CUMMINS N14 Especificações

Simbolos Usados En Este ManualLos si´mbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuandoaparece uno de

Turn the camshaft gear by hand in the opposite directionas far as it will freely move, and read the dial indicator.Backlash Between the Camshaft and t

The injection timing code appears on the enginedataplate. Codes are alphabetic letters that relate to anumerical specification.Specifications can be f

NOTE: The injection timing check is a measurement whichdetermines the injector push rod travel in relation to thepiston travel. Due to normal parts to

Align the plunger rod (1) and the injector push rod (3) witheach other, and parallel to the plunger rod.NOTE: Tighten the clamp handle (2) after the p

NOTE: The timing tool indicator needles will both start tomove in the same direction of rotation as the piston ap-proaches TDC if the cylinder is on t

Put the push rod travel dial indicator in the center of theinjector push rod plunger. Lower the indicator to within0.63 mm [0.025-inch] of fully compr

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

NOTE: The injection timing can be changed by removing thecam follower housing and by increasing or decreasing thegasket thickness. Each 0.18 mm [0.007

The accompanying chart lists the different cam followerhousing gaskets, the gasket thickness, and approximatechange in push rod travel at 19 degrees B

Accessory Drive - InstallationRotate the crankshaft until the accessory drive timingmarks on the camshaft gear are at approximately the 1:00o’clock po

Symboles Utilises Dans Ce ManuelLes symboles suivants sont utilise´s dans ce manuel pour aider a` communiquer le but des instructions. Quand l’unde ce

Use a dial indicator to check the backlash between theaccessory drive gear and the camshaft gear.Install the tip of the dial indicator against a tooth

CELECT™ Engine Position Sensor(EPS) - InstallationInstall a new EPS in the mounting hole in the block. Makesure a new o-ring is present and in place.

Turn the lubricating oil pump drive gear by hand as far asit will freely move, and set the dial indicator to ‘‘0’’ (zero).Turn the lubricating oil pum

Cut off the ends of the gasket even with the cylinder blockoil pan mounting flange.Mount a dial indicator on the front face of the crankshaft.Put the

Crankshaft Seal, Front - InstallationNOTE: ‘‘LDL TFE’’ (Lay-down Lip, Teflon) oil seals for ser-vice replacement have an assembly tool which protects

The clearance between the bearing support thrust faceand the camshaft gear must be 0.20 mm to 0.33 mm[0.008- to 0.013-inch].After measuring the space

Caution: Do not use lubricating oil on the o-ring. Theo-ring will increase in size when in contact with lubri-cating oil. Use vegetable oil to lubrica

Accessory Drive Pulley - InstallationNOTE: Make sure the pipe plug behind the pulley is installedand tightened before pulley installation.Apply a film

Lubricating Oil Pan - InstallationInstall the oil pan gasket and the oil pan on the cylinderblock. Use your fingers to install and tighten one of the7

Install the water tubes (A) in the front of the No. 2 and No.3 rocker lever housings. Install the plugs (B) in the frontof the No. 1 rocker lever hous

SymboleIn diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. DieSymbole haben folgende Bedeutung:WARNUNG

Use service tool, Part No. 3823819, to slide the two watertubes into the adjacent water manifold.Install the two water tube retainer clamps.Install an

If injector puller, Part No. 3823579, is not available, ascrewdriver can be used to install the injector by puttingthe screwdriver on the injector bod

NOTE: When installing injectors for reuse, new o-rings mustbe installed on the injector.Lubricate the o-rings with lubricating oil just beforeinstalla

Install the push tubes in the corresponding numberedlocation.On CELECT™ engines, take care to route the injectorsolenoid leads to avoid contact with t

Use a wire gauge to check the clearance between thecrosshead and the valve spring retainer. The clearancemust be a minimum of 0.51 mm [0.020-inch].NOT

Make sure the push rods are in the cam follower sockets,and align the push rods with the injector and valve rockerlever adjusting screws.Alternately t

The valves and the injectors on the same cylinder areadjusted at the same index mark on the accessory drivepulley.One pair of valves and one injector

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 2.8N•m [25

Select a feeler gauge for the correct valve lashspecification.Valve Lash SpecificationsIntake Exhaust0.35 mm 0.68 mm[0.014-inch] [0.027-inch]Insert th

If using the feel method, attempt to insert a feeler gaugethat is 0.03 mm [0.001-inch] thicker between the cross-head and the rocker lever pad. The va

IllustrationsThe illustrations used in this manual are intended to give an example of how to perform the action or the repairbeing described. Many of

All overhead (valve and injector) adjustments must bemade when the engine is cold (any stabilized coolanttemperature at 60°C [140°F] or below).Each cy

Check the valve rocker levers on cylinder No. 5 to see ifboth the intake and exhaust valves are closed.NOTE: Both the intake and exhaust valves are cl

Apply thumb pressure to the tool handle to hold the tappetin the maximum upward position.Caution: An overtightened setting on the injector ad-justing

With the ‘‘A’’ set mark aligned with the pointer on the gearcover and both valves closed on cylinder No. 5, loosenthe lock nuts on the intake and the

After tightening the lock nut to the correct torque value,check to make sure the feeler gauge will slide backwardand forward between the crossheads an

Engine Brake - InstallationInstall two guide pins into each rocker lever housing.Install new C-Brake housing gaskets and the C-Brakes.Remove the guide

Rotate the crankshaft in the direction of engine rotation.Align the ‘‘A’’ mark on the accessory drive pulley with thepointer on the gear cover.When th

Loosen the lock nut for the No. 5 slave piston adjustingscrew.Install a dial indicator, Part No. 3375006, over the No. 5slave piston adjusting screw.

Use the torque wrench adapter, Part No. ST-669, and a1/4-inch eight point socket to tighten the lock nut.Torque Value: 24 N•m [18 ft-lb]Repeat this pr

Tighten the slave piston adjusting screw until the slavepiston contacts the feeler gauge and creates a slightdrag.Use the torque wrench adapter, Part

Glossary Of TermsAFC: Air Fuel Control; a device in the PT fuel pump that limits the fuel delivery untilthere is sufficient intake manifold pressure t

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

CELECT™ Intake Air TemperatureSensor - InstallationInstall the sensor in the engine. Tighten the sensor.Torque Value: 35 N•m [25 ft-lb]Make sure the s

Connect the sensor drain line (1) to the tee fitting on thecylinder block.Torque Value: 27 N•m [20 ft-lb]Connect the pressure signal line (1) to the l

Install a new o-ring on the oil pan lubricating oil suctiontube.Use clean vegetable oil to lubricate the o-ring.Loosely install the lubricating oil tr

Air Compressor - InstallationInstall the splined coupling on the accessory drive.Make sure the gasket surfaces of the accessory drive andthe air compr

STC EnginesInstall the fuel pump drive spider coupling.Use a new gasket to install the fuel pump.Install the four fuel pump mounting capscrews.Torque

Connect and tighten the inlet and outlet fuel hoses to thecooling plate.Inspect for paint or grease on the cooling plate.CELECT™ Lubricating Oil Press

CELECT™ Sensor Harness - Installa-tionInstall the sensor wiring harness on the engine.Install the sensor harness amp connector to the elec-tronic cont

On engines equipped with engine brakes, connect theengine brake harness to the sensor harness.Wire tie the harness to the fuel tubing at the rear of t

Connect the actuator harness to each of the pass throughconnectors along the side of the rocker lever housing.Make sure the connector clicks/snaps int

Magnetic Particle Inspec-tion:A method of checking for cracks in either steel or iron parts. This method re-quires a Magnaflux machine, or an equivale

STC External Oil Plumbing - Installa-tionConnect the following lines to the STC oil control valveand tighten them to the specified torque:1. Fuel pres

Engine Support Bracket, Front -InstallationInstall the engine support bracket and the eight mountingcapscrews.Tighten the capscrews.Torque Value: 68 N

Install the dial indicator on the gear cover as indicated tomeasure damper eccentricity.Rotate the crankshaft, and record the indicator move-ment. Rep

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 th

Water Pump Belt - Installation andAdjustmentVisually inspect the pulley alignment. Pulley misalign-ment must not exceed 0.5 mm per cm [1/16-inch per f

Thermostat Housing - InstallationInstall the water transfer tube with new o-rings into thewater pump housing. Apply a non-petroleum based lu-bricant s

Install the coolant tubes to the air compressor and thewater pump.Install the coolant tube to the thermostat housing.Fan Hub and Fan Hub Support Brack

Fan Belts - Installation and AdjustmentVisually inspect the pulley alignment. Pulley misalign-ment must not exceed 0.5 mm per cm [1/16-inch per foot]o

Refer to the Belt Tension Chart shown to select the cor-rect gauge and tension values for the belt width.A belt is considered used if it has been in o

Use the hoist to move the weight of the engine off of therebuild stand.Remove the capscrews that hold the engine to the adapterplate.Install the engin

Engine IdentificationThe engine dataplate provides the model identificationand other important information about the engine.Have the following engine

Install and tighten the capscrews.Torque Value: 16 N•m [140 in-lb]Dipstick Tube and Housing - Installa-tionInstall the dipstick tube housing and a new

Lubricating Oil Cooler Assembly -InstallationInstall two guide studs in the oil cooler support mountingholes in the cylinder block.Install a new oil c

Alternator Mounting Bracket - Installa-tionInstallthealternator mountingbracket.Tightenthe mount-ing capscrews.Torque Value: 47 N•m [35 ft-lb]Alternat

Adjust the belt tension to the following values:New Belt Tension Used Belt Tension620 N [140 lbf] 490 N [110 lbf]NOTE: A belt is considered used if it

Starting Motor - InstallationCaution: Make sure to use the same thickness of start-ing motor spacer (if used) as the one removed to installthe startin

Tighten the capscrews in two steps in the sequenceshown.Torque Values: Step 1 47 N•m [35 ft-lb]Step 2 81 N•m [60 ft-lb]Turbocharger - InstallationAppl

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

Crankcase Breather Tube - InstallationInstall the breather vent tube on the breather tube, andtighten the hose clamps.Torque Value: 4.5 N•m [40 in-lb]

If the engine is to be run-in on an engine dynamometer,make sure the shutoff valve is closed. Open the valveafter the run-in.Be sure the engine drainc

Section 1 - Cylinder Block - Group 01Section ContentsPageCamshaft - Cleaning and Inspection ...

Engine DiagramsThe following drawings contain information about engine components, filter locations, drain points, and accesslocations for instrumenta

PageCylinder Block - Exploded View...

