • Radiator Thermostat 5.03 0.198 5.13 0.202 • Bypass Thermostat 5.03 0.198 5.13 0.202...
  • Page 566 Cooling System -Torque Values Specifications Page 18-62 NT 855 Torque Values Part or Assembly Step N•m ft-lb Cooling System -Torque Values Assembly of the Water Pump Idler (Flat Head Capscrew) Fan Hub Lock Nut Filter Head Adapter in the Housing (Big Cam IV and New Big Cam IV) Water Transfer Cover to Thermostat Housing (Big Cam IV and New Big Cam IV)
  • Page 567 Specifications Cooling System -Torque Values NT 855 Page 18-63 Torque Values Part or Assembly Step N•m ft-lb Coolant Transfer Tube Clamp Capscrew (88 Big Cam IV) Coolant Filter Head Retaining Capscrew Coolant Filter Element Adapter...
  • Page 568 Fuel Pump and Compressor Drive - Rebuild Specifications Specifications Page 18-64 NT 855 Part or Assembly Ref. Point Fuel Pump and Compressor Drive - Rebuild Specifications Drive Shaft End Clearance 0.05 0.002 0.30 0.012 Drive Housing Bushing Bore I.D. 33.43 1.316 33.55 1.321...
  • Page 569 Specifications Fuel Pump and Compressor Drive - Torque Values NT 855 Page 18-65 Part or Assembly Ref. Point Drive Gear Bore I.D. 39.730 1.5642 39.751 1.5650 Drive Shaft Gear Fit Journal O.D. 39.789 1.5665 39.814 1.5675 Drive Housing Bearing Bore I.D. 36.73 1.446 36.75...
  • Page 570 Turbocharger - Inspection Specifications Specifications Page 18-66 NT 855 Part or Assembly Ref. Point Turbocharger - Inspection Specifications Turbocharger Shaft End Clearance Model No. BHT3B/HT3B 0.03 0.001 0.10 0.004 BHT4C/HT4B 0.05 0.002 0.13 0.005 Turbocharger Compressor Impeller Radial Clearance Model No. BHT3B/HT3B 0.15 0.006...
  • Page 571 Specifications Engine Testing - Test Specifications NT 855 Page 18-67 Part or Assembly Ref. Point Engine Testing - Test Specifications Note: The specifications and instructions for testing the engine are provided this manual. Refer to Engine Testing - Group 14, Page 14-1. Vehicle Braking - Rebuild Specifications Note: The specifications and instructions for rebuilding the Jacobs Brake are provided in the Jacobs Brake Installation Manual.
  • Page 572 Vehicle Braking Page 20-1 Section 20 - Vehicle Braking - Group 20 Section Contents Page Vehicle Braking General Information ............................20-2 Cummins C Brake............................. 20-2 Jacobs Engine Brake..........................20-2...
  • Page 573 A compression brake is a device that uses the energy of the engine compression to provide vehicle retardation. Cummins C Brakes provide the maximum retarding power at governed engine speeds; therefore, gear selection is important. For installation, operation, maintenance, troubleshooting and repair of the Cummins C Brake, refer to the following service publications: Bulletin No.
  • Page 574 Component Manufacturers Page C-1 Component Manufacturers NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins engines. Suppliers can be contacted directly for any specifications not covered in this manual. Air Cylinders Coolant Heaters A.C.
  • Page 575 Component Manufacturers Page C-2 Fans Flexplates Governors Truflo Ltd. Corrugated Packing and Woodward Governors Ltd. Westwood Road Sheet Metal P.O. Box 15 Birmingham Hamsterley 663/664 Ajax Avenue B6 7JF Newcastle Upon Tyne Slough England Telephone: 0207-560-505 Bucks Telephone: 021-557-4101 SL1 4DD Detroit Diesel Allison England Hayes-Albion...