Cylinder Block - Service ToolsST-561Connecting Rod Checking FixtureMeasure connecting rod bend and twist.ST-598Gear Cover Bushing MandrelDesigned to i

ST-1272-12Loctite CompoundUse to install repair bushings.ST-1272-13Loctite Primer TUse to clean the counterbore area and the outside diameter ofthe re

3375861Camshaft Bushing DriverUse camshaft bushing driver set, Part No. 3376637, and driver,Part No. 3375861, to remove bushing No. 1 through No. 7.33

Cylinder Block - Exploded ViewCylinder Block - Exploded View Cylinder BlockN14Page 1-6

Ref.No.Description Quantity1 Damper, Vibration 12 Pulley, Crankshaft 13 Bushing, Gear Cover Accessory Drive 14 Cover, Gear 15 Support, Camshaft 16 Shi

Cylinder Block - General Information1. A WARNING statement is included for any component or assembly that weighs more than 23 kg [50 lb]. To avoidpers

Cylinder Block - Disassembly (01-01)Cam Bore Rear Cup Plug - RemovalTo remove the cup plug from the camshaft bore, use acenter punch to mark the cup p

Remove the straight thread plug and pipe plug from thepiston cooling oil passage on the exhaust side of thecylinder block.Remove pipe plugs from the c

Camshaft Bushings - RemovalUse camshaft bushing driver set, Part No. 3376637, anddriver, Part No. 3375861, to remove bushings No. 1through No. 7.Remov

Engine Diagrams Section I - IntroductionN14Page i-14

Clean the following cylinder block areas:Cylinder liner counterbore ledge and press fit area.Cylinder liner packing ring bore.Cylinder head deck surfa

Camshaft bore cup plug area.All gasket surfaces.All component mounting surfaces.Clean all oil passages. Use a bottle brush with a longhandle.Cylinder

Warning: Use a face shield, rubber gloves, an apron,and boots and obey the warning label on the cleaningsolution used to prevent personal injury.Cauti

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

Use two centering rings, Part No. ST-1177-39 [4.750inches diameter]. Put the rings in the No. 2 and the No.6 main bearing locations.Use clean 15W-40 o

4. Hit the cap with a rubber mallet to push it into thecorrect position.NOTE: The main bearing caps must not have any sideclearance with the block.Cyl

Insert the bar through the centering rings while slowlyrotating the bar. The bar must turn easily.If the bar does not turn easily, check to make sure

Use a 0.08 mm [0.003-inch] feeler gauge that is not morethan 13 mm [0.5-inch] wide.Center the checking ring in the bore. Try to put the feelergauge be

Measure the inside diameter in the three positions shown.The inside diameter must be completely round within0.0190 mm [0.00075-inch].Main Bearing Bore

The height of the block must not vary more than 0.05 mm[0.002-inch] from end to end of the block. If the blockheight is not within specifications, the

Section I - Introduction Engine DiagramsN14 Page i-15

Closed end thread repair inserts can be used in conjunc-tion with upper counterbore sleeves (0.020-inch oversizeon the outside diameter or smaller), a

Coolant Passage - RepairingThe coolant passage repair kit, Part No. 3823679, con-sists of the following components:Ref.No.ToolNo. Description Qty.1 38

Tap until the stop contacts the cylinder block head decksurface.Clean the threads with safety solvent, Part No. 3823717.Allow to dry.Clean the coolant

Start the insert with your fingers, and install it approxi-mately half way.Liberally apply the sealing and retaining compound to theupper half of the

Cylinder Head Capscrew Holes - RepairingComponents included in the capscrew thread repair kit,Part No. 3376208, for the N14 block are as follows:Ref.N

Ream the failed capscrew hole to the full depth of thehole.Use a chip removing unit to remove reamer chips from thecapscrew hole.Set the tap stop coll

Clean and flush the newly cut threads with safety solvent,Part No. 3823717. Use a chip removing unit to clean thecapscrew hole of shavings and debris,

Install and tighten the repair insert.Loosen the jam nut. Remove the cylinder head capscrewand jam nut arrangement.Correct installation will provide 0

Make sure the inside portion of the repair insert is clean.Remove any file shavings or debris.Before tightening the cylinder head capscrews, allow the

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) - InstallationAn alignment po

ForewordThis manual contains complete rebuild specifications and information for the N14 model engines, and all asso-ciated components manufactured by

General Cleaning InstructionsSolvent and Acid CleaningSeveral solvent and acid-type cleaners can be used to clean the engine parts. Cummins Engine Com

Bushings (No. 6 through No. 2) - InstallationAn alignment pointer, Part No. 3823635, is used to alignthe cam bearing oil holes with the oil holes in t

Use a 2.39 mm [0.094-inch] diameter rod or a 3/32-inchhexagon wrench to check the position and the location ofthe oil hole in the bushing and the cyli

Dowel Pin - InstallationNOTE: Do not install the dowel pins in the block until theinspection and any necessary repair procedures are com-pleted.Cautio

Install a 3/8-inch pipe plug in the piston cooling oil cross-over passage at the front of the cylinder block. Tightenthe pipe plug.Torque Value: 27 N•

Cam Bore Rear Cup Plug - InstallationCaution: Do not install cup plugs in the block until thecleaning, inspection, and necessary repair proceduresare

Caution: Do not use a hone, deglazing, or prebrushingto clean the cylinder liners. Abrasives can damage thefinish and the pattern and can contaminate

InspectionVisually inspect for pitting or erosion in the crevice sealgroove.Replace the liner if pitting or erosion is greater thanone-half the width

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 crac

Replace the liner if:1. a heavy polish is present over 20 percent of the pistonring travel area.2. thirty percent (30%) of the piston ring travel area

Cylinder Liner Flange Thicknessmm inStandard 9.01 MIN 0.3559.04 MAX 0.356Oversize 9.52 MIN 0.3759.55 MAX 0.376Pistons - Cleaning and Inspection(01-07)

Section 0 - Engine Disassembly and Assembly - Group 00Section ContentsPageAccessory Drive - Installation ...

InspectionVisually inspect the piston bowl, the pin bore, and the skirtfor cracks or damage.Use crack detection kit, Part No. 3375432, or equivalentto

Measure the piston pin bore when the piston temperatureis at 21°C [70°F] in two places 90 degrees apart.Piston Pin Boremm in63.504 MIN 2.50063.530 MAX

InspectionVisually 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 assem

Visually inspect the capscrew threads for damage.Visually inspect under the capscrew heads for cracks.Measure the capscrew outside diameters.Connectin

Measure the connecting rod bearing bore inside diame-ter.Connecting Rod Crankshaft Bore I.D.mm in93.731 MIN 3.690293.769 MAX 3.6917If any of the measu

Connecting Rod Ring Dowels - RemovalCaution: Do not damage the surface or the ring dowelhole during removal of the dowel.Use pliers or locking pliers

Install the connecting rod into the fixture.Move the dial holder to position the contact points of theindicators on the mandrel in the piston pin bore

Measure the rod length and bend (alignment).Connecting Rod Lengthmm in304.75 MIN 11.998304.80 MAX 12.000Connecting Rod Alignmentmm inBushing Removed 0

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,

Crankshaft Adapter - Cleaning andInspection (01-11)CleaningWarning: When performing the following procedures,wear eye protection. Also, the wire brush

PageCELECT™ Lubricating Oil Pressure Sensor - Removal ... 0-29CELECT™ S

Measure the outside pilot diameter.Outside Pilot Diametermm in35.013 MIN 1.378535.052 MAX 1.3800Crankshaft Pulley - Cleaning andInspection (01-12)Clea

Measure the inside diameter.Spun Steel Crankshaft Pulley I.D.mm in35.08 MIN 1.38135.18 MAX 1.385Vibration Damper - Cleaning andInspection (01-13)Clean

InspectionCaution: Always wear protective gloves when handlingheated parts. Personal injury can result.Apply a spray of spot check developer, type SKD

Use a bristle brush, Part No. ST-876, and solvent to cleanall the oil drillings.Warning: When using a steam cleaner, wear protectiveclothing and safet

NOTE: A maximum of 50 percent of the threaded holes percrankshaft end can be repaired.Visually inspect the crankshaft gear for cracks and brokenor chi

Measure the front oil seal area outside diameter.Crankshaft Front Oil Seal Area O.D.mm in92.07 MIN 3.62592.10 MAX 3.626Measure the rear oil seal area

Measure the main bearing journals outside diameter.Crankshaft Main Bearing Journal O.D.mm in114.236 MIN 4.4975114.300 MAX 4.5000Measure the thrust fac

Use clean 15W-40 oil to lubricate the entire crankshaft toprevent rust.Crankshaft Gear - Replacement (01-15)RemovalOnly remove the gear when the crank

Visually inspect the crankshaft gear fit area for burrs ordamage.Use a fine crocus cloth to remove the burrs.InspectionVisually inspect the crankshaft

Measure the crankshaft gear fit area outside diameter.Crankshaft Gear Fit Area O.D.mm in95.501 MIN 3.759995.522 MAX 3.7607InstallationUse a plastic ma

PageFan and Fan Spacer - Removal ...

Caution: Always wear protective gloves when handlingheated parts. Personal injury can result.Caution: The timing mark (1) and the part number (2) onth

NOTE: Oversize bearing shells are available for crankshaftswhich are 0.25 mm [0.010-inch], 0.51 mm [0.020-inch], 0.76mm [0.030-inch], or 1.02 mm [0.04

NOTE: After the camshaft has been steam cleaned, do nottouch the machined surfaces with bare hands. This willcause rust to form. Lubricate the camshaf

Measure the seven camshaft bushing journals.Camshaft Bushing Journal O.D.mm in63.37 MIN 2.49563.42 MAX 2.497Replace the camshaft if the journal dimens

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

Measure the gear bore.Camshaft Gear Bore I.D.mm inFlangeless 45.662 MIN 1.7977Camshaft 45.682 MAX 1.7985Replace the camshaft gear if it does not meets

InstallationNOTE: The accompanying chart lists different camshaft keypart numbers, the degree of offset, and the approximateinjector timing change fro

Caution: Wear protective gloves when handling partsthat have been heated to prevent personal injury.Heat the gear in an oven at 260°C [500°F] for a mi

Remove the straight thread o-ring plug.Caution: The aluminum gasket surface can be easilydamaged if caution is not used when removing gasketmaterial.

Measure the accessory drive seal bore.Accessory Drive Seal Bore I.D.mm in80.962 MIN 3.187581.038 MAX 3.1905NOTE: Replace the gear cover if the accesso

PageLubricating Oil Transfer Tube - Installation... 0-1

Measure the gear cover accessory drive bushing bore.Accessory Drive Bushing Bore I.D.mm in43.07 MIN 1.69643.10 MAX 1.697NOTE: Replace the gear cover i

CleaningRemove the gasket material from the rear cover gasketsealing surface.Use solvent to clean the rear cover. Dry with compressedair.InspectionIns

Magnetic Crack Inspection (01-21)Refer to the Alternate Repair Manual, Bulletin No.3379035, for procedures to magnetically check for cracksin the cran

Section 2 - Cylinder Head - Group 02Section ContentsPageCylinder Head - Cleaning and Inspection for Reuse ...

Cylinder Head - Service ToolsST-257Valve Seat Insert ToolCut valve seat counterbores for oversize valve seat inserts.ST-448Valve Spring CompressorUsed

ST-876Fuel Passage Cleaning BrushClean the internal fuel passages in the cylinder head.ST-880Injector Sleeve ExpanderRoll and seal the upper portion o

ST-1179Injector Sleeve Holding ToolHold the injector sleeve in place when rolling the upper portionof the sleeve and testing the cylinder head.ST-1227

Cylinder Head - Exploded ViewReferenceNo. Description Quantity1 Head Cylinder 32 Plug, Expansion 243 Seal, O-ring 64 Sleeve, Injector 65 Guide, Valve

Cylinder Head - General InformationThe cylinder head group consists of the cylinder head, valves, valve guides, valve springs, stem seals, valve seati

Engine Disassembly and Assembly - Service ToolsST-125 or3822512Lifting FixtureDesigned to lift all H/NH engines except 5 1/8-inch bore with atop mount

Cylinder Head - Cleaning and Inspec-tion for Reuse (02-01)CleaningSteam clean the cylinder heads, and dry with compressedair.Blow out all capscrew hol

Clean with solvent, and dry with compressed air.InspectionVisually inspect the fuel drillings and the water passagesfor restrictions or foreign materi

Visually inspect the cylinder head casting for cracks ordamage.NOTE: If cracks or leaks in the cylinder head are suspected,refer to Cylinder Head - Pr

Use a pencil magnet to remove the valve collets. Discardthe valve collets.Slowly release the pressure on the valve spring.Remove the valve spring reta

CleaningWarning: Use protective measures to prevent personalinjury.Install the cylinder head and the parts in a tank of clean-ing solution.NOTE: Follo

Use a straight edge and a 0.003-inch feeler gauge tomeasure the flatness of the cylinder head gasket surface.Flatness Per 25.4 mm [1.00 in] of Lengthm

Use valve spring tester, Part No. 3375182, to measure thevalve spring load at the valve spring working height.Working Height (B)Valve SpringPart No. m

Use the N14 valve head checking tool to measure thehead thickness of the valves.NOTE: Install the valve on the tool with the valve headcontacting the

Measure the width of the valve seat area of the valve seatinserts.Valve Seat Area (Width)mm in1.60 MIN 0.0633.18 MAX 0.125NOTE: If the valve seat area

Remove the injectors from the cylinder head and checkthe pattern of the blueing compound in the injector sleeve.The blueing pattern in the injector se

ST-1178Main Bearing Cap PullerRemove main bearings caps.ST-1259-1Top PlateIncluded in oil seal puller/installer, Part No. ST-1259. Use to pullor insta

Hold the drive unit in a vertical position, and use anup-and-down movement of 12.7 mm [0.50-inch] travel andlight pressure to grind the insert.Remove

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 li

Remove the valve, and measure the valve seat width andthe seat contact area as indicated by the broken lines.The pencil or Dykem marks will be worn aw

After grinding the valve seats, use a bristle brush to cleanthe inside diameter of the valve guides.Use solvent to clean the cylinder head. Dry with c

Use valve spring compressor, Part No. ST-448, or itsequivalent (refer to the Service Tools list) to compress thevalve springs.Install the new valve sp

Visually inspect the cylinder head capscrews for dam-aged threads, corroded surfaces, or a reduced diameter(due to capscrew stretching).NOTE: Do not r

The capscrews can be checked using a set of calipers ifservice tool, Part No. 3823546, is not available. The max-imum allowable free length (dimension

Immediately after cleaning and inspecting, apply a film ofclean engine lubricating oil to capscrews that are to beused again.Cylinder Head - Replacing

AssemblyMeasure the outside diameter of the new valve guides.Valve Guide O.D.mm in19.088 MIN 0.751519.101 MAX 0.7520NOTE: Oversize valve guides have i

Cylinder Head - Ring Dowel Replace-ment (02-04)RemovalCaution: Do not damage the surface or the ring dowelhole during removal of the dowel.Use a plier

3375601Connecting Rod Guide PinsGuide connecting rods over crankshaft during removal or in-stallation of connecting rods.3375957Nylon Lifting SlingAid

InspectionVisually inspect the insert bore for cracks or damage.NOTE: If cracks or damage are found, it is possible to repairthe cylinder head by mach

Use valve seat grinding machine, Part No. ST-685, andvalve guide arbor set, Part No. ST-663, to grind the newvalve seat inserts. Refer to ‘‘Grinding t

InspectionUse the N14 valve head checking tool to measure thehead thickness of the valve.NOTE: If the valve head is below the end of the tool, the val

Cylinder Head - Replacing the InjectorSleeves (02-07)DisassemblyUse an injector sleeve puller, Part No. ST-1244, to removethe injector sleeves from th

If the grooves (steps) are damaged or mutilated, use apilot, Part No. ST-884-6; holder, Part No. ST-884-1; andcutting tool, Part No. ST-788, to machin

Use an injector sleeve expander, Part No. ST-880, toexpand the upper section of the injector sleeve.Adjust the expander roller edge (1) and the collar

Caution: Support the cylinder head to prevent damageto the injector tip that protrudes from the combustionface.Apply a very light film of blueing comp

The blueing pattern in the injector seating area (1) mustbe visible 360 degrees around the seating area.The injector bore seating width (2) must be a

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 hydr

Remove the test equipment.Dry the cylinder head with compressed air.Assemble the cylinder head. Refer to ‘‘Assembly’’ underCylinder Head - Rebuild (02

Lightly spray the metal powder onto the combustion sur-face.Use compressed air regulated to 205 kPa [30 psi] toremove excess powder from the area. The

Install the seal ring, Part No. 3823848, and the vacuumcup, Part No. 3823847, to the vacuum hose.NOTE: The valves and the valve seats must be clean an

Use a stopwatch. Start timing when the needle on thegauge indicates 457 mm-Hg [18 in.Hg].Stop timing when the needle on the gauge indicates 203mm Hg [

Valve Crosshead - Cleaning andChecking for Reuse (02-12)CleaningUse solvent to clean the crosshead. Dry with compressedair.InspectionVisually inspect

Valve Crosshead - Magnetic CrackInspection (02-13)Refer to the Alternate Repair Manual, Bulletin No.3379035, for procedures to magnetically check for

Section 3 - Rocker Lever Housing Assembly - Group 03Section ContentsPageMetri-Pack Pass Through Connector - Replacement ...

Rocker Lever Housing Assembly - Service ToolsST-691Rocker Lever Block and Mandrel SetUsed to remove and install precision steel bushings in the rocker

Rocker Lever Housing Assembly - Exploded ViewRocker Lever Housing Assembly - Exploded View Rocker Lever Housing AssemblyN14Page 3-4

Rocker Lever Housing Assembly - Exploded ViewReference No. Description Qty.1 Capscrew, Twelve Point 182 Washer, Plain 183 Capscrew, Hexagon Head 64 Ga

Engine Disassembly and Assembly - General informationThese procedures apply to all N14 engines. The differences between engine models due to the appli

Rocker Lever Housing Assembly - General InformationThe rocker lever housing assembly group consists of the rocker lever assembly, the step timing cont

Rocker Lever - Cleaning and Inspec-tion for Reuse (03-01)DisassemblyLoosen the valve and injector adjusting screw lock nutson each rocker lever.Turn t

Visually inspect the shaft for cracks or damage.Light fretting is typically found on the underside of theshaft and is not harmful, provided it meets t

Measure the rocker lever bushing bore inside diameter.Rocker Lever Bushing I.D. (Installed)mm in34.89 MIN 1.373534.99 MAX 1.3775NOTE: Replace the rock

AssemblyUse clean 15W-40 oil to lubricate the threads of the ad-justing screws.Install the adjusting screw and lock nut in each rockerlever. Do not ti

Place the rocker lever assembly over the dowel pin anddowel ring located in the rocker housing.NOTE: Do not damage the dowel pin and dowel ring locate

Use a 240 grit, or finer, emery cloth to remove any roughedges or burrs from the bore of the rocker lever.Use solvent to clean the rocker levers. Dry

Install the bushing in the injector rocker lever with the splitclinch joint toward the top of the lever.The ‘‘square hole’’ must be aligned with the o

Steam clean the reusable gaskets. Dry with compressedair, and check for cuts or deformations in the siliconebead.Replace the gasket if there are any c

TABLE OF CONTENTSPageIntroduction...

Engine Disassembly (00-01)Engine - Preparation for CleaningWarning: The engine lifting equipment must be designedto safely lift the engine and the tra

Use Scotch Brite 7448, Part No. 3823258, to clean theo-ring bores in the water manifold and the o-ring groovesin the o-ring plug and water tubes.Steam

Visually inspect the pass through connectors for cracks,bent contacts, or other damage. Replace if necessary.Refer to the N14 Troubleshooting and Repa

Visually inspect the rocker lever shaft dowel rings (1), thedowel pins (2), and the brass cup plug (3). Replace ifnecessary.Use service tool, Part No.

STC Oil Plumbing - Cleaning andInspection for Reuse (03-06)Remove the o-rings and discard.Clean the oil manifold connector, external oil manifold,and

Ring and Pin Dowel - Replacement(03-07)RemovalSelect the proper size ring dowel remover and insert thethreaded end into the ring dowel to be removed.T

Tighten the hexagon nut to grip the dowel.Mount the slide hammer on the 1/4-inch dowel removerand pull the dowel.InstallationCaution: Do not use a ham

Disconnect the actuator harness from the pass throughconnector. Remove the capscrew. Cut and remove theplastic wire tie that holds the actuator harnes

Section 4 - Cam Follower Assembly - Group 04Section ContentsPageCam Follower Assembly - Cleaning and Inspection for Reuse ...