  • Page 576 Component Manufacturers Page C-3 Torque Converters Twin Disc International S.A. Chaussee de Namur Nivelles Belgium Telephone: 067-224941 Twin Disc Clutch Co. Racine, WI 53403 Telephone: (414) 634-1981 Rockford Division Borg-Warner Corporation 1200 Windsor Road P.O. Box 7007 Rockford, IL 61125-7007 Telephone: (815) 633-7460 Modine 1500 DeKoven Avenue...
  • Page 577 Section L - Service Literature Page L-1 Section L - Service Literature Section Contents Page Additional Service Literature ..........................L-2 Service Literature Ordering Location ....................... L-3 Service Publications Order Form ........................L-5...
  • Page 578 Troubleshooting and Repair Manual - PT Pacer 3810443 PT Pacer Compulink™ Cartridge Manual 3810444 Operation and Maintenance Manual, N14 Automotive Engines, STC and CELECT™ Models U.S.A., Canada, Australia, New Zealand, and Puerto Rico 3810445 Operation and Maintenance Manual, N14 Automotive Engines, STC and CELECT™ Models Worldwide Excluding U.S.A., Canada, Australia, New Zealand, and Puerto Rico...
  • Page 579 100-G Pasir Panjang Road Singapore 0511 Australia and New Zealand Cummins Diesel Australia Maroondah Highway, P .O.B. 139 Ringwood 3134 Victoria, Australia Obtain current price information from your local Cummins Distributor or (for U.S.A.) by calling Cummins Toll Free Number 1-800-DIESELS (1-800-343-7357).
  • Page 580 Each Amount Publications Total Payment Enclosed. Make certified check or Indiana Residents: money order payable to Cummins Engine Co. Add 5% Sales Tax Please ship C.O.D. (U.S.A. only) Handling & Shipping Chg: No. Items X $1.50 = Prices subject to change without notice.
  • Page 581 Payment enclosed. Make certified check or money order payable to Cummins Engine Company, Inc. FROM: Name: Street Address: City: State: Zip Code: Country: SHIP TO: (Name and address where literature is to be shipped) Name: Street Address: City: State: Zip Code:...
  • Page 582 Index Page X-1 Accessory Drive - Cleaning and Inspection for Reuse ... 9-5 Camshaft Bearing Support - Removal ........0-38 Cleaning ................. 9-5 Camshaft Gear - Replacement ..........1-65 Inspection ................9-5 Cleaning................. 1-66 Accessory Drive - Exploded View ........... 9-3 Inspection ................
  • Page 583 Index Page X-2 Camshaft Bore - Inspection ............ 1-15 Engine - Preparation for Cleaning .......... 0-10 Coolant Passage - Inspection ..........1-21 Engine - Removal From the Rebuild Stand ......0-138 Cylinder Block - Cleaning ............1-11 Engine Brake - Adjustment ........... 0-115 Cylinder Block - Inspection ............
  • Page 584 Index Page X-3 Inspection - CELECT™ Fuel Pump ........... 5-6 Intake Manifold - Installation..........0-120 Inspection - PT Fuel Pump ............5-4 Intake Manifold - Removal ............. 0-33 Fuel Pump - General Information ..........5-2 Lubricating Oil Cooler - Exploded View ........7-5 Fuel Pump - Installation ............
  • Page 585 Index Page X-4 Piston and Connecting Rod Assemblies - Removal....0-40 Inspection ................2-41 Piston Cooling Nozzles - Installation ........0-139 Valve Crosshead - Magnetic Crack Inspection ...... 2-42 Piston Cooling Nozzles - Removal ......... 0-15 Valve Crossheads - Installation ........... 0-103 Pistons - Cleaning and Inspection..........
  • Page 586 IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. 15 • COLUMBUS, IN 47201 Postage Will Be Paid By Cummins Engine Company, Inc. Product Service Support Mail Code 80205 Box 3005 Columbus, IN 47202-3005 – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –...
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