Cam Follower Assembly - Service Tools3375068Cup Plug SealantUse when installing cup plugs on engines to stop leaks.3376813Expansion Plug DriverUse to

Cam Follower Assembly - Exploded ViewReference No. Description Qty.1 Capscrew, Hexagon Head 72 Capscrew, Hexagon Head 113 Gasket, Cam Follower Hous-in

NOTE: The maximum oil pan capacity is 34 liters [9.0 U.S.gallons].Remove the drain plug and the copper washer. Check thecopper washer for wear.Drain t

Cam Follower Assembly - General InformationThe cam follower group consists of the injector cam followers, valve cam followers, cam follower shafts, ca

Measure the cam follower roller side clearance.Roller Side Clearancemm in0.23 MIN 0.0090.61 MAX 0.024NOTE: If the roller side clearance is not within

Use clean 15W-40 oil to check the oil flow through thecam followers.Cam Follower Assembly - Rebuild(04-02)DisassemblyRemove the two locking screws.NOT

Use a dial indicator to measure the cam follower to rollerpin clearance.Roller to Pin Clearancemm in0.08 MIN 0.0030.20 MAX 0.008NOTE: If the roller to

Use clean 15W-40 oil to check the oil flow through thecam followers.Clean the cam follower shafts with solvent. Dry with com-pressed air.Make sure the

Steam clean the cam follower housings. Dry with com-pressed air.Visually inspect the cam follower housings for cracks ordamage.Visually inspect the lo

Install the levers and the shafts in the housings.NOTE: To prevent increased wear, install the cam followerlevers and the shafts back in their origina

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 le

Crankcase Breather - RemovalLoosen the hose clamp at the breather vent tube.Remove the tube support bracket capscrew and thebracket.Remove the tube an

Measure the inside diameter of the new cam follower leverroller bore.Valve Lever Roller Bore I.D.mm in12.776 MIN 0.503012.801 MAX 0.5040Injector Lever

AssemblyNOTE: The roller pin must be installed correctly to makesure the cam follower roller and the roller pin are suppliedwith oil. Inspect the new

Caution: The cam follower roller pin must be installedwith the oil feed hole (1) positioned towards the top ofthe cam follower lever (2).NOTE: Freezin

Measure the cam follower roller side clearance.Roller Side Clearancemm in0.23 MIN 0.0090.61 MAX 0.024NOTE: If the roller does not rotate freely or the

Caution: Support as shown to prevent cracks in the camfollower. An old roller can be used to support the lever.Use a brass drift or a used push rod en

Visually inspect the socket end of the push rod for unevenwear, scratches, or separation of the insert from the tube.If a worn push rod is found, the

Section 5 - Fuel System - Group 05Section ContentsPageFuel Pump - Calibration ...

Fuel Pump - General InformationNOTE: Warranty repairs are not to be made to the fuel pump unless the work is performed in a shop meeting allrequiremen

Fuel Pump - Cleaning and Inspectionfor Reuse (05-01)When removing the fuel pump from step timing control(STC) engines, check to make sure the same Con

Cleaning - CELECT™ Fuel PumpInstall plastic cup plugs or tape on all openings of the fuelpump to prevent dirt or cleaning solvent from entering thepum

Exhaust Manifold - RemovalNOTE: Two dowels are used in each cylinder head to alignthe exhaust manifold assembly.Remove two capscrews, and install two

Visually inspect the drive coupling spider for cracks orother damage.Visually inspect the front cover pilot to make sure the pilotis continuous withou

Visually inspect the fuel pump shutoff valve for loose ordamaged electrical terminals.Fuel Pump - Rebuild (05-02)PTThe disassembly, inspection, repair

The Control Parts List (CPL) Manual, Bulletin No.3379133, is a listing of basic engine parts and timingspecifications which are necessary to produce a

Section 6 - Injectors and Fuel Lines - Group 06Section ContentsPageFuel Tubes, Fittings, and Mounting Parts - Cleaning and Inspection for Reuse ...

Reference No. Description Quantity1 Ball, Check 12 Gasket, Injector 13 Retainer, Screen 14 Retainer, Cup 15 Seal, O-ring 36 Pin, Roll 27 Screen, Filte

Injector - CELECT™ - Exploded ViewReference No. Description Quantity1 Link, Top 62 Retainer, Link 63 Retainer, Spring 64 Spring, Compression 65 Shim,

Injectors - PT (type D) Step Timing Control (STC) - General InformationThe step timing control (STC) system allows an engine to operate with advanced

Injectors - Cleaning the Exterior andInspection for Reuse (06-01)Remove and discard the three injector o-rings.Cleaning - STCUse a clean, lint-free cl

Alternator - RemovalRemove the adjusting link capscrew and the adjustinglink.Remove the alternator to alternator support bracket, nut,washer, capscrew

Visually inspect the injector for carbon deposits on theinjector cup and cup retainer.Visually inspect the o-ring grooves for damage.Visually inspect

Injectors - Rebuild (06-02)The disassembly, inspection, repair, and calibration pro-cedure for STC injectors are covered in Shop Manual PT(type D) Ste

Fuel Tubes, Fittings, and MountingParts - Cleaning and Inspection forReuse (06-05)CleaningUse solvent to clean the fuel tubes, fittings, and parts. Dr

Section 7 - Lubricating Oil System - Group 07Section ContentsPageLubricating Oil Cooler - Exploded View...

Lubricating Oil System - Service ToolsST-1157Spacer MandrelInstall the gear onto the lubricating oil pump shaft.ST-1158Bushing MandrelRemove and insta

Lubricating Oil System - Exploded ViewReferenceNo. Description Quantity1 Dipstick 12 Tube, Oil Gauge 13 Cover, Hand Hole 14 Gasket, Hand Hole Cover 15

Lubricating Oil Pump Assembly - Exploded ViewReference ReferenceNo. Description Quantity No. Description Quantity1 Gasket, Lubricating Oil Pump 1 18 P

Ref. No. Description Quantity1 Hose, Flexible 12 Elbow, Male Union 23 Washer, Plain 14 Screw, Captive Washer Cap 25 Screw, Captive Washer Cap 16 Screw

Lubricating Oil System - General InformationThe lubricating oil system group consists of the oil pan, the oil suction tube, the oil transfer tube asse

Warning: Because this part weighs more than 23 kg [50lbs], two people or a hoist will be required to lift the oilcooler assembly to avoid personal inj

Lubricating Oil Pan - Cleaning andInspection for Reuse (07-01)CleaningRemove all gasket material from the oil pan gasket seal-ing surface.Warning: Whe

Lubricating Oil Transfer Tube - Clean-ing and Inspection for Reuse (07-02)CleaningUse solvent to clean the lubricating oil transfer tube andthe mounti

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

InspectionTurn the main drive gear by hand to check the internalgears for freedom of rotation.Visually inspect the gears for cracked or broken teeth.V

Remove the oil pump cover. Remove and discard thecover gasket.Remove the 7/16-20 straight thread o-ring adapter fromthe oil pump cover.Remove the high

CleaningClean the gasket material from the lubricating oil pumpbody and the cover.Use solvent to clean the lubricating oil pump parts. Drywith compres

Visually inspect the bushings in the oil pump body andthe cover for damage.Measure the inside diameter of the bushings in the oilpump body and cover.B

Measure the outside diameter of the drive and the drivenshafts in the bushing contact area.Shaft O.D.mm in22.20 MIN 0.874522.22 MAX 0.8750NOTE: Shafts

Use valve spring tester, Part No. 3375182, to determineif the spring is defective.NOTE: Compress the spring to a height of 46.23 mm [1.820inches]. The

Install the oil pump body and the drive shaft assembly inan arbor press.Support the end of the drive shaft, and press the maindrive gear onto the shaf

Water Header Covers - RemovalRemove the six capscrews from each of the two waterheader covers.Remove the covers, and discard the gaskets.Engine - Inst

Install the spring (4), the washer (3), the valve disc (2), andthe retainer plug (1) into the bore of the locating plate.NOTE: Make sure the prongs on

Install new o-rings on the main oil pressure regulatorplunger retainer plug. Lubricate the o-rings with vegeta-ble oil.Install the plunger (4), the sp

AssemblyUse bushing mandrel, Part No. ST-1158, to push the newbushings into the oil pump body and cover.NOTE: The bushings must be installed level wit

Turn the adjusting knob clockwise to push the tool bitagainst the indicator tip.NOTE: Adjust the tool bit until the indicator is set to the samesize a

Use a cutting oil, and cut the bore in both bushings in theoil pump body.NOTE: Do not push down on the drill motor. The feedmechanism in the boring to

Install the boring bar through the guide bushing.NOTE: The tool bit must go through the slot in the guidebushing. Do not allow the tool bit to hit aga

Use a cutting oil to lubricate and cool the bit while cuttingthe bore in the bushing.Stop the drill motor when the stop collar on the drive shaftis ag

Measure the inside diameter of the bushings in the oilpump body and the cover.Bushing I.D. (New)mm in22.28 MIN 0.87722.30 MAX 0.878NOTE: Bushings that

Measure the inside diameter of the new bushings in thedriven gear.Bushing I.D. (New)mm in22.28 MIN 0.87722.30 MAX 0.878NOTE: The bushings used in the

AssemblyUse clean 15W-40 oil to lubricate the drive shaft.Use spacer mandrel, Part No. ST-1157, and an arborpress to push the drive gear onto the driv

Install the mounting plate adapter on the rear waterheader.Use five 1/4-20 X 1 1/4-inch capscrews to mount theadapter. Tighten the capscrews.Torque Va

AssemblyUse gear and spacer mandrel, Part No. ST-1157, to installthe driven shaft into the oil pump body as follows:1. Lubricate the large outside dia

Remove the oil cooler core hold down capscrews.Remove the oil cooler core from the oil cooler transferconnection (housing) by pulling the oil cooler w

Remove the oil cooler bypass valve and the spacer plate.Loosen the lubricating oil filter bypass valve retainingplug with a 5/16-inch hexagon allen wr

Remove CompuchekT fittings and straight thread o-ringplugs from the transfer housing and support.Remove the transfer housing support bracket.CleaningC

Visually inspect the oil cooler support, housing, spacerplate, filter head, and support bracket for cracks ordamage.Visually inspect the oil cooler by

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,

Attach a regulated air pressure hose to the other watertransfer tube and apply 81 kPa [60 psi] air pressure.Caution: Conduct this test with extreme ca

Suspend the valve and a 116°C [250°F] thermometer ina container of new lubricating oil. Do not allow the valveor the thermometer to touch the sides or

Install the oil cooler bypass valve into the transfer housing.Place the spacer plate and a new spacer gasket on theoil cooler support. Use two of the

Install the oil cooler core on the oil cooler transfer con-nection (housing) by inserting the transfer tubes into theo-ring adapters.NOTE: Make sure t

Adjust the position of the engine so that the remainingmounting holes in the adapter plate (1) and (2) align withthe capscrew holes in the cylinder bl

Lubricate the o-ring with LubriplateT 105 or equivalent,and install the shutoff valve in the filter head.Install the retaining capscrew and washer.Tor

Section 8 - Cooling System - Group 08Section ContentsPageCoolant Filter Head Insert ...

Cooling System - Service ToolsST-658Water Pump Bearing MandrelUse to press the water pump bearing on the shaft and to installthe bearing and shaft ass

3375779Medium Duty Puller KitUse to remove the radiator thermostat seat from the thermostathousing bore.3376399O-ring PickUse to install and remove o-

N14 Water Pump and Idler Assembly - Exploded ViewReference No. Description Quantity1 Pulley, Water Pump 12 Seal, Outer Oil 13 Ring, Retaining 14 Beari

Water Pump and Idler Assembly - General InformatonThe water pump for the N14 engines is a centrifugal-type vane pump with a stamped steel shrouded imp

Water Pump Assembly - Cleaning andInspection (08-01)CleaningBefore cleaning the water pump, inspect the weephole forlarge amounts of chemical fallout.

Water Pump Assembly - Rebuild(08-02)DisassemblyRemove the pulley with puller, Part No. 3375257.Remove the impeller with puller, Part No. 3823040.Remov

Use the disassembly fixture to support the inner bearing.Push the shaft from the bearing. Discard the bearing.CleaningUse a gasket scraper to remove t

InspectionVisually inspect the water pump body for cracks, porosity,or excessive corrosion.NOTE: If the part being inspected does not meet the spec-if

Determine the capscrew thread size, and install two ‘‘T-handles’’ in the flywheel at points (4) and (5).Remove the remaining four flywheel mounting ca

Measure the water pump impeller bore inside diameter.Impeller Bore I.D.mm in15.85 MIN 0.62415.88 MAX 0.625Visually inspect the water pump drive pulley

Shaft Journal O.D.Point mm in1 19.121 MIN 0.752819.128 MAX 0.75312 25.011 MIN 0.984725.022 MAX 0.98513 15.905 MIN 0.626215.918 MAX 0.6267Visually insp

Use water pump bearing mandrel, Part No. ST-658, tosupport a new outer bearing. Install the shaft and thespacer into the bearing.NOTE: Push the shaft

Install a new outside oil seal, using a mandrel to press theseal in flush with the housing.Apply a thin film of pipe sealant, Part No. 3375066, to the

Prepare the drive pulley bore surface with LocktiteWPrimer T, Part No. ST-1272-13.Apply a light film of LocktiteW 609, Part No. 3823718, tothe bore in

InspectionVisually inspect the idler assembly for cracked, chipped,or broken pulley grooves.Turn the idler pulley by hand to inspect the shaft and the

Remove the capscrew and the washer.Press the shaft out of the bearing.Discard the bearing.CleaningUse solvent to clean the idler assembly parts. Dry w

Visually inspect the idler shaft for grooves, nicks, or dam-age.Inspect the adjusting screw and the mounting nut threadsfor wear or distortion.Measure

Support the idler pulley in an arbor press. Use bearinginstallation tool, Part No. ST-658, to press the bearinginto the pulley until the bearing is ag

Install the oil seal with the lip toward the bearing.Use seal expander, Part No. 3823885, to guide the sealonto the shaft.Use a tube mandrel to press

Cummins 22-Group System Exploded Diagram

On wet-type flywheel housings, remove the o-ring fromthe rear cover and the 11 rectangular sealing rings fromthe flywheel housing.Rear Cover - Removal

Carefully remove the thermostat seal to avoid damagingthe thermostat cover.CleaningUse a gasket scraper to remove the gasket material fromthe mating s

Inspect the thermostat seal and the thermostat covergasket surface for cracks, corrosion, or damage. Replacethe thermostat cover if necessary. The the

Measure the inside diameter of the thermostat seal count-erbore in the thermostat housing.Thermostat Seal Bore I.D.mm in67.39 MIN 2.65367.46 MAX 2.656

Coolant Filter Head Insert (08-06)Refer to Lubricating Oil Cooler Assembly - Rebuild inSection 7 for removal, cleaning, inspection, and instal-lation

Warning: Do not straighten a bent fan blade or continueto use a damaged fan. Replace the original equipmentfan with a fan of the identical part number

Section 9 - Drive Units - Group 09Section ContentsPageAccessory Drive - Cleaning and Inspection for Reuse ...

Drive Units - Service Tools3376663Coupling PullerRemove the splined coupling gear from the compressor driveDrive Units - Service Tools Drive UnitsN14P

Accessory Drive - Exploded ViewReference No. Description Quantity1 Gear, Accessory Drive 12 Pin, Groove 13 Shaft, Accessory Drive 14 Housing, Accessor

Drive Units - General InformationAccessory DriveThe accessory drive housings are available in two designs--with and without hardware for mounting an a

Accessory Drive - Cleaning andInspection for Reuse (09-01)CleaningRemove all gasket material from surfaces (1) and (2).Clean the exterior of the drive

Fan Hub and Fan Hub Support Bracket- RemovalRemove the four capscrews that attach the fan hub to thesupport bracket, and remove the fan hub assembly.R

Use coupling puller, Part No. 3376663, to remove thesplined coupling.Use a three-jaw puller to remove the hub-type coupling.Remove the capscrew.Remove

Visually inspect the shaft bore in the housing for scoringor damage.Measure the inside diameter of the shaft bore in the drivehousing.Drive Shaft Bore

Measure the inside diameter of the drive pulley bore.Drive Pulley Bore I.D.mm in34.930 MIN 1.375234.950 MAX 1.3760AssemblyUse clean 15W-40 oil to lubr

With the gear/shaft assembly supported in an arbor press,use a mandrel to install the coupling. Push the couplinguntil it touches the clamping washer.

If the end clearance is not within specifications, makesure the coupling is positioned tightly against the clamp-ing washer.Accessory Drive Gear - Rep

Visually inspect the shaft in the gear fit area for frettingor burrs.NOTE: If fretting or burrs can not be removed with a finecrocus cloth, replace th

Caution: The jaws of the vise must have copper platesto prevent damage to the shaft.Clamp the accessory drive shaft in a vise.Apply LubriplateT 105 or

Accessory Drive Pulley - Cleaning andInspection for Reuse (09-04)CleaningClean the accessory drive pulley with solvent. Dry withcompressed air.Inspect

Grind a 1.57 mm [0.062-inch] radius on the cutting edgeof a 19.05 mm [0.75-inch] chisel.Place the chisel point against the wear sleeve. Use mod-erate

Use a fine grit emergy cloth dipped in clean lubricating oilto remove minor defects.Use a crocus cloth for final polishing operation and toremove any

Thermostat Housing - RemovalDisconnect the air compressor coolant return line fromthe thermostat housing.Remove the four capscrews that attach the the

Section 10 - Intake Air System - Group 10Section ContentsPageIntake Air Piping - Elbows ...

Intake Air System - Service ToolsST-537Dial Depth GaugeMeasure turbocharger axial motion.Intake Air System - Service Tools Intake Air SystemN14Page 10

Intake Air System - Exploded ViewRef. No. Description Qty.1 Connection, Intake Manifold 12 Seal, Rectangular Ring 13 Cover 14 Cover 15 Screw, Self-Tap

Intake Air System - General Informa-tionThe intake air system consists of intake air piping, turbo-charger, charge air cooler (CAC) piping, and CAC.Th

Turbocharger - Cleaning and Inspec-tion (10-01)CleaningRemove all carbon deposits and gasket material from thegasket mating surfaces.NOTE: Tape or plu

Cracks on the turbocharger mounting flange must notreach the mounting holes.Two cracks on the turbocharger mounting flange must beseparated by 6.4 mm

Turbocharger Shaft Axial Clearance -Checking (10-02)Measure the axial clearance (end to end), using dial depthgauge, Part No. ST-537.Push the rotor as

Intake Air Piping - Elbows (10-04)InspectionVisually inspect the turbocharger compressor V-band out-let and the discharge elbow V-band connection for

Section 11 - Exhaust System - Group 11Section ContentsPageExhaust Manifold - Cleaning and Inspection for Reuse ...

Exhaust System - Exploded ViewReference No. Description Quantity1 Manifold, Exhaust (Center) 12 Manifold, Exhaust (End) 13 Manifold, Exhaust (End) 14

Water Pump - RemovalRemove thesix mounting capscrews from the water pump.NOTE: The water pump must be removed carefully to pre-vent damage to the impe

Exhaust System - General InformationThe exhaust manifold group consists of the exhaust manifolds and the turbocharger mounting studs.The exhaust manif

Exhaust Manifold - Cleaning andInspection for Reuse (11-01)DisassemblyUse a mallet to remove the exhaust manifold sections.CleaningUse a wire brush to

Exhaust Manifold TurbochargerMounting Stud - Replacement (11-02)Apply penetrating oil to the base of the turbochargermounting stud to be removed.Use a

Section 12 - Air Equipment - Group 12Section ContentsPageAir CompressorCleaning and Inspection for Reuse...

Air Equipment - General InformationAir CompressorThe air equipment group consists of Cummins single and two-cylinder air compressors, compressor check

Air Compressor - Cleaning andInspection for Reuse (12-01)CleaningRemove all gasket material from the sealing surfaces.Warning: When using a steam clea

Visually inspect the compressor drive gear and the fuelpump hub-type drive coupling for wear or damage.Measure the single cylinder air compressor cran

Section 13 - Electrical Equipment - Group 13Section ContentsPageAlternator Adjusting LinkCleaning and Inspection for Reuse ...

Electrical Equipment - General InformationThe electrical equipment used on the N14 engine is not manufactured by Cummins Engine Company, Inc.Completei

Wiring DiagramsA complete collection of electrical wiring diagrams, asapplied to all Cummins engines, is contained in WiringDiagrams, Bulletin No. 337

STC External Oil Plumbing - RemovalDisconnect the external oil manifold supply line from therear of the external oil manifold.Plug the supply line to

InspectionVisually inspect the gear (1) for cracked or broken teeth.Visually inspect the drive bushing (2) and the gear shaft(3) for excessive wear or

Section 14 - Engine Testing - Group 14Section ContentsPageChassis Dynamometer Operation...

General InformationThis section outlines engine testing and engine run-inrecommendations for N14 engines. All engines must berun-in after a rebuild or

Definition of Terms On Engine Performance CurveFig. 1Fig. 2Cummins 1991 N14 Heavy DutyEngine Operating CurveDefinitions:1. Peak Torque (N•m [ft-lb]) -

General Run-In ProceduresCaution: Refer to General Engine Test Specificationsbefore operating the engine to avoid internal componentdamage.Caution: Th

Caution: Do not shut off the engine immediately afterthe run-in is completed. Allow the engine to cool byoperating at low idle for a minimum of 3 minu

General Engine Test/Run-In SpecificationsMaintain the following limits during the engine test/run-in procedures:Due to variations in ratings of differ

Engine Testing - Service ToolsST-434Vacuum GaugeUsed to check fuel filter or intake air restriction.ST-435-6Pressure GaugeIncluded in snap rail pressu

3375150Blowby Checking ToolUsed with manometer, Part No. ST-1111-3, to measure the en-gine crankcase pressure.3375932Pressure Gauge (0-300 psi)Used to

Engine Dynamometer - Install Engine(14-01)NOTE: Be sure the dynamometer capacity is sufficient topermit testing at 100 percent of the engine rated hor

Remove the clamp, check valve, and oil supply hose fromthe engine.STC Oil Control Valve - RemovalRemove the two capscrews attaching the STC oil contro

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 temp

Remove the straight thread fitting in the accessory driveand install the lubricating oil temperature sensor.Remove the pipe plug from the main oil rif

Fuel RateThe Part No. 3376375, Fuel Measuring instrument, isused during the performance check to measure fuel con-sumption.Install the fuel measuring

Fuel PressureMeasure the fuel pressure. Install the pressure gauge,Part No. ST-435-6, or the pressure gauge in the fuelmeasuring device, Part No. 3376

Use an air tank (2). Install an air regulator (3) capable ofmaintaining 345 to 517 kPa [50 to 75 psi] air pressure atboth minimum and maximum engine R

Connect the dynamometer test OEM wiring harness AMPconnector to the ECM. Tighten the connector capscrewsto the ECM.Torque Value: 2.0 N•m [18 in-lb]Con

Connect the dynamometer test OEM wiring harness start-ing motor solenoid lead (yellow) to the starting motorsolenoid. Connect the ground lead (black)

Select the ‘‘Feature Selection’’ from the menu options bydepressing the number ‘‘1’’ on the keypad.The next screen will show if the ‘‘Progressive Shif

If the parameter is to be bypassed with the Compulink™,refer to the following instructions.Select ‘‘Troubleshooting’’, key (1), from the ‘‘Main MenuOp

On CELECT™ engines, remove the lubricating oil tem-perature sensor from the lubricating oil pump cover.Lubricating oil pumps on N14 STC engines are eq

Disconnect the Deutsch three pin connector that containsthe vehicle key switch, fan clutch, and engine brake con-trol wires from the three pin connect

NOTE: If an external pressure pump is not available, primethe lubricating system as follows:Use the dipstick to measure the lubricating oil level.Fill

Disconnect the electrical wire that supplies power to thefuel pump solenoid.NOTE: The manual override screw must be turned coun-terclockwise until it

Install the filter on the filter head and tighten the filter untilthe gasket contacts the filter head surface.Tighten the filter an additional one-hal

Install the electrical wire that supplies power to the so-lenoid.NOTE: The manual override screw on the solenoid must beturned counterclockwise until

If the filter cap opening can not be used, remove the fuelsupply hose to the gear pump.Lubricate the gear pump gears with clean engine lubri-cating oi

It is a good practice to observe these measurements evenif engine performance meets specifications. If engineperformance does not meet specifications,

Open the throttle to obtain speed at which maximumhorsepower is developed and adjust the dynamometerload to achieve 75 percent of rated fuel pressure

Caution: Shutting off the engine immediately after op-erating at full load will damage the turbocharger andinternal components. Always allow the engin

Dynamometer WorksheetDate Repair Order No. OperatorESN CPL Fuel Pump CodeComplaint SC Code (CELECT™)PARAMETER CODE SPECIFICATIONS ACTUAL READINGFuel P

Chassis Dynamometer Operation(14-04)The performance of an engine installed in ‘‘on-highway’’vehicles can be tested on a chassis dynamometer.NOTE: Due

CELECT™ Sensor Harness - RemovalRemove the retaining clamps for the sensor harness fromthe support bracket and the engine block.Although the OEM harne

• Make sure the tires are inflated to the manufactur-er’s specifications.• Remove all rocks or other material from the tread ofall tires that will be

• Make sure there is proper overhead clearance forexhaust stacks, air deflectors, or other attachmentsabove the cab.General Test Procedure - ChassisDy

To properly monitor engine performance, record the fol-lowing parameters. To limit dynamometer operating time,instrument the engine to make as many ch

Fuel RateUse fuel measuring device, Part No. 3376375, to mea-sure the rate of fuel consumption.Install the fuel measuring device as follows:• The fuel

Fuel Drain Line RestrictionUse Pressure Gauge, Part No. ST-1273, to measure fueldrain line restriction.NOTE: Do not measure fuel drain line restrictio

Charge Air Cooler RestrictionMeasure the intake pressure drop across the charge aircooler.This test can be done with a mercury manometer or twoseparat

Operate the engine at maximum horsepower RPM andAdvertised Horsepower.Observe the reading on the gauge or manometer.NOTE: Restriction must not exceed

Install a plug in the crankcase breather vent tube.Remove the ‘‘bottle stopper’’ oil filler cap and install theblowby checking tool, Part No. 3375150.

Engine Run-In Procedure - ChassisDynamometer (14-06)NOTE: Refer to Chassis Dynamometer Operation, Proce-dure 14-04, for general operating procedures a

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 th

Remove the harness retaining capscrews and disconnectthe harness from the following sensors:Oil pressure sensorOil temperature sensorAmbient air press

Operate the engine at nominal torque peak RPM, fullload, wide open throttle, for 5 minutes. Check the gauges,and record the readings.NOTE: Refer to th

Engine Run-In Procedure WithoutDynamometer (14-07)On-HighwayCaution: Refer to General Information and General En-gine Test Specifications and Procedur

Engine Painting (14-08)Cover the following:• Exhaust and Intake Openings• Electrical Components• Fuel Inlet and Drain Connections• Any Exposed Fitting

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).Opera

Turn the fuel pump manual shutoff valve counterclock-wise until it stops.Remove the electrical wiring from the fuel pump solenoid.Drain the cooling sy

Remove the Engine From Short TermStorageRemove the tape from the openings. Remove the warn-ing tag.Replace the oil, water, and fuel filters.Prime the

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 preservativeoi

Remove the intake manifold. Remove the exhaust man-ifold. Refer to Engine Disassembly (00-01).Spray preservative oil into the intake and exhaust ports

Use clean diesel fuel to flush the preservative oil from thefuel system.Remove a plug from the main oil rifle drilling. Use a lightmineral oil to flus

Section 15 - Instruments and Controls - Group 15Section ContentsPageInstruments and Controls ...

CELECT™ Lubricating Oil PressureSensor - RemovalRemove the oil pressure signal line. Remove the sensormountingcapscrews. Remove thesensor from theengi

Instruments and Controls - General InformationThe instruments and controls group consists of the gauges, speed switches, safety controls, cold weather

Instruments and Controls - General Information (Cont’d)Oil HeatersFleetguard, Inc.Route 8Cookeville, TN 38501Telephone: (615) 526-9551Kim Hotstart Co.

Section 16 - Mounting Adaptations - Group 16Section ContentsPageFlywheelCleaning and Inspection for Reuse ...

Mounting Adaptations - Service ToolsST-1134Dowel Pin ExtractorUse to pull dowel pins and crosshead guides.ST-1232-1(in Part No.ST-1232)PlateUse in con

Mounting Adaptations - Exploded ViewReferenceNo. Description Quantity1 Support, Front Engine 12 Cover, Access Hole 13 Housing, Flywheel 1ReferenceNo.

Mounting Adaptations - General InformationThe mounting adaptations group consists of the flywheel housing, flywheel, flywheel ring gear, pilot bearing

Flywheel - Cleaning and Inspection forReuse (16-01)CleaningUse a wire brush to clean the crankshaft pilot bore.Steam clean or use a solvent, and dry w

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

InspectionVisually inspect all surfaces for nicks, burrs, or cracks.Use a fine crocus cloth to remove small nicks and burrs.Inspect all threaded capsc

Measure and record the diameter of one of the dowel pinswhich was removed to determine the next oversize dowelto be installed after the housing is ali

Section I - IntroductionSection ContentsPageEngine Diagrams ...

STC EnginesRemove 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 lin

If the total indicator reading exceeds the limits listed inSection 00-02 ‘‘Flywheel Housing Installation,’’ use amallet to horizontally move the housi

Tighten the mounting capscrews in the sequence shown.Torque Value: 203 N•m [150 ft-lb]After the capscrews are torqued, check the housing boreand the s

The dowel must be long enough to protrude from theblock one-half of the flywheel housing wall thickness butmust not protrude past the housing wall.NOT

After reaming one hole, turn the plate and align it with thesecond dowel hole. Repeat the procedure in the secondhole.Remove the plate from the cranks

Front Engine Support Bracket -Cleaning and Inspection for Reuse(16-05)Warning: When using a steam cleaner, wear protectiveclothing and safety glasses

Specifications - Group 18Group IndexPageAir CompressorInspection Specifications...

PageSpecificationsGeneral Information ...

General Engine SpecificationsGeneral Engine Data Metric [U.S. Customary]Horsepower (Refer to the engine dataplate)Engine speed @ Maximum Output:• Stan

General Engine Specifications (Continued)Cooling System Metric [U.S. Customary]Coolant Capacity (engine only) ...

Capscrew Markings and Torque ValuesCaution: When replacing capscrews, always use a capscrew of the same measurement and strength asthe capscrew being

Accessory Drive - RemovalCaution: If the accessory drive dowel pin has been in-correctly installed in the accessory drive shaft, the dowelpin must be

Pipe Plug Torque ValuesSize Torque TorqueThread Actual Thread O.D. In Aluminum ComponentsIn Cast Iron orSteel Componentsin mm in N•m ft-lb N•m ft-lb1/

Decimal and Metric EquivalentsMetricmmDecimalin.Fractions MetricmmDecimalin.Fractions0.39688 0.015625 1/64 13.09687 0.515625 33/640.79375 0.03125 1/32

Specifications - General InformationThe specifications in this section are organized in the same sequence used in each group of this manual. Theminimu

Engine Assembly - SpecificationsCylinder Liner Protrusion 0.10 MIN 0.0040.18 MAX 0.007Cylinder Liner to Lower Cylinder 0.05 MIN 0.002Liner Bore Cleara

Piston Ring GapPiston• Top 0.43 MIN 0.0170.68 MAX 0.027• Second 0.51 MIN 0.0200.76 MAX 0.030• Third 0.48 MIN 0.0190.74 MAX 0.029• Oil 0.25 MIN 0.0100.

Accessory Drive Assembly TimingPosition the accessory drive shaft dowel pin at the 12:00 o’clock position.Align the timing mark on the accessory drive

PTD Top-Stop Injector AdjustmentRefer to Engine Assembly, Group 00, PTD Top-Stop Injector Adjustment, Page 0-129.PTD STC Injector AdjustmentRefer to E

Belt Tension Ref. Point Newtons Pounds ForceWater Pump Belt (Big Cam IV and NewBig Cam IV)• New Belt Tension 710 160• Used Belt Tension 290-580 65-130

Engine Assembly - Capscrew Torque ValuesAdapter Plate to Rebuild Stand 100 75Mounting Plate Adapter to Rear 97Water Header, if RemovedAdapter Plate Mo

Flywheel Housing 205 150Note: Tighten in the sequence shown.Connecting Rod Capscrews 100 75Note: Tighten the connecting rod 230 170capscrews in altern

Remove and discard the o-ring from the oil pan flangetube and the rectangular sealing ring from the lubricatingoil pump mounting flange.Lubricating Oi

Camshaft Bearing Support 25 20Accessory Drive Pulley 420 310Front Engine Support Bracket 70 50Vibration DamperCapscrew Size: 5/8-inch; SAE grade No. 8

Injectors (PTD-Top Stop)• New Big Cam IV and 88 Big Cam IV 34 25Note: For New Big Cam IV and 88 Big Cam IV engines (3/8-inch - 16 capscrews), tighten

Injector Lock Nut• With torque wrench adapter,Part No. ST-669 45 35• Without adapter 60 45Valve Lash Clearance 0.68 6 in-lb(Torque Wrench Method Using

Rocker Housing Covers• Big Cam IV/New Big Cam IV 20 15• 88 Big Cam IV 16 12Note: Tighten in the sequence shown.Oil Pan (7/16-inch Mounting Capscrews)

Fuel Pump 45 35Support Bracket to Cylinder Block 45 35Mounting CapscrewsFuel TubingTube Size1/4-inch 15-20 10-155/16-inch 20-25 15-203/8-inch 25-35 20

Water Pump (Big Cam IV and New BigCam IV) 15 1030 2045 35Note: Tighten the capscrews in the sequence shown.Water Pump (88 Big Cam IV) 15 10Idler Pulle

Water Pump Belt (88 Big Cam IV)• New Belt Tension 620 N 140 lbf• Used Belt Tension 270-490 N 60-110 lbfNote: A belt is considered used if it has been

Hand Hole Cover 45 35Coolant Filter Head (88 Big Cam IV) 45 35Thermostat Housing (Big Cam IV and NewBig Cam IV) 45 35Thermostat Housing (88 Big Cam IV

Thermostat (Reserve Flow Cooling)Rear Hold Down Strap Capscrew 110 80Oil Cooler Assembly (Big Cam IV andNew Big Cam IV) 45 35Cooler Brace 10 8Oil Cool

Water Transfer Tube (Big Cam IVand New Big Cam IV)• Retaining Clip 25 20Water Transfer Housing to 25 20Thermostat HousingWater Transfer Tube (88 Big C

Remove the two mounting bracket capscrews from thepan rail.Remove the entire assembly from the engine.CELECT™ Boost Pressure Sensor -RemovalRemove the

Aftercooler Coolant Inlet and Outlet Tubes(88 Big Cam IV)• Hose Clamps (1) and (2) 5 40 in-lbAftercooler Coolant Inlet and Outlet Tubes(88 Big Cam IV)

Air Crossover Tube Support Clamp(s) 20 15Turbocharger• Capscrews 45 35• Hose Clamps 5 40 in-lbTurbocharger Oil Supply HoseSwivel Nuts 35 25Bypass Oil

Alternator Belts• New Belt Tension 620 N 140 lbf• Used Belt Tension 270-490 N 60-110 lbfNote: A belt is considered used if it hasbeen in operation for

Cylinder Block - Rebuild SpecificationsCylinder Block Height 421.87 MIN 16.609422.45 MAX 16.632Upper Press Fit Design Counterbore Diameter• Standard 1

Cylinder Block Camshaft Bore I.D. 68.237 MIN 2.686568.262 MAX 2.6875Cylinder Liner Protrusion 0.10 MIN 0.0040.18 MAX 0.007Counterbore Sealing Ring Thi

Liner O.D. (Lower Press Fit Area)Upper Press Fit Design• Standard 159.86 MIN 6.294159.99 MAX 6.299• .020 Oversize 159.86 MIN 6.294159.99 MAX 6.299Line

Piston Pin Bore 50.762 MIN 1.998550.800 MAX 2.0000Piston Pin O.D. 50.762 MIN 1.998550.775 MAX 1.9990Note: Discard the piston pin if it is more than 0.

Crankshaft Main Bearing Journal O.D. 114.237 MIN 4.4975114.300 MAX 4.5000Crankshaft Thrust Face Width 76.23 MIN 3.00176.28 MAX 3.003Crankshaft Gear Bo

Main Bearing Shell Thickness (Standard) 3.086 MIN 0.12153.145 MAX 0.1238Thrust Bearing Thickness 6.210 MIN 0.24456.286 MAX 0.2475Connecting Rod Bearin

Connecting Rod - Twist:• (Without Bushing) 0.50 MAX 0.020• (With Bushing) 0.25 MAX 0.010The instructions for performing a magnetic crack inspection of

Rocker Housing Covers - RemovalRemove the ten capscrews from each rocker lever cover.Remove the rocker lever covers. The rocker housingcover gaskets c

Crankshaft Pulley I.D. 35.05 MIN 1.38035.10 MAX 1.382Vibration Damper ThicknessMeasure the thickness in four places 90 degrees apart approximately 3.1

Cylinder Block - Torque ValuesCylinder Block Pipe Plugs• 1/4-inch 20 15• 3/8-inch 25 20Cylinder Block Pipe Plugs• 3/8-inch 25 20• 1/8-inch 15 10Cylind

Cylinder Head - Rebuild SpecificationsCylinder Head Flatness Per 25.4 mm[1.00 in.] of Length 0.020 MAX 0.0008Cylinder Head Flatness (Total OverallLeng

Valve Guide Height (Installed) 32.26 MIN 1.27032.51 MAX 1.280Crosshead Guide O.D. 10.975 MIN 0.432111.011 MAX 0.4335Crosshead Guide Height (Installed)

Valve Seat Width Limit 1.60 MIN 0.0633.18 MAX 0.125Valve Guide Bore I.D. 19.05 MIN 0.75019.07 MAX 0.751Valve Guide O.D. 19.088 MIN 0.751519.101 MAX 0.

Crosshead Guide Bore I.D. 10.947 MIN 0.431010.972 MAX 0.4320Crosshead Guide Height (Installed) 47.25 MIN 1.86047.75 MAX 1.880Valve Head Thickness (at

Valve Crosshead Stem Pocket to Pad Face 1 9.65 MIN 0.38010.16 MAX 0.400Cylinder Head - Rebuild Specifications SpecificationsPage 18-42 NT 855Part or A

Cylinder Head - Torque ValuesInstall the Injectors into the Cylinder HeadCapscrewTiming SizeFixed 5/16 1 6 4212 9318 13Fixed 3/8 1 14 10224 18334 25ST

Rocker Lever Housing Assembly - Rebuild SpecificationsRocker Lever Bushing Bore I.D. (Installed)• Pre-88NT 28.562 MIN 1.124528.666 MAX 1.1286• 88NT 34

Rocker Lever Housing Assembly - Torque ValuesRocker Lever Shaft Set Screw 11 100 in-lbNote: The 80-degree tilt engines use spray nozzles instead of se

Valve Crossheads - RemovalRemove the crossheads. Be sure to mark them appro-priately so they can be installed in the same location andorientation duri

Cam Follower Assembly - Rebuild SpecificationsFixed Injection TimingCam Follower Roller Side Clearance 0.23 MIN 0.0090.61 MAX 0.024Cam Follower Roller

Valve Lever Bushing or Bore I.D. 19.052 MIN 0.750119.100 MAX 0.7520Injector Lever Bushing I.D. 34.963 MIN 1.376535.011 MAX 1.3784Injector Cam Follower

Actuator Shaft Guide I.D. 19.28 MIN 0.75919.35 MAX 0.762Actuator Plunger O.D. 49.60 MIN 1.95349.78 MAX 1.960Timing Spacer LengthPart No. MINMAX3021515

Cam Follower Shaft From Housing 23.25 MIN 0.915Extension Dimension 23.75 MAX 0.935The Shaft End Opposite the ActuatorMust Have a Depth in theHousing a

Valve Roller Pin O.D. 12.692 MIN 0.499712.700 MAX 0.5000Injector Roller Pin O.D. 17.772 MIN 0.699717.780 MAX 0.7000Cam Follower Roller Side Clearance

Cam Follower Assembly - Torque ValuesCam Follower Shafts Locking Screws 2 15 in-lbNote: The heads of the locking screws must be flush or below flush w

Spring Retainer Lock Nut 45 35Actuator Cap 40 30Fuel Pump - Rebuild SpecificationsThe disassembly, inspection, repair, assembly and calibration proced

U.S.Part or Assembly Ref. Point Liters GallonsLubricating Oil System - CapacitiesOil Pan Capacity:• Automotive 30 Low 8.035 High 9.5• Industrial 22.7

Lubricating Oil Pump Body andCover Bushing Bore I.D.25.387 MIN 0.999525.413 MAX 1.0005Bushing I.D. (New) 22.28 MIN 0.87722.30 MAX 0.878Driven Gear Bus

Driven Shaft Press Fit Area O.D. 22.301 MIN 0.878022.314 MAX 0.8785Driven Shaft Protrusion 17.90 MIN 0.70518.67 MAX 0.735Torque ValuesPart or Assembly

STC EnginesRemove the injector hold down clamp capscrew and theclamp.Use injector puller, Part No. 3822697, to remove the STCinjectors.Insert the thre

Oil Cooler Connection (Housing) toSupport Capscrews 45 35(88 Big Cam IV)Rear Cover to Oil Cooler Connection(Housing) Capscrews 45 35(88 Big Cam IV)Oil

Water Pump Assembly - Rebuild SpecificationsWater Pump Body Bearing Bore I.D. 61.991 MIN 2.440662.017 MAX 2.4416Water Pump Body Seal and SeatAssembly

Water Pump Idler Pulley Bearing Bore I.D. 61.996 MIN 2.4408(Big Cam IV and New Big Cam IV) 62.012 MAX 2.4414Idler Shaft O.D. 24.989 MIN 0.9838(Big Cam

Inner Bearing Spacer Length (1) 50.78 MIN 1.99950.82 MAX 2.001Outer Bearing Spacer Length (2) 50.67 MIN 1.99550.75 MAX 1.998Fan Hub End Clearance 0.08

Bypass Thermostat Seat Counterbore 2.92 MIN 0.115Depth (Big Cam IV and New Big Cam IV) 3.17 MAX 0.125Bypass Thermostat Seat O.D. 44.462 MIN 1.7505(Big

Thermostat Rectangular Seal Bore Depth• Radiator Thermostat 5.03 MIN 0.1985.13 MAX 0.202• Bypass Thermostat 5.03 MIN 0.1985.13 MAX 0.202Specifications

Cooling System -Torque ValuesAssembly of the Water Pump Idler (FlatHead Capscrew) 40 30Fan Hub Lock Nut 205 150Filter Head Adapter in the Housing (Big

Coolant Transfer Tube Clamp Capscrew(88 Big Cam IV) 45 35Coolant Filter Head Retaining Capscrew 20 15Coolant Filter Element Adapter 45 35Specification

Fuel Pump and Compressor Drive - Rebuild SpecificationsDrive Shaft End Clearance 0.05 MIN 0.0020.30 MAX 0.012Drive Housing Bushing Bore I.D. 33.43 MIN

Drive Gear Bore I.D. 39.730 MIN 1.564239.751 MAX 1.5650Drive Shaft Gear Fit Journal O.D. 39.789 MIN 1.566539.814 MAX 1.5675Drive Housing Bearing Bore

Remove the rocker lever housings.Remove the gaskets.NOTE: On CELECT™ engines while handling the rockerlever housings, protect the wiring harness pass

Turbocharger - Inspection SpecificationsTurbocharger Shaft End ClearanceModel No.BHT3B/HT3B 0.03 MIN 0.0010.10 MAX 0.004BHT4C/HT4B 0.05 MIN 0.0020.13

Engine Testing - Test SpecificationsNote: The specifications and instructions for testing the engine are provided this manual. Refer toEngine Testing

Section 20 - Vehicle Braking - Group 20Section ContentsPageVehicle BrakingGeneral Information ...

Vehicle Braking - General InformationJacobsW Engine BrakeFor installation and adjustment of the JacobsT Engine Brake, Models 440 (STC engines) and 445

Component ManufacturersNOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cumminsengines. Suppliers

FansTruflo Ltd.Westwood RoadBirminghamB6 7JFEnglandTelephone: 021-557-4101Hayes-Albion1999 Wildwood AvenueJackson, MI 49202Telephone: (517) 782-9421En

Torque ConvertersTwin Disc International S.A.Chaussee de NamurNivellesBelgiumTelephone: 067-224941Twin Disc Clutch Co.Racine, WI 53403Telephone: (414)

Section L - Service LiteratureSection ContentsPageAdditional Service Literature ...

Additional Service LiteratureThe following publications can be purchased by filling in and mailing the Service Literature Order Form:Bulletin No. Title

Service Literature Ordering LocationRegion Ordering LocationUnited States and Canada Gannett Direct Marketing Services, Inc.3400 Robards CourtP. O. Bo

Cam Follower Assemblies - RemovalRemove the cam follower housing assemblies as follows:1. Remove the six capscrews and studs from each camfollower hou

Service Publications Order FormUse this form for prompt handling of your literature order.ItemBulletinNumberTitle ofPublication QuantityU.S. PriceEach

Payment enclosed. Make certified check or money order payable to Cummins Engine Company, Inc.FROM:Name:Street Address:City: State: Zip Code:Country:SHI

Accessory Drive - Cleaning and Inspection for Reuse ... 9-5Cleaning ...

Camshaft Bore - Inspection ... 1-15Coolant Passage - Inspection ...

Inspection - CELECT™ Fuel Pump ... 5-6Inspection - PT Fuel Pump ...

Piston and Connecting Rod Assemblies - Removal... 0-40Piston Cooling Nozzles - Installation... 0-139Pisto

NO POSTAGENECESSARYIF MAILEDIN THEUNITED STATESBUSINESS REPLY MAILFIRST CLASS PERMIT NO. 15 • COLUMBUS, IN 47201Postage Will Be Paid ByCummins Engine

Literature Survey FormWe are always open to any suggestions or recommendations that will aid in improving our manuals. Use thispostage paid survey for

Lubricating Oil Pan - RemovalRemove the oil pan mounting capscrews and the oil pan.Gear Cover - RemovalRemove one capscrew on each side of the gear co

Manual OrganizationAll references to engine components in this manual are divided into 22 specific groups. The organization isconsistent with the serv

Use one hand to slowly rotate and pull the camshaft fromthe cylinder block and the other hand to balance thecamshaft as it is removed.Remove the camsh

Install two connecting rod guide pins, Part No. 3375601.Use a ‘‘T-handle’’ piston pusher to push the rod awayfrom the crankshaft.NOTE: Push the rod aw

Remove the upper rod bearing.Mark the cylinder number and the letter ‘‘U’’ in the flatsurface of the bearing tang.Caution: Do not over expand the pist

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

Use a liquid metal marker to mark the cylinder number oneach liner.If the sealing rings were removed, do the following:1. Use a tag to mark the cylind

Use main bearing cap puller, Part No. ST-1178, to re-move the caps. The service tool must be centered on themain bearing cap.NOTE: Use a pencil or scr

Warning: Because this part weighs more than 23 kg [50lbs], two people or a hoist will be required to lift thecrankshaft to avoid personal injury.Use a

Install the mounting plate adapter on the rear waterheaderif removed during the cleaning or inspection procedure.Use five 1/4-20 X 1 1/4-inch capscrew

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 c

Caution: The upper main bearing shells have a grooveand an oil hole to provide crankshaft lubrication. Thelower main bearing shells do not. Both beari

General Repair InstructionsThis engine incorporates the latest diesel technology; yet, it is designed to be repaired using normal repairpractices perf

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 app

Use a lint free cloth to clean the thrust bearings, the mainbearing shells, and the main bearing caps.NOTE: If used thrust bearings are to be installe

Install the dowel ring in the dowel ring counterbore of thecylinder block.Install the lower main bearing shells as follows:Use clean LubriplateT 105 o

The end of the lower main bearing shell opposite thedowel ring must be engaged between the crankshaft andthe cylinder block and be seated against the

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 cyl

Tighten the main bearing capscrews to the followingtorque values:1. Tighten to 122 N•m [90 ft-lb].2. Tighten to 230 N•m [170 ft-lb].3. Tighten to 346

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 o

Measure the crankshaft end clearance. The end clear-ance specification for a new or reground crankshaft withnew thrust bearings is 0.10 mm [0.004-inch

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 c

Liner installation tool, Part No. 3822953, is used to pressthe cylinder liner into the cylinder block. Protrusion canbe checked while the liner is hel

General Safety InstructionsImportant Safety NoticeWARNINGRead and understand all of the safety precautions and warnings before performing any repair.

Use a depth gauge, Part No. 3823495, to measure theliner protrusion at four points 90 degrees apart. The pro-trusion must be from 0.10 mm to 0.18 mm [

Piston and Connecting Rod Assem-blies - Assembly and InstallationInstall a new snap ring in one of the snap ring grooves ofthe piston pin bore on each

The piston ring shipping package identifies the locationof each piston ring by the part number. Install the ringsin the sequence shown and in the prop

Use clean LubriplateT 105 or its equivalent to lubricatethe bearing shell.Apply a heavy film of clean 15W-40 oil to the liner.Put the piston and the r

Caution: To avoid piston damage, do not use a metalobject to push the piston in the liner.NOTE: The tang of the connecting rod must be toward thecamsh

Caution: The rod cap alpha-numeric characters mustmatch the alpha-numeric characters on the connectingrod and must be installed with the characters al

Remove the pins from the crankshaft oil seal driver, PartNo. ST-997; and use the driver to align the rear cover withthe crankshaft.Install the seal dr

Install the pins in crankshaft oil seal driver, Part No.ST-997.Use crankshaft oil seal driver, Part No. ST-997, to installthe oil seal in the rear cov

Bore Alignment - MeasurementCaution: The flywheel housing bore and the surfacemust be in alignment with the crankshaft to preventpossible damage to th

Determine the total indicator runout (T.I.R.) as follows:Example: mm in12 o’clock 0.00 0.0003 o’clock +0.08 +0.0036 o’clock - 0.05 - 0.0029 o’clock +0

Symbols Used in this ManualThe following group of symbols has been used in this manual to help communicate the intent of the instructions.When one of

If the alignment is not within specifications and the boreis round, the housing can be shifted. Refer to Section 16.If the alignment is not within spe

Continue rotating the crankshaft until the dial indicator isat the 12:00 o’clock position.Check the dial indicator to make sure the needle stillpoints

If the alignment is not within specifications, remove thehousing. Check for nicks, burrs, or foreign material be-tween the block and the housing.Check

Install two t-bolts into the flywheel clutch mounting sur-face.Install two 5/8 - 18 x 6-inch guide studs in the crankshaftflange.Warning: Because this

Rotate the crankshaft one complete revolution.NOTE: The total indicator runout (T.I.R.) must not exceed0.127 mm [0.0050-inch].If the T.I.R. is greater

Install the flywheel, and inspect the bore runout again.Replace the flywheel if the runout does not meetspecifications.Face Alignment - MeasurementIns

The total indicator runout (T.I.R.) must not exceed thefollowing specifications:Flywheel Radius (A) Maximum (T.I.R.) ofFlywheel Facemm in mm in203 8 0

Install the cylinder heads over the dowel pins. If reusingoriginal cylinder heads, install them in their originalposition.Use clean 15W-40 oil to lubr

After all 12 capscrews on one head have been torqued to298 N•m [220 ft-lb], they must be rotated in the tighteningdirection an additional 90 degrees.

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 thebore until